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Multiple Compressor Controller

Featuring ModBus Communications

MULTIPLE COMPRESSOR CONTROLLER USERS MANUAL


Danfoss Turbocor Compressors Inc. ECD-00014-U-R09 January 2008

Proprietary Notice
This publication contains information proprietary and confidential to Danfoss Turbocor Compressors Inc. (DTC). Any reproduction, disclosure or unauthorized use of this publication is expressly prohibited without written approval from DTC. DTC reserves the right to make changes without notice in product or component design as warranted by evolution in user needs or progress in engineering or manufacturing technology. DTC has exercised its best efforts to ensure that the information contained in this manual is correct. However, no warranty of reliability or accuracy is given with respect to the information and DTC shall not be responsible or liable for the correctness or suitability of the information or for any error or omission. If you encounter any difficulty in using this manual, please forward your query to Danfoss Turbocor Compressors Inc. or its authorized sales agent.

All brand names and product names used in this manual are trademarks, registered trademarks, or trade names of their respective holders.

For product support issues, contact: Product Support product_support@turbocor.com Danfoss Turbocor Compressors Inc. 1769 E. Paul Dirac Drive Tallahassee, FL 32310 USA Telephone: (850) 504-4800 Fax: (850) 575-2126 www.turbocor.com

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Contents
1 Multiple Compressor Controller - Overview Introduction Application Display Features Communication Features Environment Constraints Ordering Details 2 Multiple Compressor Controller - Interface Interface Introduction Hardware I/O Interface Controls Controller Interlocks Communications Interfaces Carel Modbus Gateway BMS Network Modbus Protocol 3 Multiple Compressor Controller - Functionality General Control Strategy Application Setup Types Freeze Control Parallel Control Mode Staged Control Mode Staged Control Considerations Minimum Off Timers Alarms 4 Multiple Compressor Controller - Operating Procedures Introduction PLC Control Panel Operations Alarms General Alarms System Alarms Appendix A Carel Control Panel Display PLC Overview Selection Screens Interlock Messages Interlock Message options Viewing Circuits Circuit Temperature Status Circuit Pressure Status Condenser Fans Status Compressor Status System Setup Analog Input Configuration Compressor Configuration Compressor Configuration Configuration Screens Evaporator Configuration Screens
Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

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Contents
Controller Stage Settings Condenser Configuration Modbus Settings Miscellaneous Configuration Screens Compressor Circuit IDs Appendix B Drawings Appendix C Inputs/Outputs 14 14 15 16 16 18 19

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

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Multiple Compressor Controller - Overview

1
1.1

Multiple Compressor Controller - Overview


Introduction
1.2.2 Communication Features
The MCC communicates with the compressors via ModBus, which enables it to read various parameters and control the compressors by writing to certain parameters. It can act as the centralized controller for systems with one to six compressors.

This manual describes the functionality and operation of the Multiple Compressor Controller (MCC). The controller features generic software that is configurable for use with either the basic I/O or the expanded I/O hardware platforms. In its expanded form, the controller can accommodate up to six compressors. NOTE While the controller algorithm is designed to maintain desired set point with minimal variations, it could swing depending on the configuration settings and the system characteristics.

1.2.3 Environmental Constraints


The following information provides recommended environmental conditions.

Environment
Storage Operation

Range
-20C to 60C* -10C to 60C*

1.2

Application

The MCC performs the following primary functions:


Controls the entire chiller/system and some auxiliary devices Performs monitoring, analysis and fault display.

* Relative humidity less than 80%, non-condensing

Table 1 Temperature Range

1.3

Ordering Details

1.2.1 Display Features


The controller features a remote semi-graphic display with the ability to:
View the compressor status and detailed information View the input and output status View and adjust set points View and adjust timers where applicable Acknowledge and reset warnings and alarms View the alarm history Configure the pre-programmed software to suit the specific application Enable and/or disable inputs and/or outputs that are optional

The following information provides the ordering details for this controller.

Description
Part Description Part Number Notes

Details
Retrofit Controller Kit 111047 Kit includes Turbocor Specific software, temperature sensors, remote semi-graphic screen, connector kit, and 1.5 meter (5 feet) RJ-12 communication cable.

Table 2 Ordering Details

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Multiple Compressor Controller - Interface

2
2.1

Multiple Compressor Controller - Interface


Interface Introduction
interlock must be connected to the Multiple Compressor Controller at all times. All external safety and system interlocks can be wired in series, if required.

The latest model of the Carel pCO series is used, the Pco3, which enables very fast communication with the compressor by means of the serial port over ModBus.

2.1.1 Hardware I/O Interface Controls


Each TT300/TT400 compressor is equipped with the following I/O points for controls and interfacing:
Interlock (voltage-free contact), compressor start/ stop, 1 * DI Numerous parameters including demand, which is an input parameter modulating the compressor capacity between 0 - 100%, 1 * RS485 Port. (1) Status (SPD contact), generic compressor fault status, 1* DO (2) Compressor run status, based on user-selectable motor RPM, 1*DO

2.2

Communications Interfaces

The Multiple Compressor Controller (MCC) supports upstream communications to a Building Management System (BMS) through a Carel Modbus protocol.

2.2.1 Carel Modbus Gateway


The MCC Carel Modbus requires a relevant gateway card in order to establish a communications link to the BMS Network, a gateway interface card for the MCC Carel Modbus is available from Carel company, contact Carel technical support (www.carel.com). NOTE The purchase and installation of a Carel Modbus interface card by a third party company to enable communications to a BMS Network may be required.

For a detailed list and typical wiring of all I/Os available on the Turbocor compressor, refer to Drawings (see APPENDIX B). Also refer to pCO3 manual, document no. 050003290, which can be found at http://carelusa.com/pco3_literature.htm.

2.1.2 Controller Interlocks


The following inputs are connected to the Multiple Compressor Controller:
Remote on/off switch Evaporator flow switch Condenser water flow switch (water-cooled unit only) Cooling call

2.2.2 BMS Network Modbus Protocol


For BMS Networks connected to the MCC Carel Modbus requires the BMS network can communicate via Modbus protocol. For BMS Networks utilizing Modbus Protocol, no protocol conversion is required. For BMS Networks connected to the MCC Carel Modbus via a non Modbus protocol (such as LON or BacNet) an interface card is required to convert communications from the MCC Carel Modbus protocol to the BMS communications protocol. NOTE The purchase and installation of a protocol conversion interface card by a third party company may be required. See your BMS administrator for interface card parameters and your BMS supplier for the appropriate interface card.

All of these inputs enable/disable the controller. Refer to electrical schematics for input configuration. NOTE All other inputs that are not used must be bridged.

To ensure protection against system freeze-ups or other major failures, at least one external safety

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Multiple Compressor Controller - Functionality

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3.1

Multiple Compressor Controller - Functionality


General Control Strategy
based on head-pressure and the other is where a headpressure transducer is connected to the controller, and the fans are switched by the controller in up to three steps per compressor.

The Multiple Compressor Controller (MCC) is configurable to control either leaving or entering chilled-water temperature, depending on the application requirements. In principle, the demand to the compressor(s) is determined by the Demand Generator*. The output of the Demand Generator is based on the difference between the setpoint and the controlled value. In addition, the control strategy is based on system demand (Low Load Control). When the main application is controlling leaving chilled water temperature, and the entering chilled water temperature drops below a certain value, the setpoint is shifted upwards to compensate for a lower load. Similarly, when the main application is controlling entering chilled water temperature, and the leaving chilled water temperature drops below a certain value, the setpoint is shifted upwards to compensate for a lower load.
* The Demand Generator is a proportional integral (PI) controller based on the SSTEP2 macro block from Carel. Proportional band and integral time adjustments can be made through the Band, Update, and Max. Change parameters.

3.3

Freeze Control

Regardless of using leaving or entering water control, when the leaving chilled water temperature drops below the leaving chilled water freeze point, the demand drops to zero and an alarm is generated. The compressors can only start again after this alarm is reset, and when the leaving chilled water is above the setpoint. Freeze control is implemented by monitoring the leaving water temperature at the MCC. The leaving water temperature can be monitored at either the temperature sensor input at the MCC (B2 default) or via the Modbus from any compressor. As an additional safeguard, interlocks are used to signal the MCC when there is insufficient pump flow or condenser leaving water flow. The interlock circuit is connected to a digital input (ID1-14) of the MCC.

3.4

Parallel Control Mode

NOTE While the controller algorithm is designed to maintain desired set point with minimal variations, it could swing depending on the configuration settings and the system characteristics.

With parallel control, all operating compressors are shut down. After their IGVs are reset, they are restarted along with an additional compressor that was previously off. The compressors ramp up together with the load equally distributed across all of them.

3.2

Application Setup Types

The software setup is largely generic. Sensors can be connected for entering and leaving chilled water temperatures in all applications.
When the system is set up for a water-cooled chiller application, additional sensors can be connected to display the entering and leaving condenser water temperatures. In an air-cooled application, there is an option to connect an outside air temperature sensor.

The appropriate screens are activated according to the specific set-up. There are also two options for condenser fan switching: one is where the fans are switched locally (in steps) with pressure switches

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Multiple Compressor Controller - Functionality The bandwidth between the actual demand and the requested demand on a compressor can be configured by the user to allow more or less time for system stabilization in the staging sequence of the compressors. It is important to recognize, however, that the compression ratio of the system needs to reduce to an acceptable level to allow the efficient and safe starting of the second or subsequent compressors. This time interval may vary depending on the conditions of the system. The hysteresis for switching one, two or three (groups of) compressor(s) in this example is set to 5 percent. However, it is a parameter that can be set via Level 2 user access for tuning purposes. At start-up, the integral term of the Demand Generator is switched off for 90 seconds to prevent overshoot because the compressors themselves have a ramp-up time.

3.5

Staged Control Mode

In staged control, the running compressors are unloaded until they reach a specific pressure ratio, as defined in the user interface. An additional compressor that was previously off is started. When the compressor attains the same pressure ratio as the other compressors, the compressors ramp up together with the load equally distributed across all of them. This mode can give better capacity control of the system, as it harnesses the ability for a single compressor to be operating under really low load conditions, and you are not restricted by the minimum point of all compressors combined. The 'System demand' (the output from the Demand Generator) varies from 0-100 percent based on the difference between the setpoint and the controlled value (e.g. ChW temperature). As the system demand increases, the demand to the first compressor also increases. Once the compressor is no longer able to meet the system demand within a certain time period, the controller will begin to stage on the second compressor. This will involve the running compressor unloading to facilitate the optimum system conditions needed to start the next compressor. This process will occur for each subsequent compressor that is in the system. As the system demand decreases from 100 percent, the controller will unload all the compressors in parallel until the system demand has dropped below the minimum combined capacity of the running compressors. At this point, the controller will begin to shut down compressors (one at a time), and then allow the remaining compressors to increase their capacity as needed to match the system demand.

3.5.2 Minimum Off Timers


Minimum Off Time is the time the compressor will stay off after the demand to that compressor has reached zero. The Minimum Off Timers are to prevent any unwanted switching of compressors while the compressors are ramping up to satisfy an increasing demand.
For staged control, these timers operate on the individual demands to the compressors. For parallel control, the timers operate on the combined demand.

3.6

Alarms

3.5.1 Staged Control Considerations


When one compressor is running at a demand below the requested demand from the controller, the second one will start. Theoretically, after they have been started, both compressors will then approximately operate on half of the initial capacity. The demand to the initial compressor(s) will drop (e.g. from 100 percent to 50 percent), while the second will be started with a 50-percent demand.

Each compressor can indicate a fault via Modbus communication. If a compressor fails, the demand to that compressor will go to zero and a generic fault will appear on the controller display. After the fault on the compressor has been resolved, the fault message on the controller can be reset.

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Multiple Compressor Controller Operating Procedures

4
4.1

Multiple Compressor Controller Operating Procedures


Introduction
Monitoring the Conditions 1. Press Esc until the main menu appears. 2. Select SYSTEM STATUS and press the button. System status such as water temperature and compressor running time can be viewed.
Danfoss_Turbocor_Inc. Carel_Controller Ver.0.0.110 <---To_System_Setup <---To_System_Monitor

The controller is designed to run the compressor at various motor kW conditions. The setpoint is set at the PLC control panel, which also controls and monitors other functions in the chiller and acts as an interface between the chiller and the compressor. Alarms and compressor status can be read from the PLC screen. Refer to PLC Control Panel (see Figure 1).

Figure 3 System Start-Up Screen

4.3

Alarms

4.3.1 General Alarms


Figure 1 PLC Control Panel The PLC monitors the status of the temperature inputs. Disconnecting any one of the three temperature sensors trips an alarm and the unit will stop.

4.2

PLC Control Panel Operations

Starting the PLC Control Panel 1. Ensure all interlocks are closed. 2. Press Esc until the main menu appears.
Danfoss_Turbocor_Inc. Carel_Controller Ver.0.0.110

4.3.2 System Alarms


The following alarms can be present:
Compressor fault Pump failure Generated by the compressor if there is an internal alarm. The pump is not running due to a thermal overload, or it is not switched on. The condenser water flow switch detects a low-flow condition. The compressor is not running due to a fault, or it is not switched on. This alarm is triggered when the condenser water temperature sensor registers a temperature above its trip setpoint (40C).

Condenser water flow too low

Figure 2 Main Menu Screen


3. 4. Using the button, select SYSTEM ON/OFF. Press the button to view the System Status screen. Press the button again to select the compressor on/ off option. Press the or button to switch the compressors on or off. Press the button. If the compressor is switched on, it will ramp up according to the system demand to maintain the setpoint; otherwise, it will shut down. Press Esc to return to the main menu.

Compressor not powered on


High condenser water temperature

5.

Table 3 System Alarms

6.

Danfoss Turbocor Compressors Inc. ECD-00014U-R09

APPENDIX A Carel Control Panel Display


A.1 PLC Overview
This section describes the various screens that are available on the PLC control panel display. 5. Record BOOT and BIOS info. When finished, press Esc. Record Carel cont VER 0.0.110. 6. Press Esc button to return to start-up menu.

A.1.1 Selection Screens


Monitoring screens allow you to view the system data while the system is running. Navigating the Start-Up Screen Upon initial power-up, the start-up screen will appear (see Figure A-1).
BOOT V 3.08 01/02/06 BIOS V 4.01 01/04/07 > 2+2 MB < APP. CRC: A756 2MB

Figure A-3 System Info Screen 7. To verify if controller is set up to log data, perform step 2 again. Use the up and down arrow keys to move > symbol in front of LOG DATA (see Figure A-2), then press . 8. If there is no log data, the following screen appears (see Figure A-4):

Danfoss_Turbocor_Inc. Carel_Controller Ver.0.0.110


<---To_System_Setup <---To_System_Monitor

Figure A-1 Start-Up Screen 1. Record Carel Controller version number (see Figure A-1). 2. Simultaneously press alarm button and button and hold for approximately four seconds. 3. A blinking cursor will appear (see Figure A-2). Use arrows to choose System Info and press button.
NO LOG DATA PRESS [MENU] OR [ESC]

Figure A-4 No Log Data Screen 9. Selecting OTHER INFORMATION brings up the ID number (see Figure A-5).

SYSTEM INFO LOG DATA OTHER INFORMATION ID NUMBER 00263-12829-15022

Figure A-2 Controller Information Screen 4. Ensure bios is above 4.00 (see Figure A-3). Figure A-5 Other Information Screen

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

10. Press the Prg button. To System Setup will display (see Figure A-6).

Navigating the System Info Screen Screen

System_Info: System_Info:
<----To_System_Setup <----To_System_Setup ____Go_To_System_Info_---> ____Go_To_System_Info_--->

Figure A-6 System Info Screen 11. Press the Esc button to go to System Info. To System Monitor will display.

Navigating the System Configuration Screen

Figure A-8 System Info Screen 14. Press the '' button to go To System Setup, will display, System Configuration Screen (see Figure A-7). 15. Press the Prg button to Go To System Info, will display either: 16. an interlock status screen will display, Interlock Status Messages (see Figure A-9), or 17. an interlock status screen will display, View Circuit # Selector (see Figure A-10), or The following are abbreviations used in displays.
VFD LBV EXV AEXV IGV MB LWT EWT LWP EWP CWT ECT LCT HP HT BMS ST SP ID# B# C# Y# A/W Degrees Pressure *

System_Configuration:

_____To_Continue_Setup---> <-Press_to_View_System

Figure A-7 System Configuration Screen 12. Press the button To Continue Setup, to will display, System Configuration Menu (see Figure A-18). 13. Press the Esc button to View System will display, System Info Screen (see Figure A-8).

Variable fan Drive Load Balance Valve Electronic Expansion Valve Auxiliary Electronic Exapansion Valve Inlet Gas Valve ModBus Leaving Water Temperature Entering Water Temperature Leaving Water Pressure Entering Water Pressure Condenser Water Temperature Entering Condenser Temperature Leaving Condenser Temperature Head Pressure Head Temperature Building Management System Suction Temperature Suction Pressure (ID1-14)* B1 to B8* C1 to C13* Y1 to Y4* Air Water Temperature is measured as F or C. Pressure is measured as Psi or kPA. Numbers above these ranges may appear, these items are reserved.

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

A.2

Interlock Messages

A.2.1 Interlock Message options


Close the Interlock Item, through system configuration. Press the '' button to access the View Circuit # Selector (see Figure A-10). Press the Prg button to access the System Configuration Screen (see Figure A-7). Press the Esc button to access the System Info Screen (see Figure A-8).

The following screen is a message, telling that an Interlock to the Carel controller is open.
Interlock_Open! Remote_On/Off open!

A.3
Interlock_open! Evaporator_# interlock_open!

Viewing Circuits

The following screen provides the option to choose which circuit to monitor. For Typical I/O Wiring for Multi-Compressor Controller (see Figure B-1).
_>View_Circuit_1< __View_Circuit_2 __View_Circuit_3 __View_Circuit_4 __View_Circuit_5 __View_Circuit_6

Interlock_open! Condenser_# interlock_open!

Figure A-10 View Circuit # Selector Figure A-9 Interlock Status Messages The following table details the screens fields.
Interlock Open

Selecting a View Circuit 1. Scroll using '' or '' buttons to select a circuit to monitor.
View Circuit # (Circuits 1-6)

The screen will appear only if the interlock is open. Interlock is open

when the Interlock input has 24 Volts present.


Remote _On/Off

Evaporator _#

Condenser _#

The screen would not appear, when the interlock is closed. See Miscellaneous System (see Figure A-33) "Remote On/Off ch#" to check which channel is set as the remote On/ Off channel. Indicates that interlock on evaporator side, circuit #, is opened. See Evaporator Control (values represent generic defaults) (see Figure A-25) to check channel settings. Indicates that interlock on condenser, circuit #, is opened. See Condenser # Interlock Status (see Figure A-31) to check channel settings.

2. Press button to view circuit. 3. View Circuit Screen Details (see details by type)
Circuit # Readings (see Figure A-11) Circuit Pressure Readings (see Figure A-12) Condenser Fans Voltage (see Figure A-13) Condenser Fans Setpoints (see Figure A-14) Compressor # Status (see Figure A-15)

A.3.1 Circuit Temperature Status


This screen represents the current status of the system.

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Circuit_#
Setpoint:__0044.0F* Process:___0044.1F Demand:_____080.0_% *Setpoint_reset_active

Condenser_#_fans(1/2):
Displ.Voltage:00.0 Fan_1:_No Fan_2:_No Fan_3:_No

Figure A-11 Circuit # Readings The following table details the screens fields.
Setpoint

Figure A-13 Condenser Fans Voltage The following table details the screens fields.
Display Voltage Fan #

Adjustable set point for Temperature or Pressure. For Temperature set point see 'Control' field in Evaporator Configuration (see Figure A-22) screen. Process Current Process reading of the circuit. Demand Percent - of current system demand. Pressure Pressure is measured as Psi or kPA. Temperature Temperature is measured as degrees F or C.

In Volts No = Voltage is not Available. Yes = Voltage is available.

Condenser_#_fans(2/2):
Fan_1_Setp:_100.0 Fan_2_Setp:_110.0 Fan_3_Setp:_120.0 Fan_Diff:___020.0

A.3.2 Circuit Pressure Status


Circuit Pressure Status displays the current status of the identified circuit.
Circuit_#
Suction_P_(psi):__35.0 Suction_T_(F):___42.0 Disch._P_(psi):__115.0 Disch._T_(F):___120.0 Evap_A/W_____Condr_A/W In:__055.0F____075.1F Out:_044.1F____084.5F

Figure A-14 Condenser Fans Setpoints The following table details the screens fields.
Fan # Setpoint Fan Diff Pressure Temperature

Set point for Fan# for pressure or temperature. Hysteresis for Temperature or Pressure for each fan set point. Pressure is measured as Psi or kPA. Temperature is measured as degrees F or C.

Figure A-12 Circuit Pressure Readings The following table details the screens fields.
Suction P Suction T

A.3.4 Compressor Status


This example represents one compressor attached to the circuit. A status screen is dedicated to each compressor. NOTE The screen below will appear only if the compressor # is assigned to a condenser circuit#. ('Condenser:' field of the Compressor Configuration screen (see Figure A-21) should be 'Condenser: 1')

Suction Pressure at Compressor. Suction Temperature (degrees) at Compressor. Disch. P Discharge Pressure at Compressor Disch. T Discharge Temperature at Compressor. Evaporator Air/ Inlet Evap Air/Water Temp Water Outlet Evap Air/Water Temp
Temperature Condenser Air/ Inlet Cond Air/Water Temp Water Outlet Cond Air/Water Temp Temperature

A.3.3 Condenser Fans Status


Fan screens are only visible if fans are enabled :

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

Compressor_#:
Demand:______080.0% IGV:_________110.0% kW(Req.):____0023.5 kW(actual):__0023.7 RPM(actual):_25600 Not_Ready

System_Configuration: >Analog_Inputs< >Compressors< >Evaporators< >Condensers< >Modbus< >Miscellaneous<

Figure A-15 Compressor # Status The following table details the screens fields.
Demand IGV kW (Req) kW (actual) RPM (actual) Messages

Current demand of Compressor# Current IGV position of Compressor# Electrical kW requested Electrical kW actual Current RPM 'In Fault...' if compressor is in fault mode. 'Not Ready...' if compressor is not ready

Figure A-18 System Configuration Menu 4. Press the button to Continue Setup for the selected menu item. MENU ITEMS
Analog Inputs Configuration (see Figure A-19) Pressure Sensor Settings (see Figure A-20) Compressor Configuration (see Figure A-21) Evaporator Configuration (see Figure A-22) Condenser Communications (see Figure A-28) Condenser # Fans Settings (see Figure A-29) Modbus Configuration (see Figure A-32) Miscellaneous System (see Figure A-33)

A.4

System Setup

To make the controller fully operational, we have to configure it first. To access the System Configuration Menu 1. Press the Prg button
Danfoss_Turbocor_Inc. Carel_Controller Ver.0.0.000 <---To_System_Setup <---To_System_Monitor

A.4.1 Analog Input Configuration


Analog Inputs are identified as channels with an associated input type.The following figures detail the available channels.

Figure A-16 Start Up Screen 2. Press the button to Continue Setup.


System_Configuration:

_____To_Continue_Setup---> <-Press_to_View_System

Figure A-17 System Configuration Screen 3. Scroll using '' or '' buttons to select a Menu Item.

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ANALOG_INPUTS(J2,_J3): marked:_input_type: B1_Disconnected B2_Disconnected B3_0-10V B4_Disconnected B5_Disconnected

B#_4-20mA___Set_up: 4mA_corresponds:_00000 20mA_corresponds:00000 Current_output:__00000

ANALOG_INPUTS:(J6) marked:__input_type: __B6_____Carel_NTC __B7_____Carel_NTC __B8_____Carel_NTC

Figure A-20 Pressure Sensor Settings NOTE This screen will appear if 4 - 20 mA is selected for channel#. The following table details the screens fields
4mA corresponds 20mA corresponds Current output

Minimum pressure range of sensor Maximum pressure range of sensor Actual pressure of circuit at sensor

ANALOG_INPUTS:(J20) marked:__input_type: __B9_____Disconnected __B10____Disconnected__

A.4.2 Compressor Configuration


Figure A-19 Analog Inputs Configuration
Scroll using the '' button to view inputs B6 to B8.

The settings for the compressor(s) require using the MODBUS for communications between the controller and the compressor(s). A4.2.1Communication requirements The following requirements are applicable for each compressor: REQUIRED SETTINGS
A unique 'MB ID' (ModBus) per compressor. Evaporator circuits must be assigned to a compressor. See Evaporator Circuits ID (see Figure A35). Condenser circuits must be assigned to a compressor. See Condenser Circuits ID (see Figure A36). The compressor may be enabled or disabled.

A4.1.1Analog Inputs Fields The following table details the screens fields.
Marked

Input Type

Lists the channels as b#. For Analog Inputs Configuration (see Figure A-19) Disconnected indicates No sensor is associated with this channel. Temperature Sensors Carel NTC ON-OFF PT1000 Pressure Sensors 4 - 20 mA

A4.1.2Sensor Setup Sensor Setup provides the pressure parameters to be associated with the Sensor.
For Pressure Sensor Settings (see Figure A-20)

OPTIONAL SETTINGS
An LWT sensor attached to its I/O board, and/or An EWT sensor attached to its I/O board.

A.4.3 Compressor Configuration


Compressor Configuration identifies the circuits and sensors related to the compressor.

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A.5.1 Evaporator Configuration Screens


Compressor##:1
MB_ID:_______001 Evaporator:__1 Condenser:___1 LWT_sensor:__No EWT_sensor:__No Enabled:_____Yes

The following set of screens lets the user configure evaporative circuits.
Evaporator Configuration (see Figure A-22) Evaporator PID settings (see Figure A-23) Evaporator Hold PID (see Figure A-24) Evaporator Control (values represent generic defaults) (see Figure A-25)

Values shown are default settings for associated parameters.

Figure A-21 Compressor Configuration The following table details the screens fields.
MB ID

NOTE
Identifies the ModBus ID # for this compressor. Evaporator Identifies the Evaporator Circuit # for this compressor. Condenser Identifies the Condenser Circuit # for this compressor. LWP Yes, if LWP sensor is connected. sensor No, if LWP sensor is NOT connected. EWT Yes, if EWT sensor is connected. sensor No, if EWT sensor is NOT connected. Enabled Yes, if compressor is present. No, if compressor is NOT present.

Evaporator Screens appear only if at least one compressor is assigned to a circuit#. A5.1.1Evaporator Configuration Evaporator Configuration sets the connection path and other control settings.
1st_Evaporator_Config:
SP_sensor:__via_Modbus ST_sensor:__via_Modbus LWT_sensor:_via_Modbus EWT_sensor:_via_Modbus Control:____Off Fault_level:000.0F Set_point:__000.0psi

A.5

Configuration Screens
Figure A-22 Evaporator Configuration The following table details the screens fields
via ModBus* via ModBus* via ModBus* via ModBus* OFF, Air/Water IN, Air/Water OUT, Pressure Fault Level Freezing Protection. Set CUT OFF water temperature Set point May be either temperature or pressure, based on selected control mode. *via ModBus B1 to B8
SP Sensor ST Sensor LWT sensor EWT sensor Control

In order to adjust the variables, apply the following generic rules: Data entry operations 1. Select a field.
Press the '' button, to place the cursor to select a variable field to be adjusted.

2. Adjust field value.


When the cursor is at the desired field, the value may be adjusted by pressing '' or '' buttons.

3. Storing or Saving a value.


When the value is correct, the user may store it (make it active) by pressing '' button.

4. Exiting without Saving


The user may abort current operation by pressing 'Esc' button.

A5.1.2Evaporator PID Settings The section provides information about programming the PID settings for the Evaporator.

Danfoss Turbocor Compressors Inc. ECD-00014-U-R09

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1st_Evap.P_ID: Set_point:_044.0
_______R:____F: Band:___00600_00600 I_Time:_00080_00080 D_Time:_00007_00007 Period:_00250_00250

Holding pressure ratio *

Values shown are default settings for associated parameters.

Figure A-23 Evaporator PID settings The following table details the screens fields.
Column "R" Column "F" Set P term.

R is for 'Raw' "F" is for "Fine" Higher the number, lower P. Range:0-32767 Set I term. Higher the number, lower I. Range:0-32767 Set D term. Higher the number, higher D. Range:0-32767 Set update time in milliseconds. Range 0-32767

Range 0.0 - 6.0 Pressure ratio, which running compressors will try to maintain while additional compressor is coming on line. Hold pid Range: 0-32767 band Holding PID Loop, P term. Hold pid I Range: 0-32767 time Holding PID Loop, I term. Hold pid D Range: 0-32767 time Holding PID Loop, D term. Hold pid Range: 0-32767 (mSec) period Holding Loop update time. Holding Range: 0.0-6.0
Pr.Delta.

* If the current pressure ratio is within Hold P ratio Hold Pr.Delta, additional compressor allowed to start up. Otherwise, it is not allowed to start.

A5.1.4Evaporator Controls Evaporator Controls can be configured for miscellaneous parameters.


__1st_Evaporator: Hld._TimeOut:____600_ 'OFF'_DMD_delta:___030.0%_ 'OFF'_IGV_delta:___110.0%_ Flow_interlock:__No Interlock_ch#:___N/A_ Cooling_Call_Ch#:N/A

There is a logic inside controller, which allows to use 2 different loops, depending how far from set point the actual process value is. The loops will switch from 'Raw tuning' to 'Fine tuning' automatically. This feature is recommended only for the final fine tuning of the system. Setting both columns identical will disable above mentioned feature. In this case, the controller will behave as having only one PID loop. A5.1.3Evaporator Hold
Start/Hold_demand(ev1) Start_Demand:____058.3 Hold__P_ratio:_____2.1 Hold__pid_band:__00071 Hold__pid_I_time:00023 Hold__pid_D_time:00007 Hold__pid_period:00133 Hold__Pr.Delta:___00.4

Values shown are default settings for associated parameters.

Figure A-25 Evaporator Control (values represent generic defaults) The following table details the screens fields.
Hld. TimeOut 'OFF' DMD delta 'OFF' IGV delta Flow interlock

Values shown are default settings for associated parameters.

Figure A-24 Evaporator Hold PID Evaporator Hold defines PID Hold parameters. The following table details the screens fields.
Start Demand

Interlock ch# Cooling Call Ch#

Holding TimeOut. Range 0-32767. Demand hysteresis, when compressor staged down. IGV position, at which compressors staged down. Water flow interlock No - Disable Yes - Enable N/A or (ID1-14) N/A or (ID1-14)

A5.1.5Valve Voltage If more than one evaporative circuit has been selected during the compressor set up, than each evaporative circuit uses this screen.

Range 0.0 - 100.0 The demand, applied to the compressor during its acceleration from 0 rpm to min. speed (21000 rpm default).

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UP delta = kW requested - kW actual


LBL_configuration: EXV_min.voltage:__00.0 EXV_max.voltage:__10.0 EXV_channel:______N/A AEXV_min.voltage:_00.0 AEXV_max.voltage:_10.0 AEXV_channel:_____N/A

Figure A-26 Valve Voltage The following table details the screens fields.
EXV min. voltage EXV max. voltage EXV channel AEXV min. voltage AEXV max. voltage AEXV channel

Voltage, corresponding to EXV valve at 0% position Voltage, corresponding to EXV valve at 100% position One of the analog output channels. Voltage, corresponding to AEXV valve 0% position One of the analog output channels

One of the analog output channels NOTE: Range on all voltages is 0.0-10.0. To reverse action, it is 10.0 - 0.0.

2. 'UP delta' delay indicates time, during which 'UP delta' should be exceeded, before a call for additional compressor is made. 3. 'Dwn delta' parameter has the same meaning as 'UP Delta' parameter, but applied when the system is unloading: Dwn delta = kW actual - kW requested 4. 'Dwn delta' delay indicates time, during which 'Dwn delta' should be exceeded, before a call to drop one of the compressors is made. 5. 'OverPWR delay' indicates the time, which the system should exceed being in overpower mode providing more cooling power than needed before a call to drop one of the compressors is made. 6. 'No_ID Delta' is calculated as an absolute difference between requested and actual kW: No_ID Delta = kW requested -kW actual| NOTE If the current absolute difference between requested and actual kW exceeds 'No_ID Delta', then integral and derivative parts of the main PID control loop are disabled. The purpose of the parameter - to remove overshooting when additional compressors are added or removed from the system.

A.5.2 Controller Stage Settings


This part details the set up for the staging algorithms within Carel controller.
Request_&_Actual_Deltas: UP_delta:_______004.1 Up_delta_delay:_150 Dwn_delta:______007.3 Dwn_delta_delay:060 Over_Pwr_Delay:_080 No_ID_Delta:____002.8

A.5.3 Condenser Configuration


The following set of screens lets the user configure condenser circuits.
Condenser # Fans Settings (see Figure A-29) Fan Output Assignment (see Figure A-30) Condenser # Interlock Status (see Figure A-31)

Values shown are default settings for associated parameters.

Figure A-27 Delta Settings The following table details the screens fields.
UP delta Up delta delay Dwn delta Dwn delta delay Over Pwr Delay No ID Delta

Set UP delta parameter. Set Up delta delay. Set Dwn delta parameter. Set Dwn delta delay. Set OverPwr Delay. Set No_ID Delta.

NOTE Condenser Screens appear only if at least one compressor is assigned to a circuit#. A5.3.1Condenser Communications Condenser Communications are configured for Heads and Air Water Temperatures.

The following generic rules are followed: 1. When the compressor speed is increased, the requested electrical kW are usually higher than actual electrical kW. The difference between requested kW and Actual kW creates 'UP delta':

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1st_Condenser_Config: HP_sensor:___via_Modbus HT_sensor:___via_Modbus In_A/W_Temp.:absent Out_A/W_Temp:absent

C_Output_assignments: Fan1_to_relay:_____00 Fan2_to_relay:_____00 Fan3_to_relay:_____00 Inv._to_analog_out:00

Figure A-28 Condenser Communications The following table details the screens fields.
HP sensor HT sensor In A/W Temp. Out A/W Temp

Figure A-30 Fan Output Assignment The following table details the screens fields.
Fan# to relay Inv. to analog out

via Modbus or B1 to B8 via Modbus or B1 to B8 absent or B1 to B8 absent or B1 to B8

N/A or C1 to C13 N/A or Y1 to Y4

A5.3.4Interlock Settings Interlock Settings are used to set the Interlock ID.
1_Condenser_Interlock
Interlock_ID_Ch#.:00' Status:_closed

A5.3.2Condenser Fans Condenser Fans contain configurable set points.


1st_Condenser_Fans: Control_Type:___Off No._of_Fans:_____None Setpoint:______0000.0 Band:__________0000.0 Inv.MaxVoltage:__00.0 Inv.MinVoltage:__00.0 Inv.SpeedUpTime:00000

Figure A-29 Condenser # Fans Settings The following table details the screens fields.
Control Type

Figure A-31 Condenser # Interlock Status The following table details the screens fields.
N/A or (ID1-14) Set the Condener status as, open closed NOTE: N/A above stands for 'not applicable', meaning that the interlock is not in use.
Interlock ID Ch#. Status

Select the control type as, Off Temperature Pressure No. of Fans Select the number of fans as None, 1, 2, 3 Set point Set the setpoint as, temperature pressure Band Set the band as, temperature pressure Inv.Max Voltage Set the maximum voltage for VFD Inv.Min Voltage Set the minimum voltage for VFD Inv.SpeedUp Set the VFD speed up time in Time seconds

A.5.4 Modbus Settings


Modbus Settings is used to set the communication between the ModBus and the Compressor via RS485 communications.

A5.3.3Fan Output Assignment Fan Output Assignment allocates a Condenser fan to a relay circuit.

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Modbus_Settings: Com._port::Field Baud::::_::19200 Parity::_::none Stop_bits::1 Poll_Rate::00s Protocol:_:MB_Master

Comp. ON/OFF ch# System ON/ OFF

Set the compressor interlock(s) as, N/A or (ID1-14) Set the System ON/OFF: for the Carel controller as enabled (ON), disabled (OFF)

Values shown are default settings for associated parameters.

A5.5.2Ambient Temperature Ambient Temperature is used for setting the sensor variables. This screen is shown only if an ambient temperature for channels for B1 to B8 is selected.
Ambient_Temp._Sensor: Channel:::::__n/a Swit_chat::::_000.0 Cut_OFF:::::__No Close_Relay:__00 Current_Temp._000.0F

Figure A-32 Modbus Configuration The following table details the screens fields.
Com. port

Field for Field Card, Serial for Serial Card Baud Set Baud rate (1200 to 19200) Parity None, Even, Odd Stop bits 0, 1, 2 Poll Rate Set Modbus poll rate in seconds Protocol MB Master Local Remote ## (01-20) WINLOAD MODBUS Above screen is shown with the default values for communication with DTC compressor(s) over RS485 bus. The same settings - baud rate, parity, and stop bits - should be set up on each compressor, connected to the RS485 bus.

Figure A-34 Ambient temperature The following table details the screens fields.
Channel

Swit chat Cut OFF

A.5.5 Miscellaneous Configuration Screens


A5.5.1Miscellaneous Miscellaneous Sets several system items.
_Miscellaneous: Remote_On/Off_ch#:N/A Units:_Imperial Comp._ON/OFF_ch#::N/A System_ON/OFF::___ON

Close Relay Current Temp

Set the input channel for temperature, as, N/A or B1 to B8 Set the temperature, that will trigger an event. Set to stop all compressors at event, as No for OFF Yes for ON Set the relay to close at event, as N/A or C1 to C13 In degrees.

A.6

Compressor Circuit IDs

The following diagram details compressor ID in relation to the Evaporator circuit ID.

Figure A-33 Miscellaneous System The following table details the screens fields.
Remote On/Off Set the channel for remote On/Off as ch# N/A or (ID1-14) Units Sets display measurement units as,

Imperial, or Metric

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Figure A-35 Evaporator Circuits ID The following diagram details compressor ID in relation to the Condenser circuit ID.

Figure A-36 Condenser Circuits ID

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APPENDIX B Drawings
This section contains the controller field wiring for water-cooled, air-cooled, and DX applications. For engineering limitations and specifications, refer to document no. 050003290 at http://carelusa.com/ pco3_literature.htm.

Figure B-1 Typical I/O Wiring for Multi-Compressor Controller

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PCO3 input output limits

ECD-00014-U-R09
Digital Inputs
Digital Inputs (J5) DI's (J8) ID14 ID15 Digital inputs (J7) DI (J20) DI's (J19) ID16 B2 Y Y Y Y Y Y Y Y N N N Y Y N Y Y N N N N N Y Y Y Y Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y N Y Y Y Y Y Y Y Y Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y N N N N Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y B3 B6 B7 B8 B4 B5 B9 B10 ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 ID9 ID10 ID11 ID12 ID17 ID18 ID13

Inputs

To supply power to active probes, use 21Vdc on J2 "+Vdc" 150ma is max current

To supply power to 0 to 5 V probes, use 5Vdc on J24 "+5Vref" 60ma is max current

Analog Inputs Analog Inputs (Universal) Analog inputs

B1

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Carel NTC(-50T90C software selectable.

Carel NTC(R/T 10kO1% at 25C) software selectable

HT NTC (0T150C) software selectable

Appendix C: Inputs / Outputs

Voltage:(V) 0 to 1Vdc selectable

software

Voltage:(V) 0 to 5Vdc ratiometric software selectable

Voltage:(V) 0 to 10Vdc selectable

software

Current:(I) 0 to 20 ma input resistance:100 Ohms software selectable Current:(I) 4 to 20 ma input resistance:100 Ohms software selectable PT1000 (-100T200C) software selectable

PT1000 (R/T 1kOhm at 0C) software selectable

Digital input from voltage free contact. Software selectable.

24 volts DC

24 volts AC @ 50/60 Hz

230 Vac @ 50/60 Hz.

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Danfoss Turbocor Compressors Inc., 1769 E. Paul Dirac Drive, Tallahassee, FL 32310 Phone: (850) 504-4800 Fax: (850) 575-2126 www.turbocor.com

Copyright 2008

Printed in USA