Sub-Zero Mega Chill Manuale utente
COMPRESSOR2 ON
MED. LIQUID LEVEL
0
29.5C
R
R
A. S. C
ONTROLS
PVT. LTD.
Navi Mumbai, India 91-22-27782005 91-22-27782002Tel: Fax: email: [email protected] www.ascontrols.comweb:
CONTENTS
1. Accessaries in Box 3
2. Introduction
2.1 Main Features 4
2.2 Hardware Description 4
3. Hardware 5
3.1 Mega Chill User Interface 5
3.2 Input/Output Board 7
3.3 Sensors 8
3.4 Prokey 8
3.5 Transformer 8
3.6 Dimensions 9
3.7 Connections 10
4. Operations 12
4.1 Description - Inputs / Outputs 12
4.2 Mega Chill Keypad 13
4.3 How to Turn On/Off the Chiller 15
4.4 Water Pump 16
4.5 Water Temperature 16
4.6 Set-Point and Differential 16
4.7 Antifreeze 16
4.8 PUMP-DOWN 17
4.9 Water Level 17
5. Programming 18
5.1 Programming Levels 18
5.2 USER Parameters 18
5.3 FACTORY Parameters 19
5.4 Parameter Description & Values 21
6. Alarms 25
7. Technical Specifications 26
8. Precautions & Care 27
1
2 COMPRESSOR2 COMPRESSOR
NO.
1.
2.
3.
4.
QTY
1No.
1No.
4Nos.
1No.
ITEMS
TOROIDAL TRANSFORMER WITH SCREW
(I/P: 0-230V, O/P1: 0-9V @0.35A, O/P2: 0-10V @0.5A)
CATALOG
PROKEY
SCREWS (4X12)
5. 2Nos.
NTC SENSORS (1.5m)
6. 1No.
COMMUNICATION CORD(2m)
LIQUID LEVEL SENSORS (2m)
OR
LIQUID LEVEL SWITCH
23
1.AccessariesinBox
ItemsIncluded
Specifications are subject to change due to continuous improvements of
our products. No consequential damage or field labour is included in the
sales of products mentioned in this manual. The manufacturer is not
liableforincorrectuse/misuseoftheproductmentioned.
A.S. Controls Pvt Ltd. All rights reserved Sub-Zero and the Sub-Zero logo are
registeredtrademarksofA.S.ControlsPvtLtd.
NO.
1.
QTY
3Nos.
ITEMS
OptionalItems
NTC SENSORS (1.5m)
2. 4Nos.
2 COMPRESSOR2 COMPRESSOR
54
2. INTRODUCTION
The “MEGA CHILL-2COMP” is a
two compressor chiller controller .
This integrates all the required
functionsofthechiller.
It is very user friendly due to the
LCD provided which gives all the
parameters, messages, alarms
etc on the display. In addition to
the LCD there are LED's provided
for instant status on all controls in
thesystem.
2.1 MainFeatures
The Mega Chill controller allows
you to manage refrigeration units
havingdifferentconfigurations.
WATERcondensation.
AIRcondensation.
System’sFunctions:
Thesystemcontrolsandregulates
thefollowingconditions:
Water temperature
according to the user’s
location of the sensor.
Protection of the
compressor with indication
of any possible fault.
Display of Chiller status on
temperature on
LCD and
LED display.
Regulates level of water via
a water solenoid valve.
2.2HardwareDescription
Thebasicsystemcomprisesof
MegaChillUserinterface
Input/Outputboard
Mega chill is the intelligent part
of the system. It also represents
the ‘user interface’ for an easy
communication between user and
thecontroller.
3.1 MegaChillUserInterface
Mega Chill User Interface is a user friendly board which integrates all
controllerkeys,displayLCDanddisplayLEDs.
3. Hardware
COMPRESSOR2 ON
MED. LIQUID LEVEL
2 COMPRESSOR2 COMPRESSOR
29.5
COMPRESSOR2 ON
MED. LIQUID LEVEL
29.5
67
LiquidCrystalDisplay(LCD)
TheLCDscreenshowsdescription
of the controller parameters, and
any other information concerning
thecontrolledvariables.
Display2rowsX16characters.
CharacterSize5.56X2.96mm.
Liquid Crystal Display (LCD)
LightEmittingDiodes(LED)
There are 23 LED indications on
thechillerfrontpanelindicating:
Phases-all3phasesare
displayedasRYB.
Faults - Red blinking LED
ALERT Indicates that there is a
fault.
Individual device fault - Red
LED indicates that there is a
faultinthatparticulardevice.
Device OK status - Green LED
indicatesthatthedeviceisOK.
Deviceisinactive-Blank LED
indicatesthatthedeviceis
inactive.
COMPRESSOR 2 ON
MED. LIQUID LEVEL
Light Emitting Diodes (LED)
3.2 Input/OutputBoard
The Relay board represents the
core of the system, where the
signals coming from the probes,
digitalinputsetc.areprocessed.
Onthisboardyoucanlocate:
1. Terminalsforpowersource-
10Vac(yellow)&9Vac(red).
2. Liquid level sensor inputs
(LevelSensors).
3. Analoginputs(sensors).
4. DigitalInputs(alarms).
5. Digitaloutputs(relay).
6. Telephone connector for user
interfaceconnection.
Input/ Output
2 COMPRESSOR2 COMPRESSOR
89
3.3 Sensors
Japanese NTC thermistors, housed in a water proof I.P. 68 metal
casing.
(Custom made sensors are available in various sizes and material)
3.4 Prokey
This hardware key enables the manufacturer to enter programming
Level2(FactoryLevelProgramming).
Prokey
(Only for equipment manufacturer)
3.5 Transformer
System uses a highly reliable Toroidal transformer as it’s power supply
source.
Transformer
Standard Sensor ½”BSP Sensor SS 316L Sensor
3.6 Dimensions
Input/OutputBoard
MegaChillUserInterface
Panelcutout124mmX167mm (Alldimensionsinmm)
167
45
124
160
205
178
163
119
134
2 COMPRESSOR2 COMPRESSOR
243mm
130mm
150mm
75mm
50mm
10mm
10mm
85mm
50mm
223mm
To Display
10 11
3.7 Connections
8wayLANcable
Chiller Interface Terminal for panel mounting
Input/OutputBoard
2 COMPRESSOR2 COMPRESSOR
ALL FUSE = 1.5Amp
FUSE
FUSE
C
NO
FUSE
NC
PUMP
COND.1
COMP.2
COND.2
C
NO
COMP.1
C
NO
C
NO
C
NO
C
NO
FUSE
FUSE
WATER SV
FUSE
To Display
AC1
AC2
TRANSFORMER
~ ~
9V
10V
PUMP
DOWN SV2
PUMP
DOWN SV1
FUSE
FUSE
ALARM
C
NO
C
NO
C
NO
FUSE
HIGH
MED
LOW
LIQ
LEVEL
SENSOR
ANTI FREEZE
WATER IN
COND OUT
COND IN
CONTROL
WATER OUT
TRIP SIGNAL
B PHASE
Y PHASE
R PHASE
HP1
LP1
COMP1 O/L
OSS1
HP2
LP2
COMP2 O/L
OSS2
COND1 O/L
COND2 O/L
EWFS
SPP
NEUTRAL
PUMP O/L
SENSOR
COMPRESSOR2 ON
MED. LIQUID LEVEL
29.5
LIQ
LEVEL
SWITCH
OR
MED
LOW
REF.
12 13
4.1 Description- Input /Outputs
Analog Inputs (Probe)
The system has the following
analog (probe) inputs.
1. CONTROL - Used as the
main controlling probe based
on which the set point will
regulate the system.
2. COND IN - Indicates
Condenser Inlet temperature.
3. COND OUT - Indicates
Condenser Outlet
temperature.
4. WATER IN - Senses Water
(Chiller) Inlet temperature.
5. WATER OUT - Senses Water
(Chiller) Outlet temperature.
6. ANTI FREEZE : Used as an
Internal Anti Freeze control.
Digital Outputs (Relay)
System will operate the following
devices
1. Chiller Pump
2. Compressor1
3. Condenser Fan1
4. Liquid SV1 for Pump Down1
5. Compressor2
6. Condenser Fan2
7. Liquid SV2 for Pump Down2
8. Water SV
9. Alarm
Mega chill manages the following
protections
Digital Inputs (Trip Signals)
1. HP1 - High Pressure for Comp1
2. LP1 - Low Pressure for Comp1
3. Compressor Overload1
4. OSS1 - Oil Safety Switch1
5. COND. Fan O/L1 -
Condenser Fan Overload1
6. HP2 - High Pressure for Comp2
7. LP2 - Low Pressure for Comp2
8. Compressor Overload2
9. OSS2 - Oil Safety Switch for
Comp2
10.COND. Fan O/L2 -
Condenser Fan Overload2
11.EWFS (water cooled)-
Evaporator Water Flow
Switch.
12.Pump Overload
13.Single Phase Preventor
14.Antifreeze Trip (Internal)
15.R - R Phase (Input)
16.Y - Y Phase (Input)
17.B - B Phase (Input)
Controller informs the user of a fault
condition via a Buzzer and an
ALARM RELAY.
WARNING:
AllHP,LP,OSSandAntifreezearebydefaultinmanual
resetmode.Incaseofanyfaulttheusercanresetthemby
pressingtheCLEARkeyfor4sec.Thesecanbechanged
toautoresetbychangingP4parameter.
4.Operations
00.04
MUTE
CLEAR
4.2 MegaChillKeypad
1
2
3 4 5 6 7
COMPRESSOR2 ON
MED. LIQUID LEVEL
2 COMPRESSOR2 COMPRESSOR
29.5
14 15
TEMP
4. MUTE
Press this key for 1 second, to
disablethebuzzerandalarmrelay.
5. TEMP
Press and hold this key for 1
seconds to display temperatures
for all probes. Use up/down key to
scroll through the various probes
attached. To exit this mode, press
thetempkey.
6. PUMPDOWN
Pressing PUMP DOWN for 4
seconds forces a manual pump
Down cycle (If pump down
parameterH1isactive).
7. PRG,SEL,UP&DOWN
Used to enter and navigate in
programmingmode.
1. START
Press and hold this key for 4
seconds to bring the controller in
an operative status from the
stand-by status, in which it
normally is after being powered
on except if H2 parameter is set
toAUTOSTARTmode.
2. STOP
Press and hold this key for 4
seconds to stop the system and
operateinStandBymode.
3. CLEAR
Press and hold this key for 4
seconds to reset HP, LP and
antifreeze alarms which have
been set for MANUAL RESET
incase P4 parameter is set to
MANUALRESETmode.
START
00.04
STOP
00.04
MUTE
00.0 I
CLEAR
00.04
Press and hold the ‘START’key for
4 sec. the unit will change from
standbyto working status.Unit can
onlybeswitchedonwhenthereare
noerrors.
Thefirstdevice to startistheWater
Pump. Then, as required, Mega
Chill will switch on the compressor
and other devices depending on
thesetting.
Pump trip
pump ol 0=auto start off
i=auto start on
4.3 HowtoTurnON/OFFtheChiller
WARNING:
The pump functioning has total
priority. If the pump stops due to
anyalarmcondition,thecontroller
will be placed in a standby
position.
Theunitalsoturnsoffandmovesto
astandby position when thereisan
errorstatus.
NOTE:
It is also possible to enable
the auto start function by
selecting ‘1’ in H2 parameter.
Once selected, the machine
will automatically restart after
apoweroffcondition.
START
00.04
STOP
00.04
Pressandhold the ‘STOP’keyfor 4
sec. to switch the controller into
standbyposition.
2 COMPRESSOR2 COMPRESSOR
PUMP
DOWN
16 17
4.4 WaterPump
PUMP is the first device to be
activated after the chiller has
started. Pump functioning has
absolutepriorityamongstall other
devices.
The pump’s status is always ON
even if the set temperature has
beenachieved.
ALARMS
Thealarmsthatcanblock
thepumpare:
WATERFLOWSWITCH
(Thisalarmisignoredfor
a selectedtimeas
per parameter P1&P2)
PUMPOVERLOAD
LOWLIQUIDLEVEL
4.6 Set-PointandDifferential
Set point is the temperature at
which the chiller has to be
regulated.At this temperature the
compressor will switch off.
Differential is the temperature
added to the set point after which
the compressor restarts. For
0
example, If the Setpoint is 7 C,
0
and the differential is 2 C, the
0
compressor will switch off at 7 C
0 0 0 0
andrestartat9 C(7 C+2 C=9 C).
4.7 Antifreeze
The antifreeze procedure
activates when the AFT probe
temperature reaches or goes
below the selected threshold in
parameter A1, The compressors
are immediately stopped, without
pump-down procedure and the
liquid line solenoid valve is de-
energised.Theantifreezealarmis
displayedontheLCD.
The system will not allow a restart
until AFT temperature reaches or
goesaboveA1+A2.
To disable the ANTIFREEZE
based on the internal AFT
probe, change A0 parameter
to0.
4.5 Watertemperature
Regulation of the water
temperature is based on the
CONTROL PROBE. This control
probe can be installed by the user
at the inlet or outlet of the
evaporator, or any other location,
where he wants to regulate the
water/media.
4.8 PUMP-DOWN
The PUMP-DOWN procedure can
beenabledthroughH1parameter.
PUMP-DOWNSTAGE:
A. De-energisation of the Liquid
SolenoidValve.
B. The compressor keeps
operating until the LOW pressure
cutout input intervenes.
C.Whenthesystemcutsoffonthe
inputfrom the low pressure cutout,
the compressor turns OFF and the
PUMP-DOWNprocedureisover.
If the compressor remains on for
more than 50 seconds without
cutting off on the low pressure
switch, Megachill will force a
compressor shut down and
indicate a FAULTY PUMP-DOWN
procedure provided the CUT IN
temp has not been achieved. In
this case check the LIQUID
SOLENOID VALVE and LOW
PRESSURE CONTROL. If within
50 seconds, the CUT IN temp has
been achieved, the system will
activate the solenoid and continue
operating normally without pump
down.
PUMP-DOWNCYCLE
A pump-down cycle is used to
pump all refrigerant into a receiver
orcondensor during theOFF cycle.
The purpose is to prevent
refrigerant from migrating to the
crankcase, where it can condense
and saturate the oil. Without a
pump-down cycle, the crankcase
can fill liquid refrigerant during a
long off-cycle.At start up, the liquid
refrigerant can flood the cylinders
and damage the compressor much
like a floodback. (Large
compressors have springs on
intake)After the system has cooled
the evaporator sufficiently, a
solenoid valve closes in the liquid
line and the compressor pumps
refrigerant into the condenser or
receiver, where it remains until the
nexton-cycle.
4.9 WaterLevel
System controls the level of water
in the evaporator tank via three
water level sensors, High, Med &
Low. As soon as the level of water
goes below the Medium level, the
controller will activate a Water
Solenoid Valve. In case the level
goes below the Low level sensor,
thesystemtripsanddisplays a Low
LiquidLevelFault.
WARNING
If the machine controlled by mega chill is not using
the water level sensing feature, it is necessary to
short all water inputs concerning the water level.
Thiswilldisabletheliquidlevelerrors.
2 COMPRESSOR2 COMPRESSOR
WATER
MEDIUM
WATER
LOW WATER
SV
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