User Manual Navigator Card
Contents
1. Laptop PC R232 port dB9 connector Rj9 female connector 2 Make sure you have the following settings on your operative system Time hh mm Date gg MM yy If NOT please change settings according to it 3 Click on Start gt Programs gt MEC gt NavigatorBoard gt Nav 22 User Manual Navigator Card 01 08 2005 ENGLISH 4 The following window will appear s not connected OF gt lt File About CONNECT NAVIGATOR BOARD GET DATE 5 Click on CONNECT 6 Click on GET DATA starting form this point the program will download the data from the Navigator 7 The data will be stored in a folder named as Data under the installation directory The data will appear as a form of Excel files 13 01 2004 14 10 24 6 37 Page 1292 13 01 2004 14 10 25 13 01 2004 14 10 26 13 01 2004 14 10 27 13 01 2004 14 10 28 13 01 2004 14 10 29 13 01 2004 14 10 30 13 01 2004 14 10 31 13 01 2004 14 10 32 13 01 2004 14 10 33 13 01 2004 14 10 34 13 01 2004 14 10 35 13 01 2004 14 10 36 13 01 2004 14 10 37 13 01 2004 14 10 38 13 01 2004 14 10 39 13 01 2004 14 10 40 13 01 2004 14 10 41 13 01 2004 14 10 42 13 01 2004 14 10 43 13 01 2004 14 10 44 13 01 2004 14 10 45 13 01 2004 14 10 46 13 01 2004 14 10 47 13 01 2004 14 10 48 13 01 2004 14 10 49 13 01 2004 14 10 50 13 01 2004 14 10 51 23 User Manual Navigator Card 01 08 2005 ENGLISH The first colu2. Software installation The file is distributed and stored inside a Zip archive named as Nav031203 zip Once decompressed it generates a file Named as Nav exe Launching this file the Pc will proceed automatically to create the installation of the program Ja Welcome This program will install NawigatorBoard on Welcome ta Naw gatorboard Setup program your Computer iz strongly recommended that you exit all Windows programs before running this Setup Program Click Cancel to quit Setup and close any programs you have running Click Nest to continue with the Setup program WARNING This program is protected by copyright law and International treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum exstent possible under law Setup will install MEC NavigatorBoard in the following folder To install into a different folder click Browse and select another folder Tou can choose not to install NavigatorBoard by clicking Cancel to exit Setup Destination Folder CAME CSN avigatorB oard Browse Cancel 16 User Manual Navigator Card 01 08 2005 ENGLISH Select the Destination Folder for installing the software Please note that the Data will be stored inside the same destination So make sure it will be in a safe place easy to recover and find in your PC configu
3. board is not closer to the MicroFace Otherwise the Humitemp can be connected directly to the Navigator card as indicated in the picture below 1 ota Microface 111111 fe 11 of AE JE J D000 0111 111110 1 1 1 Navigator card I to Humitemp EEAP Hirosensor 2T Sensors User Manual Navigator Card 01 08 2005 ENGLISH 2 2 2 Sensor connection The suitable pressure transducer to be connected to the Navigator card are the following High pressure Keller PA 21 range 0 30bar LH code 275306 Low pressure Keller PA 21 range 0 10bar LH code 275304 The pressure transducers shall be connected in the following way to the board V1 BROWN Y EJ V1 WHITE Navigator board Vi i The PTC sensor for the connection to the Navigator card are the following PTC length 2mt LH code 275183 PTC length 10mt LH code 275155 The PTC sensor shall be connected to the board as the picture below 8 User Manual Navigator Card 01 08 2005 ENGLISH In case of using the Navigator card in Address 3 for Fc Dx the following configuration shall be used The suitable pressure transducer to be connected to the Navigator card are the
4. editor for example Notepad the following parameters will appear ij Nav cfg Notepad _ Oy XI File Edit Format Help CoM 1 COMCONNECT 0 FAGESFERFILE 100 Calcvaluesz PTCl Temp offset In Tenth kKzs PTC2 Temp offset In Tenth kK PTC3 Temp offset In Tenth kKzs PL Pressure At winimum In Tenth Bars PL Pressure At Maximum In Tenth Bars3 Pl voltage At Minimum In Tenth vaolt Pl voltage At Maximum In Tenth valrzl P2 Pressure At winimum In Tenth Bars P2 Pressure At Maximum In Tenth Barsa3 P2 voltage At Minimum In Tenth valtz P2 voltage At Maximum In Tenth vaolt l 0 User Manual Navigator Card 01 08 2005 21 ENGLISH 7 MAKE the following modification a Change CalcValues from 0 to 1 b Insert the PTC correction according to the settings made on the Hiromatic window MULTIPLIED by 10 Example If in the Hiromatic window the following offsets were selected 520 NAVIGATOR 6 6 CALIBRATION 521lPW LO 22727 OFFSET 522 C1 DISCH T 0 7 523 C1 SUCT T 2 6 924 C1 LIQU T 0 0 925102 DISCH T 0 0 926162 SUCT T 0 0 927102 LIQU T 0 0 In the Nav cfg file the following variables should be changed accordingly to it PTC1 Temp Offset In Tenth K 7 PTC2 Temp Offset In Tenth K 26 PTC3 Temp Offset In Tenth 0 C Insert the High and low pressure settings accordingly to what selected in the Hiromatic MULTIPLIED by 10 Example If in the Hiromatic window the following correc
5. following Low pressure 1st compressor Keller PA 21 range 0 10bar LH code 275304 Low pressure 2nd compressor Keller PA 21 range 0 10bar LH code 275304 The pressure transducers shall be connected in the following way to the board vwe T gin LP2 V2 WHITE The order connection shall be according to chapter 2 1 2 and the following table resume the connection order Navigator Card Layout High pressure supply Condensing pressure High pressure signal N2 Lowpressure signal _ J 9 User Manual Navigator Card 01 08 2005 ENGLISH 2 2 3 Addressing When Navigator Cards are connected with HIROBUS it is necessary to assign a different address to each of them by means of jumpers on the board The units must be addressed starting from 1 consecutively If there are 2 Navigator cards on the same unit they shall have address 1 and 2 In case of using the Navigator as expansion board for Fc Dx single or dual compressor Address 3 shall be selected Address 1 Address 2 Address 3 2 3 Hirobus The connections between Navigator and Microface are carried out with cables having a eight wires and RJ45 male connector plugs Following you can find how these cables have to be done For the type of c
6. plastic Usage of microface s housing for two Navigator 1717177957 RT ae nn EI M4 F E on oe 13 User Manual Navigator Card 01 08 2005 ENGLISH 2 7 RS422 Connection To download the data stored in the navigator it is necessary to use a RS422 RS232 converter The connector where to attach the cable is indicated in the picture below RJ9 female connector RS422 Type connection The PinOut of the connector is the following Connector RJ9 i il 1 RS422 RX 2 RS422 RX 3 RS422 TX 4 RS422 TX The parameters issued by the communications are the followings 57600 bauds 8 data bits No parity 1 bit stop No flow control LH according the following code codifies the suitable cable for issue the communication within the card and the PC The cable shall be connected in the following way to download data from the card cable Laptop PC R232 port 4 dB9 connector Rj9 female connector 14 User Manual Navigator Card 01 08 2005 ENGLISH 3 Data Memory To download the data special software shall be installed on the Laptop Pc to permit the communication with the Navigator card For downloading of the logged data it is necessary only to connect a PC to the RS422 port of the Navigator card using a specific cable and to run a specific download application The application exports all lo
7. 05
8. ENGLISH User Manual Navigator Card Hw Rev 1 20 Engl sh HPAC Code 272599 Revision 2 01 08 2005 User Manual Navigator Card 01 08 2005 ENGLISH Il INTRODUCTION 3 Neri EEEE een Rene Eee er 3 PEE LE IIR Uem 3 2 1 NAVIGATOR CARD uncut eurer 3 2 2 HW CONFIGURATION een nee anne lee 6 2 2 1 Hirobus connection eee eee eee ese etse essa eres essa esse essere is 6 2 2 2 Sensor connection 2 cccccccccccccucuccccucuccccccucuccccucucucuecucucueueuecucaceucucaseseseusucueenenees La AQ OVS SO csi CHAINE E 10 2 NN ne 10 2AF FPROM DRE RR REA 11 DENSORS eo dees 12 PE Oise EI e nee eee eee 13 2 1 R9422 CONNECTION zungen 14 3 DATA MEMORY oO PEE 15 3 1 DAT AS USC 15 3 2 SOFTWARE INSTALLATION cccceccecceccccescescescenccecceccescescescescesseucessceceescescuseuseass 16 3 3 FIRST RUN CONFIGURATION c cccceccecccccscesccscencceccescescescescescescenceseceseescescescuseass 19 3 5 DATA DOWNLOADING cccccccesceccecceccecescesceccecescesceccsccscescescscescescesessessescescesescess 22 esse _____ 6_6_6________ __ 26 4 1 TECHNICAL SPECIFICATION ccccsccecceccecceccescesccnccecceccescescscescescesceesesscescescscescs 26 4 2 SPARE PARTS LIST ccsccscceccecceccecceccecccsceecc
9. able and connectors refer to the spare part list included in this manual Please note that a wrong connection could cause serious problems to the electronic devices Microface and Hiromatic for this reason we strongly recommend to use only first quality products or to buy the cables directly from your sales reps EIGHT POLES MODULAR EIGHT WIRES FLAT CABLE USE SCREENED CABLE WHEN CABLE IS RUNNING OUTSIDE THE UNIT Eight wires HIROBUS cable for Navigator connections eight poles connectors 10 User Manual Navigator Card 01 08 2005 ENGLISH 2 4 EPROM The Eprom is the device which stores the Program the Microface has to work with It doesn t store any user settings this is done by the Microface itself in the RAM and the E Prom The Version Name and the Number are printed on the Label of the Eprom The following Eproms shall be used to embed the Navigator Card in the EVM 1 60 043 or higher 2 MBit HPAC for Microface E 24VAC DC E48 1 60 043 or higher 2MBIT HPAC FOR MICROFACE E 48VDC E1G 1 60 043 or higher 2 MBit HPAC for HIROMATIC G EVGL1 1 60 043 or higher 4 MBit HPAC for HIROMATIC E EVGL1 2 60 043 or higher 4 MBit HPAC for HIROMATIC E Un power the Microface before mounting dismounting the Eprom Remove Eprom only with special tool never use a Screwdriver For correct direction of mounting please refer to the Micorface and Hiromatic Manuals Compare the Mark in the Eprom with the direction
10. e indication of the Hiromatic display 1 Go to the folder where you have installed the program For example as the case above C MEC NavigatorBoard 2 Explore the folder the following files should be present File Edit View Favorites Tools Help Back A Search Folders Po B Gf Nav exe S LINWISE EXE INSTALL LOG M5SimEv 8 OfficeScan MT E orcad Program Files E PSD Data is _ RECYCLER H4 SHADOW _ System volume Information sysbem sav VariCAD WINNT 423 WUTemp La in L 3 objectis Disk Free space 9 45 GB 327 KB Computer 5 Naw not connected DE File About COM CONNECT DISCONNECT NAVIGATOR BOARD GET 4 Goto File and select Exit 19 User Manual Navigator Card 01 08 2005 ENGLISH 5 Return to explore the folder now a file named as Nav cfg should be present in the directory 4 C MEC NavigatorBoard File Back A Search 54 Folders OS X zer Address __ CAMEC NavigatorBoard Edit View Favorites Tools Help Folders 2 INSTALL LOG NavigatorBoard E 64 MSimEv_8 OfficeScan NT orcad H Program Files PSD_Data 11 RECYCLER System Volume Information HL system sav tmp H VariCAD WINNT _ Temp gt Ae r Type Application Size 180 KB 180 KE J Computer 6 Open the Nav cfg file with a normal text
11. eccecceccescescescescusceecesceectssceseescuscuseeeees 26 2 User Manual Navigator Card 01 08 2005 ENGLISH 1 Introduction 1 1 Foreword Unit management and diagnostic runs in parallel to the level of service that a company can provide There are several parameters to be watched in order to understand how the machine runs and in order to anticipate possible failure which may happen into the unit To reach this target it is necessary to equip each unit with the Navigator card which can store all the necessary information for a programmable period The Navigator Card shall be connected with the Microface in order to share the information collected For this purpose a particular Eprom shall be installed in the Microface and in the Hiromatic to manage and evaluate the further data collected This User Manual describes the Navigator Card and contains information concerning the architecture of the refrigerant diagnose system 2 Hardware 2 1 Navigator Card The Navigator Card is a microprocessor based electronic board which is used to offer the option to monitor some additional temperature and pressure sensors capable to detect fundamental parameters to understand how the refrigerant circuit works These parameters are Evaporating Pressure Low pressure Condensing Pressure High pressure Refrigerant discharge Temperature Refrigerant suction Temperature Refrigerant liquid Temperature The refrigerant diagnosis requires 3 additiona
12. gged data automatically in Excel format for further processing The program itself connects through one of the computer s com ports it is enough to CONNECT and to GET DATA 3 1 Data storing The Navigator card has a 4 MBit flash memory on board which allows to store the logged data For logging intervals every 1 second all 5 sensors the logging time is 22 4 hours For logging intervals every 5 seconds only 1 sensors the logging time is 560 hours The selectable logging interval ranges from 1 second 22 4 hours for 5 sensors 112 hours for 1 only sensor to 12 75 minutes app 2 years for 5 sensors app 10 years for 1 only sensor Logging of various sensors can be enabled disabled separately for each individual sensor the logging interval can be set and is valid for all sensors with logging enabled In case of exceeding a specific threshold example dangerous high pressure the logging interval changes automatically to 1 second If this critical operating mode is passed without any cut out of safety devices the original logging interval will be set back If the critical operation results in a compressor failure the logging will stop 5 minutes after the failure with the advantage that the logging resolution regardless which general logging interval was set is 1 second when reaching the critical operating mode until 5 minutes after the fault 15 User Manual Navigator Card 01 08 2005 ENGLISH 3 2
13. in the Drawing 11 User Manual Navigator Card 01 08 2005 ENGLISH 2 5 Sensors PTC Temperature Sensor The PTC Sensor is used in Air Conditioners as well as in Chillers Superchillers There are different Types and lengths available please refer to the Spare Part List PTC Sensors are temperature sensors changing the resistance according to the temperature positive temperature coefficient The connection is 2 poles The length of the cable for the sensor ranges from 1 5 to 10 meters Measuring Element un Cable D PTC Sensor Pressure Transducers The KELLER Series 21 21PRO are extremely reliable and cost effective pressure transmitters They are use to convert hydraulic or pneumatic pressure into an electrical current output signal in the reange 4 20 mA linearly proportional to the input pressure The signal can be sent directly to the Navigator Card which provides also to furnish the phantom supply for the transducer The connection is 2 poles The length of the cable for the transducer is 2 meters Pressure Transducer Cable D Pressure Transducer 12 User Manual Navigator Card 01 08 2005 ENGLISH 2 6 Housing The Navigator card is compatible with the Microface housing as indicated in the following pictures This encansing could be used as alternative solution to the 4 plastic pins Usage of microface s housing for one Navigator 1424014 Note the stop point on the
14. l PTC temperature sensors and 2 pressure sensors for each refrigerant circuit Those information will be evaluated by the Microface To connect this sensors to the Microface an additional Navigator card is necessary 2 for twin circuit units The Navigator card shall be connected to the Microface through Hirobus Never add remove Jumpers when Hirobus is connected on the Navigator The Navigator Card can also be suitable to get the low pressure measurement for single or twin compressor circuit in case to use the Fc Dx options set in the software see Sw manual 3 User Manual Navigator Card 01 08 2005 ENGLISH 2 1 1 Navigator card layout RS422 connector Address Selector P2160 ri kj Bi P j in 2 1 20 Temperature connector 4 User Manual Navigator Card 01 08 2005 ENGLISH 2 1 2 Details of Inputs PTCI Discharge PTC2 Suction PTC3 Liquid D User Manual Navigator Card 01 08 2005 ENGLISH 2 2 Hw Configuration 2 2 1 Hirobus connection The refrigerant diagnosis as said above requires 3 additional PTC temperature sensors and 2 pressure sensors for each refrigerant circuit To connect this sensors to the Microface the Navigator card shall be connected to the Microface through Hirobus in the following way a 01011 BD B B B LB I TE a a a 00110111 D mi TYPE B JE AK un n
15. mn CJC3 CONNECTION HIROBUS 8 wires screened flat cable Microface Navigator card 1 200000 200000 EPROM Screen connected on both sides to earth MAX LENGTH 5m inside unit For twin circuit units an additional Navigator Card shall be used and connected with Hirobus as in the following drawing 1111111111111111 0110100010101 0010101 0110110010100 0010111 Microface Navigator card 1 Navigator card 2 200000 200000 Cle o KALI MA CONNECTION TYPE B HIROBUS 8 wires screened flat cable Screen connected on both sides to earth MAX LENGTH 5m inside unit 6 User Manual Navigator Card 01 08 2005 ENGLISH In case of other devices are connected on the same bus like Humitemp they can share the same bus as in the example indicated to Humitemp EEAP Hirosensor 2T Sensors O 7100010 DII 0 D000000000000000 Microface Navigator card I 200000 B CONNECTION TYPE B HIROBUS 8 wires screened flat cable Screen connected on both sides to earth MAX LENGTH 5m inside unit The T adapter is necessary only in case the position of the Navigator
16. mn TIME indicates the data and the time of the sample stored inside the non volatile memory of the navigator The other columns indicate PTCO Refrigerant discharge temperature PTC1 Refrigerant suction temperature PTC2 Refrigerant liquid temperature High pressure With this data it is possible to make tables comparisons and charts Temperarature Probes Compressor ON 70 Discharge Temp Liquid Temp Suction Temp Temperature C 24 User Manual Navigator Card 01 08 2005 25 Pressure bar ENGLISH Pressure Transducers Compressor ON User Manual Navigator Card 01 08 2005 High Pressure Low Pressure ENGLISH 4 APPENDIX 4 1 Technical specification NAVIGATOR CARD Power Supply Directly form HiroBus slave bus resistive for PTC 2k KTY81 210 probes Maximun Operating Temperature 0 not condensating to 55 C Microcontroller Used ATMEL 8 10 bit ADC 8K Bytes FLASH IKByte RAM 512Bytes EEPROM Non volatile memory EEprom AT45DB041B with 4Mbit memory 1 000 000 000 4 MBit Memory Flash with time date to store sensors data write cycles for about 1000 values with time index 4 2 Spare parts list _ eee Pressure Transducer Keller PA21M 0 10 Bar 26 User Manual Navigator Card 01 08 20
17. ration Ja Select Program Manager Group Enter the name of the Program Manager group to add NavigatorBoard icons to MECN avigatarBaard Accessores Administrative Tools Bussmann Software Cadence License Manager L atris ICA Client Corel Graphics Suite 11 Crimson Editor CyberDOCS Integration Component 4 0 DOCSFusion Services 55 Graphilode HI TECH Software Macromedia Metrowerks Cancel The installation program will ask you the name of the program manager group that will be created Press Next if you don t want any modifications to the default options otherwise proceed to modify the group name Ja Start Installation ou are now ready to install NavigatorBoard Fress the Mest button to begin the installation or the Back button to reenter the installation information Cancel 17 User Manual Navigator Card 01 08 2005 ENGLISH Finally pressing Next the last warning will let to start the installation of the main program in your PC Installation Complete At the end of the successfully installation the above message will be displayed Press Finish to go ahead 18 User Manual Navigator Card 01 08 2005 ENGLISH 3 3 First run configuration Once finished to install the program the following steps should be performed in order to ensure the correct data synchronization between the data stored in the Navigator Card and th
18. tion parameters were selected 490 NAVIGATOR 3 6 SETUP 491 REFRIGERANT R407C 0 0V 10V 31 0 0 0V 10V 10 5 4947HP1 LP1 4 7V 28V 57 0 0V 10 0V 30 0 0 0V 10 0V 10 0 497 2 LP2 4 7V 28V 57 In the Nav cfg file the following variables should be changed accordingly to it P1 Pressure At Minimum In Tenth Bar 75 P1 Pressure At Maximum In Tenth Bar 310 P1 Voltage At Minimum In Tenth Volt 0 P1 Voltage At Maximum In Tenth Volt 100 P2 Pressure At Minimum In Tenth Bar 25 P2 Pressure At Maximum In Tenth 105 P2 Voltage At Minimum In Tenth Volt O P2 Voltage At Maximum In Tenth Volt 100 User Manual Navigator Card 01 08 2005 ENGLISH 8 Save the configuration and exit the text editor Standard configuration The following configuration parameters should be applied for the High and Low pressure sensors High Pressure Low Pressure SENSOR OFFSET Ip 0 0V 2 5 bar 10V 10 5 bar Once configured the system the data read from the Hiromatic through the Navigator must coincide both with the manometer indication on the machine and with the indication of data to download The following tables were verified for both high and low pressure 3 5 Data downloading Once configured the system accordingly to the steps above it is possible to download the data stored in the non volatile memory of the navigator following the next steps 1 Connect Rs422 232 cable according the picture below
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