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1. EVD evolution 030222041 rel 1 0 01 06 2008 46 CAREL CAREL S p A Via dell Industria 11 35020 Brugine Padova Italy Tel 39 049 9716611 Fax 39 049 9716600 e mail carel carel com www carel com Agenzia Agency 030222041 rel 1 0 01 06 2008
2. 6 3 Special control status 7 PROTECTORS 28 PA M 28 8 PARAMETERS TABLE 31 81 Unit of MU ertet tete e eec 34 8 2 Variables shown on the display 255 8 5 Variables only accessible via serial 35 9 ALARMS 37 S ABI ete eiat le ape 37 9 2 Alarm relay configuration 38 93 SENSO ettet edente 38 OA Control 39 95 EEV motor alarm 39 9 6 PLAN error 40 9 7 LAN error alarm for tLAN and RS485 Modbus driver 40 10 TROUBLESHOOTING 4l 11 TECHNICAL SPECIFICATIONS 43 12 APPENDIX VPM VISUAL PARAMETER MANAGER 44 12 1 Installation 44 122 Programming VPM ici 44 12 5 Copying the setup 124 Setting the default parameters P 12 5 Updating the driver and display 45 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL 1 INTRODUCTION EVD evolution is a driver for double pole stepper motors designed for to control the electronic expansion valve in refrigerant circuits It is designed for DIN rail assembly and is fitted with plug in screw terminals It controls refrigerant superheat and optimises the efficiency ofthe refrigerant circuit guaranteeing maximum flexibility being compatible with various types of refrigerants and valves in applications with chil
3. Main control Variable displayed Superheat control Transcritical Hot gas Hot gas EPR back Analogue Auxiliary control CO bypass bypass pressure positioning HiTcond Modulating temperature pressure thermostat Valve opening 96 Valve position step Current cooling capacity unit Control set point Superheat Suction temperature Evaporation temperature Evaporation pressure Condensing temperature Condensing pressure Modulating thermostat temperature EPR pressure back pressure Hot gas bypass pressure Hot gas bypass temperature CO gas cooler outlet temperature CO gas cooler outlet pressure CO gas cooler pressure set point Sensor S1 reading Sensor S2 reading Sensor 53 reading Sensor S4 reading 4 to 20 mA input value 0 to 10 Vdc input value Status of digital input DI1 Status of digital input DI2 EVD firmware version Display firmware version Tab 8 b Digital input status 0 open 1 closed Note the readings of sensors 51 52 53 S4 are always displayed regardless of whether or not the sensor is connected 8 3 Variables only accessible via serial link Description Default Min Max Type CAREL SVP Modbus R W Sensor S1 reading 0 20 290 200 2900 A 1 0 R Sensor 52 reading 0 60 870 200 392 A 2 R Sensor 53 reading 0 20 290 200 2900 A 3 2 R Sensor S4 reading 0 60 76 200 392 A 4 3 R Suction temperature 0 60 76 200 392 A 5 4 R Evaporation temperatur
4. The superheat set point is too low Increase the superheat set point Initially set it to 12 C and check that there is no longer return of liquid Then gradually reduce the set point always making sure there is no return of liquid Low superheat protection ineffective If the superheat remains low for too long with the valve that is slow to close increase the low superheat threshold and or decrease the low superheat integration time Initially set the threshold 3 C below the superheat set point with an integration time of 3 4 seconds Then gradually lower the low superheat threshold and increase the low superheat integration time checking that there is no return of liquid in any operating conditions Stator broken or connected incorrectly Disconnect the stator from the valve and the cable and measure the resistance of the windings using an ordinary tester The resistance of both should be around 36 ohms Otherwise replace the stator Finally check the electrical connections of the cable to the driver Valve stuck open Check if the superheating is always low 2 C with the valve position permanently at 0 steps If so set the valve to manual control and close it completely If the superheat is always low check the electrical connections and or replace the valve The valve opening at start parameter is too high on many cabinets in which the control set point is often reached for multiplexed cabinets onl
5. 9 6 pLANerroralarm If the connection to the pLAN network is offline for more than 6s due to an electrical problem the incorrect configuration of the network addresses or the malfunction of the pCO controller a pLAN error alarm will be signalled The pLAN error affects the control of the driver as follows case 1 unit in standby digital input DI1 disconnected the driver wil remain permanently in standby and control will not be able to start case 2 unit in control digital input DI1 disconnected the driver wil stop control and will go permanently into standby case 3 unit in standby digital input DI1 connected the driver wil remain in standby however control will be able to start if the digita input is closed In this case it will start with current cooling capacity 100 case 4 unit in control digital input DIT connected the driver wil remain in control status maintaining the value of the current cooling capacity If the digital input opens the driver will go to standby and control will be able to start again when the input closes In this case i will start with current cooling capacity 100 9 7 LAN error alarm for tLAN and RS485 Modbus driver If the driver used is fitted for tLAN or RS485 Modbus connection to a supervisor or other type of controller no LAN error will be signalled and the situation will have no affect on control The green NET LED will however indicate any
6. incorrect driver valve electrical connection electronic problems with the valve control driver secondary fluid evaporator fan pump malfunction insufficient refrigerant in the refrigerant circuit refrigerant leaks lack of subcooling in the condenser electrical mechanical problems with the compressor processing residues or moisture in the refrigerant circuit O Note the valve unblock procedure is nonetheless performed in each of these cases given that it does not cause mechanical or control problems Therefore also check these possible causes before replacing the valve 27 EVD evolution 030222041 rel 1 0 01 06 2008 These are additional functions that are activated in specific situations that are potentially dangerous for the unit being controlled They feature an integral action that is the action increases gradually when moving away from the activation threshold They may add to or overlap disabling normal PID superheat control By separating the management of these functions from PID control the parameters can be set separately allowing for example normal control that is less reactive yet much faster in responding when exceeding the activation limits of one of the protectors 7 1 Protectors The protectors are 4 LowSH low superheat LOP low evaporation temperature MOP high evaporation temperature HiTcond high condensing temperature
7. CONFIGURAZIONE A_ Network address 198 A Refrigerant R404A R22 R134a R407C R410A R507A R290 R600 R600a R717 R744 R728 R1270 R417A R422D A Valve CAREL Alco EX4 Alco EX5 Alco EX6 A A 207 11 138 13 140 R404A CAREL 5 x 14 141 co EX7 co EX8 330Hz suggested by CAREL co EX8 500Hz specified by Alco Sporlan SEI 0 5 11 Sporlan SER 1 5 20 Sporlan SEI 30 Sporlan SEI 50 Sporlan SEH 100 Sporlan SEH 175 Danfoss ETS 25B Danfoss ETS 50B Danfoss ETS 100B Danfoss ETS 250 Danfoss ETS 400 A Sensor 51 Ratiometric OUT 0 to 5 V 1 to 42 barg gt 1 1 1 Ratiometric 143 Electronic OUT 4 to 20 MA 1 to 9 3 barg 0 5 to 7 barg 0 4 to 9 2 barg 1 to 9 3 barg 0 to 17 3 barg 0 4 to 34 2 barg 0 to 34 5 barg 0 to 10 barg 0 to 18 2 bar 0 to 25 barg 0 to 30 barg 0 to 44 8 barg 0 to 45 barg remote 0 5 to 7 barg remote 0 to 10 barg remote 0 to 18 2 barg remote 0 to 25 barg remote 0 to 30 barg remote 0 to 44 8 barg External signal 4 to 20 mA A Main control Multiplexed Multiplexed cabinet cold room cabinet cold Cabinet cold room with on board compressor room Perturbed cabinet cold room Cabinet cold room with sub critical CO R404A condenser for sub critical CO2 Air conditioner chiller with plate heat exchanger Air conditioner chiller with tube bundle heat exchanger Air conditioner chiller with finned coil heat exchanger A
8. 0 alarm disabled C High evaporation temperature alarm delay MOP 600 0 8000 5 42 169 0 alarm disabled C High condensing temperature alarm delay HiTcond 600 0 8000 5 44 171 0 alarm disabled C Low suction temperature alarm threshold 50 60 76 200 392 CAF A 26 25 Low suction temperature alarm delay 300 0 8000 5 9 36 0 alarm disabled VALVE C Minimum EEV steps 50 0 9999 step 30 157 C Maximum EEV steps 480 0 9999 step 31 58 C EEV closing steps 500 0 9999 step 36 163 C_ Rated EEV speed 50 1 2000 step s 32 159 C Rated EEV current 450 0 800 mA 33 160 C EEV holding current 100 0 800 mA 35 162 C EEV duty cycle 30 1 100 34 161 C_ Synchronise position in opening 1 0 1 D 20 19 C_ Synchronise position in closing 1 0 1 D 21 20 Tab 8 a User A Service installer C Manufacturer Type of variable A analogue D digital I integer 8 1 Unit of measure In the configuration parameters menu with access by manufacturer password the user can choose the unit of measure for the driver international system C K barg imperial system F R psig A Attention the drivers EVD evolution pLAN code EVDOOOE1 connected in pLAN to a pCO controller do not manage the change of the unit of measure O Note the units of measure K and R relate to degrees Kelvin or Rankine adopted for measuring the superheat and the related parameters
9. 48 A LowSH protection threshold 5 40 72 superheat set K R A 56 55 point C_ LowSH protection integration time 15 0 800 5 A_ 55 54 A LOP protection threshold 50 60 76 MOP protec C F A 52 51 tion threshold C LOP protection integration time 0 0 800 5 51 50 OP protection threshold 50 LOP protec 200 392 C F A 54 53 tion threshold C OP protection integration time 20 0 800 S A 53 52 A_ Enable manual valve positioning 0 0 1 D 24 23 A anual valve position 0 0 9999 step 39 166 SPECIAL A HiTcond threshold 80 60 76 200 392 C CP A 58 57 C_ HiTcond integration time 20 0 800 5 A 57 56 A odulating thermostat set point 0 60 76 200 392 C CF A 61 60 A odulating thermostat differential 0 1 0 1 0 2 100 180 CF A 60 59 E odulating thermostat superheat set point offset 0 0 0 100 180 K R A 59 58 C Coefficient A for CO control 33 100 800 A 63 62 33 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL a e tla 8 Parameter description Def Min Max UOM e m 2 Notes 3 5 C Coefficient B for CO control 22 7 100 800 A 64 63 ALARM CONFIGURATION C Low superheat alarm delay LowSH 300 0 8000 S 43 70 0 alarm disabled C Low evaporation temperature alarm delay LOP 300 0 8000 5 41 168
10. Protection action Check the LOP protector alarm thre ion temp activated flashing configuration already active shold and delay parameters parameter OP high evapo MOP protection ALARM amp MOP Depends on automatic Protection action Check the MOP protector alarm ration tempera activated ashing configuration already active threshold and delay parameters ture parameter HiTcond high HiTcond protec ALARM amp MOP Depends on automatic Protection action Check the LowSH protector alarm condensing ion activated ashing configuration already active threshold and delay parameters emperature parameter Low suction Threshold and de ALARM flashing Depends on automatic o effect Check the threshold and delay temperature ay time exceeded configuration parameters parameter 37 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL Type of alarm __ Cause of alarm LED Display Relay Reset Effect on control Checks solutions EEEPROM dama EEPROM for red alarm ALARM flashing Depends on Replace dri Total shutdown Replace the driver Contact service ged operating and or LED configuration ver Contact unit parameters parameter service damaged EEV motor error Valve motor fault red alarm ALARM flashing Depends on automatic Interruption Check the connections and the con L
11. 6 control status Display writings Control status Protection active ON Operation LowSH Low superheat OFF Standby LOP Low evaporation tempe rature POS Positioning MOP High evaporation tempe rature WAIT Wait HiTcond High condensing tempe rature CLOSE Closing Tab 3 b Keypad Button Function Prg opens the screen for entering the password to access program ming mode 5 e if in alarm status displays the alarm queue Fe T e in the Manufacturer level when scrolling the parameters shows the explanation screens Help Esc exits the Programming Service Manufacturer and Display modes after setting a parameter exits without saving the changes 4 4 navigates the display screens increases decreases the value UP DOWN switches from the display to parameter programming mode Enter confirms the value and returns to the list of parameters Tab 3 c O Note the variables displayed as standard can be selected by configuring the parameters Variable 1 on display and Variable 2 on display accordingly See the list of parameters 3 3 Display mode display Display mode is used to display the useful variables showing the operation of the system The variables displayed depend on the type of control selected 1 press Esc to switch to the standard display 2 press UP DOWN the display shows a graph of the superheat the percentage of valve opening the evaporation pre
12. Modbus connection aa porta seriale di servizio rimuovere il coperchio per potervi accedere Tab 2 a 9 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL 2 4 Installation and ammonia fumes saline mist smoke to avoid corrosion and or oxidation strong magnetic and or radio frequency interference avoid installing the appliances near transmitting antennae exposure of the driver to direct sunlight and to the elements in general For installation proceed as follows with reference to the wiring diagrams 1 connect the sensors and power supply the sensors can be installed a maximum distance of 10 metres away from the controller as long as shielded cables are used with minimum cross section of 1 mm connect only one end of the shield to the earth in the electrical panel 2 connect any digital inputs maximum length 30 m 3 connect the power cable to the valve motor recommended 4 wire shielded cable AWG 18 22 Lmax 10 m 4 carefully evaluate the maximum capacity ofthe relay output specified in the chapter Technical specifications 5 program the driver if necessary see the chapter User interface 6 connect the serial network if featured follow to the diagrams below for the earth connection A Important When connecting the driver the following warnings must be observed incorrect connection to the power supply may seriously damage the driver use cable ends suitable fo
13. O Note all the driver parameters can be modified by entering the Manufacturer level if no button is pressed after 5 min the display automatically returns to the standard mode CAREL 4 COMMISSIONING 4 1 Commissioning Once the electrical connections have been completed see the chapter on installation and the power supply has been connected the operations required for commissioning the driver depend on the type of interface used however essentially involve setting just 4 parameters refrigerant valve type of pressure sensor S1 and type of main control Types of interfaces DISPLAY after having correctly configured the setup parameters confirmation will be requested Only after confirmation will the driver be enabled for operation the main screen will be shown on the display and control will be able to commence when requested by the pCO controller via pLAN or when digital input DI1 closes See paragraph 4 2 VPM to enable control of the driver via VPM set Enable EVD control o 1 this is included in the safety parameters in the special parameters menu under the corresponding access level However the setup parameters should first be set in the related menu The driver will hen be enabled for operation and control will be able to commence when requested by the pCO controller via pLAN or when digital input DI1 closes If due to error or for any other reason Enable EVD control should be set to 0 zero t
14. When changing the unit of measure all the values of the parameters saved on the driver and all the measurements read by the sensors will be recalculated This means that when changing the units of measure control remains unaltered Example 1 The pressure read is 100 barg this will be immediately converted to the corresponding value of 1450 psig Example 2 The superheat set point parameter set to 10 K will be immediately converted to the corresponding value of 18 R Example 3 The Temperature 4 maximum alarm value parameter set to 150 C will be immediately converted to the corresponding value of 302 F O Note because of some internal arithmetics limitations of the driver it will not be possible to convert the pressure values higher than 200 barg 2900 psig and the temperature values higher than 200 C 392 F EVD evolution 030222041 rel 1 0 01 06 2008 34 CAREL 8 2 Variables shown on the display Thetable below shows the variables available in display mode depending on the setting of the Main control and Auxiliary control parameters press the UP DOWN button to enter display mode press the DOWN button to move to the next variable screen press Esc to return to the standard display
15. check the electrical connections of the cable to the driver Valve stuck closed Use manual control after start up to completely open the valve If the superheat remains high check the electrical connections and or replace the valve The cabinet does not reach the set temperature and the position of the valve is always 0 for multiplexed cabinets only The driver in pLAN or tLAN configura tion does not start control and the valve remains closed Check the pLAN tLAN connections Check that the pCO application connected to the driver where featured correctly manages the driver start signal Check that the driver is NOT in stand alone mode The driver in stand alone configuration does not start control and the valve remains closed Check the connection of the digital input Check that when the control signal is sent that the input is closed correctly Check that the driver is in stand alone mode Tab 10 a EVD evolution 030222041 rel 1 0 01 06 2008 42 CAREL 11 TECHNICAL SPECIFICATIONS Power supply di Vac 10 15 50 60 Hz to be protected by an external 2 A type T fuse Use a dedicated class 2 transformer max 100 VA max 5 m Power input 30 VA Emergency power supply 22 Vdc 5 If the optional EVBATOO200 300 module is installed Lmax 5 m Insulation between relay output and other outputs reinforced 6 mm in air 8 mm on surface 3750 V insulation Motor
16. 53 54 Tab 6 b Parameter description Def Configuration Sensor 53 Ratiom 1 to Ratiometric OUT 0 to 5 V Electronic OUT 4 to 20 mA 9 3 barg 1 to 4 2 barg 0 5 to 7 barg 0 4 to 92 barg 0 to 10 barg 1 to 9 3 barg 0 to 18 2 bar Oto 17 3 barg 0 to 25 barg 0 4 to 34 2 barg 0 to 30 barg 0 to 34 5 barg 0 to 44 8 barg 0 to 45 barg remote 0 5 to 7 barg remote 0 to 10 barg remote 0 to 18 2 barg remote 0 to 25 barg remote 0 to 30 barg remote 0 to 44 8 barg Tab 6 c EVD evolution 030222041 rel 1 0 01 06 2008 24 CAREL 6 FUNCTIONS Calibrating pressure sensors S1 3 and temperature sensors S2 and S4 offset and gain parameters In case it is necessary to make a calibration of the pressure sensor 51 and or S3 it is possible to use the offeset parameter which represents a constant that is added to the signal across the entire range of measurement and can be expressed in barg psig If the 4 to 20 mA signal coming from an external controller on input S1 needs to be calibrated both the offset and the gain parameters can be used the latter which modifies the gradient of the line in the field from 4 to 20 mA ofthe temperature sensor S2 and or S4 it is possible to use the offset parameter which represents a constant that is added to the signal across the entire range of measurement and can be expressed in C F If the 0 to 10 Vdc signal coming from an external controller on input S2 nee
17. O Note The HITCond protection requires an additional sensor 53 to those normally used either installed on the driver or connected via tLAN or pLAN to a controller The protectors have the following main features activation threshold depending on the operating conditions of the controlled unit this is set in Service programming mode integration time which determines the intensity if set to 0 the protector is disabled set automatically based on the type of main control alarm with activation threshold the same as the protector and delay if set to 0 disables the alarm signal O Note The alarm signal is independent from the effectiveness ofthe protector and only signals that the corresponding threshold has been exceeded If a protector is disabled null integration time the relative alarm signal is also disabled Each protector is affected by the proportional gain parameter K for the PID superheat control The higher the value of K the more intense the reaction of the protector will be Characteristics of the protectors Protection Reaction Reset LowSH Intense closing Immediate LOP Intense opening Immediate MOP Moderate closing Controlled HiTcond Moderate closing Controlled Tab 7 a Reaction summary description of the type of action in controlling the valve Reset summary description of the type of reset following the activation of the protector Reset is controlled to avoid sw
18. an alarm relay output See the chapter on Alarms This parameter should be set based on the ratio between the rated cooling capacity of the evaporator and the valve e g rated evaporator cooling capacity 3kW rated valve cooling capacity 10kW valve opening Parameter description Def Configuration Relay configuration Alarm Disabled Alarm relay open when alarm active Solenoid valve relay relay open in standby Valve relay alarm open in standby and control alarms Tab 6 f 6 2 Control status The electronic valve driver has 6 different types of control status each of which may correspond to a specific phase in the operation of the refrigeration unit and a certain status of the driver valve system The status may be as follows forced closing initialisation of the valve position when switching the instrument on standby no temperature control unit OFF wait opening of the valve before starting control also called pre positioning when powering the unit and in the delay after defrosting control effective control of the electronic valve unit ON positioning step change in the valve position corresponding to the start of control when the cooling capacity of the controlled unit varies only for pLAN EVD connected to a pCO stop end of control with the closing of the valve corresponds to the end of temperature control of the refrigeration unit unit OFF Forced closing Forced
19. closing is performed after the driver is powered up and corresponds to a number of closing steps equal to the parameter Closing steps based on the type valve selected This is used to realign the valve to the physical position corresponding to completely closed The driver and the valve are then ready for control and both aligned at 0 zero On power up first a forced closing is performed and then the standby phase starts Parametro description Def Min Max UOM Valve EEV closing steps 500 0 9999 step Tab 6 g Standby Standby corresponds to a situation of rest in which no signals are received to control the electronic valve This normally occurs when the refrigeration unit stops operating either when switched off manually e g from the button supervisor or when reaching the control set point during defrosts except for those performed by reversing of the cycle or hot gas bypass In general it can be said that the electronic valve driver is in standby when the compressor stops or the control solenoid valve closes The valve is closed or open delivering around 2596 of the flow rate of refrigerant based on the setting of the valve open in standby parameter In this phase manual positioning can be activated Parameter description Def Min Max UOM Valve open in standby 0 0 1 O disabled valve closed 1 enabled valve open 25 Tab 6 h Pre positioning
20. confirm the value repeat steps 2 3 4 5 to modify the values of the parameters refrigerant valve pressure sensor S1 main control O check that the electrical connections are correct if the configuration is correct exit the procedure otherwise choose NO and return to step 2 Configurtion End configuration Le EO y t Fay Prg Esc To simplify commissioning and amp possible malfunctions the driver will not start until the following have been configured network address refrigerant valve pressure sensor 51 type of main control that is the type of unit the superheat control is applied to O Note to exit the guided commissioning procedure press the DOWN button repeatedly and finally confirm that configuration has been completed The guided procedure CANNOT be ended by pressing Esc if the configuration procedure ends with a configuration error access Service parameter programming mode and modify the value of the parameter in question if the valve and or the pressure sensor used are not available in the list select any model and end the procedure Then the driver will be enabled for control and it will be possible to enter Manufacturer programming mode and set the corresponding parameters manually Loi on ccs EVD evolution 030222041 rel 1 0 01 06 2008 Network address The network address assigns to the driver an address for the serial connec
21. connection 4 wire shielded cable AWG 18 22 Lmax 10 m Digital input connection Digital input to be activated from voltage free contact or transistor to GND Closing current 5 mA Lmax 30m Sensors Lmax 10 m S1 ratiometric pressure sensor 0 to 5 V resolution 0 1 96 FS measurement error 2 FS maximum 1 typical electronic pressure sensor 4 to 20 mA resolution 0 5 96 FS measurement error 8 FS maximum 7 typical combined ratiometric pressure sensor 0 to 5 V resolution 0 1 96 FS measurement error 2 96 FS maximum 1 96 typical 4to 20 MA input max 24 mA resolution 0 5 FS measurement error 8 FS maximum 7 typical 52 low temperature NTC 1OkO at 25 C 50T90 C measurement error 1 C in the range 50T50 C 3 C in the range 50T90 C high temperature NTC 50kQ at 25 C 40 150 C measurement error 1 5 C in the range 20T115 C 4 C in the range outside of 20 115 C combined NTC TOKO at 25 C 40T120 C measurement error 1 C in the range 40T50 G 3 C in the range 50T90 C 0 to 10 V input max 12 V resolution 0 1 FS measurement error 9 FS maximum 8 typical 53 ratiometric pressure sensor 0 to 5 V resolution 0 1 96 FS measurement error 2 FS maximum 1 typical electronic pressure sensor 4 to 20 MA resolution 0 5 96 FS measurement error 8 FS maximum 7
22. electrical panels 230Vac Fig 2 e Case 3 multiple drivers connected in a network powered by different transformers with just one earth point Typical application for a series of drivers in different electrical panels 230 Vac Fig 2 h Key 1 service serial port Fig 2 f 2 adapter 3 USB tLAN converter 4 personal computer A Important avoid installing the driver in environments with the following characteristics O Note when using the service serial port connection the VPM relative humidity greater than the 9096 or condensing program can be used to configure the driver and update the driver strong vibrations or knocks and display firmware downloadable from http ksa carel com exposure to continuous water sprays See appendix 1 exposure to aggressive and polluting atmospheres e g sulphur EVD evolution 030222041 rel 1 0 01 06 2008 10 CAREL 2 6 Upload Download and Reset parameters display press the Help and Enter buttons together for 5 seconds 2 a multiple choice menu will be displayed use UP DOWN to select the required procedure 3 confirm by pressi 4 the display will p ng ENTER ompt for confirmation press ENTER 5 atthe end a message will be shown to notify the operation if the operation was su UPLOAD the disp source driver DOWNLOAD the di target dr
23. evolution 030222041 rel 1 0 01 06 2008 CAREL Content 1 INTRODUCTION 7 Ti Models iubente bela dts 7 12 Functions and main characteristics 7 2 INSTALLATION 9 2 1 DIN rail assembly and 9 22 Description of the 9 2 5 Connection diagram superheat control 9 2 4 Installation riale 10 2 5 Connecting the USB tLAN converter 10 2 6 Upload Download and Reset parameters display 11 2 7 General connection 12 3 USER INTERFACE 13 3 1 Assembling the display board ACCESSOry 13 32 Display and keypad UU 3 5 Display mode display 3 4 Programming mode display 14 4 COMMISSIONING 15 4 Commissioning 15 4 Guided commissioning procedure 15 4 5 Checks after commissioning tee 17 44 Other UNGON S niiina 17 5 CONTROL 18 5 Main and auxiliary control 18 52 Supetlheat conttol ctii 18 5 5 Special cto mirala bete ndn 19 5 4 Auxiliary Control tnter 22 6 FUNCTIONS 24 6 Inputs and outputs isisisi nini 6 2 Control status
24. in the suitable direction to realign the valve when fully opened or closed Note realignment is in intrinsic part of the forced closing procedure and is activated whenever the driver is stopped started and in the standby phase the possibility to enable or disable the synchronisation procedure depends on the mechanics of the valve When the setting the valve parameter the two synchronisation parameters are automatically defined The default values should not be changed Unblock valve This procedure is only valid when the driver is performing superheat control Unblock valve is an automatic safety procedure that attempts to unblock a valve that is supposedly blocked based on the control variables superheat valve position The unblock procedure may or may not succeed depending on the extent of the mechanical problem with the valve If for 10 minutes the conditions are such as to assume the valve is blocked the procedure is run a maximum of 5 times The symptoms of a blocked valve doe not necessarily mean a mechanical blockage They may also represent other situations mechanical blockage of the solenoid valve upstream of the electronic valve if installed electrical damage to the solenoid valve upstream of the electronic valve blockage of the filter upstream of the electronic valve if installed electrical problems with the electronic valve motor electrical problems in the driver valve connection cables
25. is always in bar gauge barg In the manufacturer menu the parameters corresponding to the range of measurement and the alarms can be customised if the sensor used is not in the standard list If modifying the range of measurement the driver will detect the modification and indicate the type of sensor S1 as Customised The software on the driver takes into consideration the unit of measure If a range of measurement is selected and then the unit of measure is changed from bars to psi the driver automatically updates in limits of the range of measurement and the alarm limits BY default the main control sensor S2 is set as CAREL NTC Other types of sensors can be selected in the service menu Unlike the pressure sensors the temperature sensors do not have any modifiable parameters relating to the range of measurement and consequently only the models indicated in the list can be used see the chapter on Functions and the list of parameters In any case in manufacturer programming mode the limits for the sensor alarm signal can be customised Main control Setting the main control defines the operating mode of the driver Parameter description Def Configuration Main control multiplexed Superheat control cabinet cold multiplexed cabinet cold room room cabinet cold room with on board compressor perturbed cabinet cold room cabinet cold room with sub critical CO2 R404A condenser for sub criti
26. needs to be decreased This can be done by controlled closing of the electronic valve implying superheat is no longer controlled and an increase in the superheat temperature The protector will thus have a moderate reaction that tends to limit the increase in the condensing temperature keeping it below the activation threshold while trying to stop the superheat from increasing as much as possible Normal operating conditions will not resume based on the activation of the protector but rather on the reduction in the outside temperature The system will therefore remain in the best operating conditions a little below the threshold until the environmental conditions change T_COND T_COND_TH TCONDIH A PS 71272222 ro os HiTcond OFF ON PID OFF ALARM OFF LE 1 i D i t tt Fig 7 d Key T COND Condensing temperature T COND HiTcond TH threshold HiTcond HiTcond protection status ALARM Alarm PID PID superheat control t Time D Alarm delay O Note the HiTcond threshold must be greater than the rated condensing temperature of the unit and lower then the calibration of the high pressure switch the closing of the valve will be limited if this causes an excessive decrease in the evaporation temperature EVD evolution 030222041 rel 1 0 01 06 2008 30 CAREL 8 PARAMETERS TABLE Parameter description Def Min Max UOM Notes user CAREL SVP Modbus
27. problems in the line The NET LED flashing or off indicates the problem has lasted more than 150 s EVD evolution 030222041 rel 1 0 01 06 2008 40 CAREL CAREL 10 TROUBLESHOOTING The following table lists a series of possible malfunctions that may occur when starting and operating the driver and the electronic valve These cover the most common problems and are provided with the aim of offering an initial response for resolving the problem PROBLEM CAUSE SOLUTION The superheat value measu red is incorrect The probe does not measure correct values Check that the pressure and the temperature measured are correct and that the probe position is correct Check that the minimum and maximum pressure parameters for the pressure transducer set on the driver correspond to the range of the pressure probe installed Check the correct probe electrical connections The type of refrigerant set is incorrect Check and correct the type of refrigerant parameter Liquid returns to the com pressor during control The type of valve set is incorrect Check and correct the type of valve parameter The valve is connected incorrectly rotates in reverse and is open Check the movement of the valve by placing it in manual control and closing or ope ning it completely One complete opening must bring a decrease in the superheat and vice versa If the movement is reversed check the electrical connections
28. typical electronic pressure sensor 4 to 20 mA remote Maximum number of controllers connected 5 combined ratiometric pressure sensor 0 to 5 V resolution 0 1 96 FS measurement error 2 96 FS maximum 1 96 typical 54 low temperature NTC 10KO at 25 C 50T105 C measurement error 1 C in the range 50150 C 3 C in the range 50T90 C high temperature NTC 50kQ at 25 C 40 150 C measurement error 1 5 C in the range 201115 C 4 C in the range outside of 201115 C combined NTC 10kO at 25 C 40T120 C measurement error_1 C in the range 40T50 C 3 C in the range 50T90 C Relay output normally open contact 5 A 250 Vac resistive load 2 A 250 Vac inductive load PF 0 4 Lmax 10 m Power to active sensors V m programmable output 5 Vdc 2 or 12 Vdc 10 RS485 serial connection Lmax 1000 m shielded cable LAN connection Lmax 30 m shielded cable pLAN connection Lmax 500 m shielded cable Assembly DIN rail Connectors plug in cable size 0 5 to 2 5 mm 12 to 20 AWG Dimensions LxHxW 70x110x60 Operating conditions 10T60 C lt 90 rH non condensing Storage conditions 20T70 C humidity 90 rH non condensing ndex of protector P20 Environmental pollution 2 normal Resistance to heat and fire Category D mmunity against voltage surges Category 1
29. ED configuration dition of the motor parameter PLAN error EVD pLAN network green ALARM flashing Depends on automatic Control based Check the network address settings pLAN only communication ET LED configuration on ID1 error ashing parameter pLAN network ETLED ALARM flashing Depends on automatic Control based Check the connections and that the connection error off configuration on ID1 pCO is on and working parameter LAN error EVD Network commu NETLED No message o change automatic No effect Check the network address settings tLAN RS485 Mo nication error ashing dBus Connection error NETLED No message o change automatic No effect Check the connections and that the off pCO is on and working Tab 9 a 9 2 Alarm relay configuration The relay contact is open when the driver is not powered L During normal operation it can be disabled and thus will be always n open or configured as A alarm relay during normal operation the relay contact is closed and NO opens when any alarm is activated It can be used to switch off the compressor and the system in the event of alarms solenoid valve relay during normal operation the relay contact is mon closed and is open only in standby There is no change in the event E 2 of alarms Y solenoid valve relay alarm during normal operation the relay contact Lul is closed and opens in standby and or for LowSH MOP HiTcond Fig 9 4 and low suc
30. EVD evolution CAR E L electronic expansion valve driver User manual LEGGI E CONSERVA gt QUESTE ISTRUZIONI lt READ AND SAVE THESE INSTRUCTIONS Integrated Control Solutions amp Energy Savings CAREL WARNINGS CAREL bases the development of its products on decades of experience in HVAC on the continuous investments in technological innovations to products procedures and strict quality processes with in circuit and functional testing on 100 of its products and on the most innovative production technology available on the market CAREL and its subsidiaries nonetheless cannot guarantee that all the aspects of the product and the software included with the product respond to the requirements of the final application despite the product being developed according to start of the art techniques The customer manufacturer developer or installer of the final equipment accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and or equipment CAREL may based on specific agreements acts as a consultant for the positive commissioning of the final unit application however in no case does it accept liability for the correct operation ofthe final equipment system The CAREL product is a state of the art product whose operation is specified in the technical documentation supplied with the product or can be downloaded e
31. K 0000 or piezoresistive pressure 3 brown transducer SPKTOO CO 4 green C Connection as positioner 4 to 20 mA input 5 configuration computer D Connection as positioner 0 to 10 Vdc input 6 USB tLAN converter E Connection to combined pressure temperature sensor SPKPOO TO 7 adapter 8 ratiometric pressure transducer F Connection to backup sensors 3 4 9 NTC sensor G Ratiometric pressure transducer connections SPKTOO RO O digital input 1 to enable control H Connections o other types of valves 1 contact up to 230 Vac A The maximum length of the connection cable to the EVBAT200 300 module is 5 m 2 solenoid valve 1 3 alarm signal The connection cable to the valve motor must be 4 wire shielded AWG 18 22 4 red 2 Lmax 10m 5 black 6 blue 7 supervision computer EVD evolution 030222041 rel 1 0 01 06 2008 12 CAREL 3 USER INTERFACE The user interface consists of 5 LEDs that display the operating status as shown in the table Fig 3 a Legenda LED ON OFF Flashing NET Connection available No connection Communication error OPEN Opening valve Driver disabled CLOSE Closing valve Driver disabled Active alarm Driver powered Driver not powered Tab 3 a Awaiting completion of the initial configuration 3 1 Assembling the display board accessory The display board once installed is used to perform all the configuration and p
32. K e t tr Jedi i Ta 5 Seide is required in the refrigerant iu For example a refrigeration system may include different showcases that operate at different Key temperatures showcases for frozen foods meat or dairy The different u t Valve position Ti Integration time temperatures of the circuits are achieved using pressure regulators e t Error Td Derivative time installed in series with each circuit The special EPR function Evaporator K Proportional gain Pressure Regulator is used to set a pressure set point and the PID control parameters required to achieve this Note that control is calculated as the sum of three separate contributions V V proportional integral and derivative the proportional action opens or closes the valve proportionally to E he variation in the superheat temperature Thus the greater the K proportional gain the higher the response speed of the valve The AM proportional action does not consider the superheat set point but ather only reacts to variations Therefore if the superheat value does la not vary significantly the valve will essentially remain stationary and P he set point cannot be reached the integral action is linked to time and moves the valve in proportion o the deviation of the superheat value from the set point The greate he deviations the more intense the integral action in addition the ower the value of T integration time the
33. ONFIGURATION Auxiliary control Disabled Disabled High condensing temperature protection on 53 Modulating thermostat on 54 Backup sensors on 53 amp 54 Tab 5 h For the high condensing temperature protection only available with superheat control an additional pressure sensor is connected to 53 that measures the condensing pressure For the modulating thermostat function only available with superheat control an additional temperature sensor is connected to S4 that measures the temperature on used to perform temperature control see the corresponding paragraph The last option available always requires the installation of both sensors 53 amp SA the first pressure and the second temperature Note if only one backup sensor is fitted under the manufacture parameters the sensor thresholds and alarm management can be set separately HITCond protection high condensing temperature The functional diagram is shown below Key CP Compressor EEV Electronic expansion valve C Condenser V Solenoid valve L Liquid receiver E Evaporator F Dewatering filter P Pressure sensor transducer S Liquid indicator T Temperature sensor For the wiring see paragraph 2 7 General connection diagram As already mentioned the HITCond protection can only be enabled if the control measures the condensing pressure temperature and responds moderately by closing the valve in the event where the condensi
34. Type of relay action 1C microswitching Class of insulation 2 Software class and structure A Conformity Electrical safety EN 60730 1 EN 61010 1 Electromagnetic compatibility EN 61000 6 1 EN 61000 6 2 EN 61000 6 3 EN 61000 6 4 EN61000 3 2 EN55014 1 EN55014 2 EN61000 3 3 Tab 11 4 43 EVD evolution 030222041 rel 1 0 01 06 2008 12 1 Installation On the http ksa carelcom website under the Parametric Controller Software section select Visual Parameter Manager A window opens allowing 3 files to be downloaded 1 VPM CDzip for burning to a CD 2 Upgrade setup 3 Full setup the complete program For first installations select Full setup for upgrades select Upgrade setup The program is installed automatically by running setup exe O Note if deciding to perform the complete installation Full setup first uninstall any previous versions of VPM 12 2 Programming VPM When opening the program the user needs to choose the device being configured EVD evolution The Home page then opens with the choice to create a new project or open an existing project Choose new project and enter the password which when accessed the first time can be set by the user Fig 12 a Then the user can choose to directly access to the list of parameters for the EVD evolution saved to EEPROM select tLAN This is done in real time ONLINE mode at the top right set the n
35. an also be used to check that the sensor and valve motor wiring is correct Once installation is complete the display can be removed as it is not necessary for the operation of the driver or alternatively kept in place to display the significant system variables any alarms and when necessary set the control parameters The driver can also be setup using a computer via the service serial port In this case the VPM program Visual Parameter Manager needs to be installed downloadable from http ksa carel com and the USB tLAN converter EVDCNVOOEO connected 1 1 Models Code Description EVDOOOOEO0 __ EVD evolution tLA EVDOOOOE10 EVD evolution pLA EVDOOOOE20 EVD evolution RS485 Modbus EVDOOOOEO1 EVD evolution tLAN multiple pack of 10 pcs EVDOOOOE11 EVD evolution pLAN multiple pack of 10 pcs EVD0000E21 EVD evolution RS485 Modbus multiple pack of 10 pcs EVDISOODEO Display for EVD evolution German EVDISOOENO Display for EVD evolution English EVDISOOESO Display for EVD evolution Spanish EVDISOOFRO Display for EVD evolution French EVDISOOITO Display for EVD evolution Italian EVDISOOPTO Display for EVD evolution Portuguese EVDCONOO21 EVD evolution connector kit 10 pcs for multiple pack Tab 1 a The codes with multiple packages are sold without connectors available separately in code EVDCON0021 1 2 Functi
36. ature 0 0 D 10 9 R amp MOP high evaporation temperature 0 0 D 11 10 R S LowSH low superheat 0 0 D 12 11 R lt lHiTcond high condensing temperature 0 0 D 13 12 R Status of digital input DI1 0 0 D 14 13 R Status of digital input DI2 0 0 D 15 14 R Enable EVD control 0 0 D 22 21 R W Tab 8 c Type of variable A analogue D digital l integer SVP variable address with CAREL protocol on 485 serial card Modbus variable address with Modbus protocol on 485 serial card EVD evolution 030222041 rel 1 0 01 06 2008 36 CAREL 9 ALARMS 9 1 Alarms There are two types of alarms system valve motor EEPROM sensor and communication control low superheat LOP MOP high condensing temperature low suction temperature The activation of the alarms depends on the setting of the threshold and activation delay parameters Setting the delay to 0 disables the alarms The EEPROM unit parameters and operating parameters alarm always stops control All the alarms are reset automatically once the causes are no longer present The alarm relay contact will open if the relay is configured as alarm relay using the corresponding parameter The signalling of the alarm event on the driver depends on whether the LED board or the display board is fitted as shown in the table below Note the alarm LED only comes on for the system alarms and not for the control alarms Example display syst
37. ave a minimum stable value allowed by the valve unit system A low superheat temperature in fact corresponds to a situation of probable instability due to the turbulent evaporation process approaching the measurement point of the sensors The expansion valve must therefore be controlled with extreme precision and a reaction capacity around the superheat set point which will almost always vary from 3 to 14 K Set point values outside of this range are quite infrequent and relate to special applications CAREL Key Parameter description Def Min Max UOM CP_ compressor EEV electronic expansion valve MOP protection threshold 50 LOP 200 392 C F C condenser V__ solenoid valve threshold L liquid receiver E evaporator MOP protection integ time 20 0 800 5 F dewatering filter P pressure sensor transducer SPECIAL S liquid indicator T temperature sensor HiTcond threshold 80 60 76 200 392 C CP HiTcond integration time 20 0 800 5 For the wiring see paragraph 2 7 General connection diagram Tab 5 4 PID parameters Superheat control as for any other mode that can be selected with the main control parameter is performed using PID control which in its 5 3 Special control simplest form is defined by the law i i EPR back pressure 1 de t This type of control can be used in many applications in which a constant u t
38. cal CO2 air conditioner chiller with plate heat exchanger air conditioner chiller with tube bundle heat exchanger air conditioner chiller with finned coil heat exchanger air conditioner chiller with variable cooling capacity perturbed air conditioner chiller Special control EPR back pressure hot gas bypass by pressure hot gas bypass by temperature transcritical CO gas cooler analogue positioner 4 to 20 mA analogue positioner 0 to 10 V Tab 4 6 The superheat set point and all the parameters corresponding to PID control the operation of the protectors and the meaning and use of sensors 51 and or S2 will be automatically set to the values recommended by CAREL based on the selected application During this initial configuration phase only the superheat control mode can be set which differs based on the application chiller refrigerated cabinet etc In the event of errors in the initial configuration these parameters can later be accessed and modified inside the service or manufacturer menu If the driver default parameters are restored RESET procedure see the chapter on Installation when next started the display will again show the guided commissioning procedure CAREL 4 3 Checks after commissioning After commissioning check that the valve completes a full closing cycle to perform alignment set if necessary in Service or Manufacturer program
39. ceeded se LED configuration parameter Sensor the Sensor S1 alarm management alarm range parameter 1 alarm manage and Pressure 1 MINIMUM 8 MAXI ment UM alarm value parameters Sensor S2 Sensor S2faulty red alarm ALARM flashing Depends on automatic Depends on Check the sensor connections Chec or exceeded se LED configuration parameter Sensor the Sensor S2 alarm management alarm range parameter S2 alarm manage and Temperature 52 MINIMUM ment AXIMUM alarm value parameters Sensor 53 Sensor S3 faulty red alarm ALARM flashing Depends on automatic Depends on Check the sensor connections Chec or exceeded se LED configuration parameter Sensor the Sensor 3 alarm management alarm range parameter 3 alarm manage and Pressure 3 MINIMUM MAXI ment UM alarm value parameters Sensor S4 Sensor 54 faulty red alarm ALARM flashing Depends on automatic Depends on Check the sensor connections Chec or exceeded se LED configuration parameter Sensor the Sensor 4 alarm management alarm range parameter 54 alarm manage and Temperature 4 MINIMUM and ment AXIMUM alarm value parameters LowSH low LowSH protection ALARM amp LowSH Depends on automatic Protection action Check the LowSH protector alarm superheat activated flashing configuration already active hreshold and delay parameters parameter low evapora LOP protection ALARM amp LOP Depends on automatic
40. ds to be calibrated both the offset and the gain parameters can be used the latter which modifies the gradient of the line in the field from 0 to 10 Vdc A a p MW Fig 6 a Key A offset B gain Parameter description Def Min Max UOM Sonde S1 calibration offset 0 60 870 60 870 barg psig 60 60 mA S1 calibration gain 4 to 20 mA 1 20 20 S2 calibration offset 0 20 290 20 290 C F volt 20 20 S2 calibration gain 0 to 10 V 1 20 20 53 calibration offset 0 60 870 60 870 barg psig S4 calibration offset 0 20 36 120 36 C F Tab 6 d Digital inputs Digital input DI1 is used to activate the control digital input 1 closed control activated digital input 1 open driver in standby see paragraph Control status As regards digital input 2 if configured this is used to tell the driver the active defrost status Defrost active contact DI2 closed When entering Manufacturer programming mode the start delay after defrost can be set see the following paragraphs Parameter description Def Configuration Configuration of DI2 Disabled Optimise valve control after defrost Control Start delay after defrost 10 0 60 Min Max UOM Disabled min Tab 6 e CAREL Output The relay output can be configured to control the solenoid valve or as
41. duct even if CAREL or its subsidiaries are warned of the possibility of such damage DISPOSAL INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE ELECTRICAL AND ELEC TRONIC EQUIPMENT WEEE In reference to European Union directive 2002 96 EC issued on 27 January 2003 and the related national legislation please note that 1 WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately 2 the public or private waste collection systems defined by local legislation must be used In addition the equipment can be returned to the distributor at the end of its working life when buying new equipment 3 the equipment may contain hazardous substances the improper use or incorrect disposal of such may have negative effects on human health and on the environment 4 the symbol crossed out wheeled bin shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 13 August 2005 and that it must be disposed of separately 5 in the event of illegal disposal of electrical and electronic waste the penalties are specified by local waste disposal legislation Warranty on the materials 2 years from the date of production excluding consumables Approval the quality and safety of CAREL S PA products are guaranteed by the ISO 9001 certified design and production system as well as by the marks 9 EVD
42. e 0 60 76 200 392 A 6 5 R Evaporation pressure 0 20 290 200 2900 A 7 6 R Hot gas bypass temperature 0 60 76 200 392 8 7 R EPR pressure back pressure 0 20 290 200 2900 A 9 8 R Superheat 0 40 72 180 324 A 0 9 R Condensing pressure 0 20 290 200 2900 A 1 0 R Condensing temperature 0 60 76 200 392 A 2 R odulating thermostat temperature 0 60 76 200 392 A 3 2 R Hot gas bypass pressure 0 20 290 1200 2900 A 4 3 R CO gas cooler outlet pressure 0 20 290 200 2900 A 5 4 R CO gas cooler outlet temperature 0 60 76 200 392 A 6 5 R Valve opening 0 0 100 A 7 6 R CO2 gas cooler pressure set point 0 20 290 200 2900 A 8 7 R 4 to 20 MA input value 4 4 20 A 9 8 R Oto 10V input value 0 0 10 A 20 9 R Control set point 0 60 76 200 392 A 21 20 R Driver firmware version 0 0 10 A 25 24 R Valve position 0 0 9999 4 31 R Current unit cooling capacity 0 0 100 7 34 RAW 35 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL Description Default Min Max Type CAREL SVP Modbus R W Low suction temperature 0 0 D 1 0 R LAN error 0 0 D 2 1 R uy EEPROM damaged 0 0 D 3 2 R amp Sensor S1 0 0 D 4 3 R lt Sensor 52 0 0 D 5 4 R lt Sensor 53 0 0 D 6 5 R Sensor 4 0 0 D 7 6 R EEV motor error 0 0 D 8 7 R Relay status 0 0 D 9 8 R un LOP low evaporation temper
43. e not communicated to the driver Key A Control request T3 Repositioning time C Change capacity W Wait NP_ Repositioning t Time R__ Control EVD evolution 030222041 rel 1 0 01 06 2008 26 CAREL Stop end control The stop procedure involves closing the valve from the current position until reaching 0 steps plus a further number of steps so as to guarantee complete closing Following the stop phase the valve returns to standby ST OFF oL c t Se OFF I T4 1 t gt Fig 6 d Key A Control request R Control S Standby T4 Stop position time ST Stop t Time 6 3 Special control status As well as normal control status the driver can have 3 special types of status related to specific functions manual positioning this is used to interrupt control so as to move the valve setting the desired position recover physical valve position recover physical valve steps when fully opened or closed unblock valve forced valve movement if the driver considers it to be blocked Manual positioning Manual positioning can be activated at any time during the standby or control phase Manual positioning once enabled is used to freely set the position of the valve using the corresponding parameter Parameter description Def Min Max UOM Control Enable manual valve positioning 0 0 1 Manual
44. e procedure for modifying the Service parameters Fig 3 e O Note if no button is pressed after 5 min the display automatically returns to the standard mode Modifying the Manufacturer parameters The Manufacturer level is used to configure all the driver parameters and consequently in addition to the Service parameters the parameters relating to alarm management the sensors and the configuration of the valve See the table of parameters 1 press Esc one or more times to switch to the standard display 2 press Prg the display shows a screen with the PASSWORD request 3 press ENTER and enter the Manufacturer level password 66 starting from the right most figure and confirming each figure with ENTER 4 if the value entered is correct the list of parameter categories is shown Configuration Sensors Control Special Alarm configuration Valve 5 press the UP DOWN buttons to select the category and ENTER to access the first parameter in the category EVD evolution 030222041 rel 1 0 01 06 2008 14 CAREL 6 press UP DOWN to select the parameter to be set and ENTER to move to the value of the parameter press UP DOWN to modify the value press ENTER to save the new value of the parameter repeat steps 6 7 8 to modify the other parameters O press Esc to exit the procedure for modifying the Manufacturer parameters OQ E CIBLI CONFIG ALLARMI VALVOLA
45. ed to any protection function t features a threshold and a delay and is useful in the event of sensor or valve malfunctions to protect the compressor using the relay to control he solenoid valve or to simply signal a possible risk In fact the incorrect measurement of the evaporation pressure or incorrect configuration of the type of refrigerant may mean the superheat calculated is much higher than the actual value causing an incorrect and excessive opening of the valve A low suction temperature measurement may in this case indicate the probable flooding of the compressor with corresponding alarm signal If the alarm delay is set to 0 s the alarm is disabled The alarm is reset automatically with a fixed differential of 3 C above the activation hreshold Relay activation for control alarms As mentioned in the paragraph on the configuration of the relay in the event of LowSH MOP HiTcond and low suction temperature alarms the driver relay will open both when configured as an alarm relay and configured as a solenoid alarm relay In the event of LOP alarms the driver relay will only open if configured as an alarm relay Parameter description Def Min Max UOM CONTROL LowSH protection threshold 5 40 C72 superheat K CR set point LowSH protection integration time 15 0 800 5 LOP protection threshold 50 60 76 MOP C F threshold LOP protection in
46. em alarm on LED board ep EVD evolution Fig 9 a O Note the alarm LED comes on to signal a mains power failure only if the EVBAT module accessory has been connected guaranteeing Table of alarms the power required to close the valve The display shows both types of alarms in two different modes system alarm on the main page the ALARM message is displayed flashing Pressing the Help button displays the description ofthe alarm and at the top right the total number of active alarms Surriscaldam 43 9 E Apertura valvola 4d FF TALAR Rele Eeprom danneggiata Fig 9 b control alarm next to the flashing ALARM message the main page shows the type of protector activated Surriscaldam 4 9 E Apertura valvola 445 iF ALARM Rele Hay Prg Esc Y Fig 9 c O Note to display the alarm queue press the Help button and scroll using the UP DOWN buttons the protector alarms can be disabled by setting the corresponding delay to zero Type of alarm Cause of alarm LED Display Relay Reset Effect on control Checks solutions Sensor 51 Sensor 51 faulty red alarm ALARM flashing Depends on automatic Depends on Check the sensor connections Chec or ex
47. etwork address 198 and choose the guided recognition procedure for the USB communication port Enter at the Service or Manufacturer level Fig 12 b EVD evolution 030222041 rel 1 0 01 06 2008 44 CAREL 12 APPENDIX VPM VISUAL PARAMETER MANAGER Fig 12 c 2 select the model from the range and create a new project or choose an existing project select Device model A new project can be created making the changes and then connecting later on to transfer the configuration OFFLINE mode Enter at the Service or Manufacturer level select Device model and enter the corresponding code AI Mutua pen di cen momen im BER RS hw ares oa o rl ci f LL md Li Se Femi Lhe ss ei Fig 12 4 goto Configure device the list of parameters will be displayed allowing the changes relating to the application to be made LL ammo n pa Ai TOO II MM Fig 12 e At the end of the configuration to save the project choose the following command used to save the configuration as a file with the hex extension File gt Save parameter list To transfer the parameters to the driver choose the Write command During the write procedure the 2 LEDs on the converter will flash CAREL 47 Fig 12 f O Note the program On line help can be accessed by pressing F1 12 3 Copying the setup On the Configure device page once the new
48. ewatering filter E Evaporator S Liquid indicator For the wiring see paragraph 2 7 General connection diagram This involves PID control without any protectors LowSH LOP MOP HiTcond see the chapter on Protectors without any valve unblock procedure and without auxiliary control Control is performed on the hot gas bypass pressure sensor value read by input S1 compared to the set point Hot gas bypass pressure set point Control is reverse as the pressure increases the valve closes and vice versa Parameter description Def Min Max UOM CONTROL Hot gas bypass pressure set point 3 20 200 barg 290 2900 psig PID proportional gain 15 0 800 PID integration time 150 0 1000 S PID derivative time 5 0 800 S Tab 5 f EVD evolution 030222041 rel 1 0 01 06 2008 20 CAREL Hot gas bypass by temperature This control function can be used to control cooling capacity On a refrigerated cabinet if the ambient temperature sensor measures an increase in the temperature the cooling capacity must also increase and so the valve must close Key CP Compressor V1 Solenoid valve C Condenser V2 Thermostatic expasnion valve L Liquid receiver EV Electronic valve F Dewatering filter E Evaporator S Liquid indicator For the wiring see paragraph 2 7 General connection diagram This involves PID control without an
49. fines the range of measurement and the alarm limits based on the manufacturer s data for each model usually indicated on the rating plate on the sensor Parameter description Def Configuration Sensor S1 Ratiom Ratiometric OUT 0 to 5V Electronic OUT 4 to 20mA 1 to 93 1 to 4 2 barg 0 5 to 7barg barg 0 4 to 9 2 barg 0 to 10barg 1 to 9 3 barg 0 to 18 2barg Oto 17 3 barg 0 to 25barg 04 to 342 barg 0 to 30barg 0 to 34 5 barg 0 to 44 8barg 0 to 45 barg remote 0 5 to 7 barg remote 0 to 10 barg remote 0 to 18 2 barg remote 0 to 25 barg remote 0 to 30 barg remote 0 to 44 8 barg External signal 4 to 20mA Tab 4 d Attention in case two pressure sensors are installed 5 and 53 they must be of the same type It is not allowed to use a ratiometric sensor and an electronic one O Note in the case of multiplexed systems where the same pressure sensor is shared between multiple drivers choose the normal option for the first driver and the remote option for the remaining drivers The same pressure transducer can be shared between a maximum of 5 drivers Example to use the same pressure sensor 0 5 to 7 bars for 3 drivers For the first driver select 0 5 to 7 barg EVD evolution 030222041 rel 1 0 01 06 2008 16 CAREL For the second and third driver select remote 0 5 to 7 barg O Note the range of measurement by default
50. g it completely One complete opening must bring a decrease in the superheat and vice versa If the movement is reversed check the electrical connections Stator broken or connected incorrectly Disconnect the stator from the valve and the cable and measure the resistance of the windings using an ordinary tester The resistance of both should be around 36 ohms Otherwise replace the stator Finally check the electrical connections of the cable to the driver see paragraph 5 1 Valve stuck closed Use manual control after start up to completely open the valve If the superheat remains high check the electrical connections and or replace the valve The unit switches off due to low pressure during control only for units with compressor on board LOP protection disabled Set a LOP integration time greater than 0 s LOP protection ineffective Make sure that the LOP protection threshold is at the required saturated evaporation temperature between the rated evaporation temperature of the unit and the corre sponding temperature at the calibration of the low pressure switch and decrease the value of the LOP integration time Solenoid blocked Check that the solenoid opens correctly check the electrical connections and the operation of the control relay Insufficient refrigerant Check that there are no bubbles of air in the liquid indicator upstream of the expansion valve Check that the subcooling is
51. he manual donotdrop hit or shake the device as the internal circuits and mechanisms may be irreparably damaged do not use corrosive chemicals solvents or aggressive detergents to clean the device do not use the product for applications other than those specified in the technical manual All of the above suggestions likewise apply to the controllers serial boards programming keys or any other accessory in the CAREL product portfolio CAREL adopts a policy of continual development Consequently CAREL reserves the right to make changes and improvements to any product described in this document without prior warning The technical specifications shown in the manual may be changed without prior warning The liability of CAREL in relation to its products is specified in the CAREL general contract conditions available on the website www carel com and or by specific agreements with customers specifically to the extent where allowed by applicable legislation in no case will CAREL its employees or subsidiaries be liable for any lost earnings or sales losses of data and information costs of replacement goods or services damage to things or people downtime or any direct indirect incidental actual punitive exemplary special or consequential damage of any kind whatsoever whether contractual extra contractual or due to negligence or any other liabilities deriving from the installation use or impossibility to use the pro
52. he driver will immediately stop control and will remain in standby until re enabled with the valve stopped in the ast position SUPERVISOR to simplify the commissioning of a considerable number of drivers using the supervisor the setup operation on the display can be limited to simply setting the network address The display will then be able to be removed and the configuration procedure postponed to a ater stage using the supervisor or if necessary reconnecting the display To enable control of the driver via supervisor set Enable EVD control his is included in the safety parameters in the special parameters menu under the corresponding access level However the setup parameters should first be set in the related menu The driver will then be enabled for operation and control will be able to commence when requested by the pCO controller via pLAN or when digital input DI1 closes As highlighted on the supervisor inside of the yellow information field elating to the Enable EVD control parameter if due to error or for any other reason Enable EVD control should be set to 0 zero the driver will immediately stop control and will remain in standby until e enabled with the valve stopped in the last position pCO PROGRAMMABLE CONTROLLER the first operation to be performed if necessary is to set the network address using the display f a pLAN tLAN or Modbus driver is used connected to a pCO family controller the set
53. he end of the evaporator and the saturated evaporation temperature calculated based on the reading of a pressure transducer located at the end of the evaporator and using the Tsat P conversion curve for each refrigerant Superheat Superheated gas temperature Saturated evaporation temperature suction Ifthe superheat temperature is high it means that the evaporation process is completed well before the end of the evaporator and therefore flow rate of refrigerant through the valve is insufficient This causes a reduction in cooling efficiency due to the failure to exploit part of the evaporator The valve must therefore be opened further Vice versa if the superheat temperature is low it means that the evaporation process has not concluded at the end of the evaporator and a certain quantity of liquid will still be present at the inlet to the compressor The valve must therefore be closed further The operating range of the superheat temperature is limited at the lower end if the flow rate through the valve is excessive the superheat measured will be near 0 K This indicates the presence of liquid even if the percentage of this relative to the gas cannot be quantified There is therefore un undetermined risk to the compressor that must be avoided Moreover a high superheat temperature as mentioned corresponds to an insufficient flow rate of refrigerant The superheat temperature must therefore always be greater than 0 K and h
54. hreshold must be lower then the rated evaporation temperature of the unit otherwise it would be activated unnecessarily and greater than the calibration of the low pressure switch otherwise it would be useless As an initial approximation it can be set to a value exactly half way between the two limits indicated the protector has no purpose in multiplexed systems showcases where the evaporation is kept constant and the status of the individual CAREL electronic valve does not affect the pressure value the LOP alarm can be used as an alarm to highlight refrigerant leaks by the circuit A refrigerant leak in fact causes an abnormal lowering of the evaporation temperature that is proportional in terms of speed and extent to the amount of refrigerant dispersed LOP ALARM Fig 7 b Key T EVAP Evaporation temperature D Alarm delay TH Low evaporation temperature ALARM Alarm protection threshold LOP LOP protection t Time B Automatic alarm reset MOP high evaporation pressure MOP Maximum Operating Pressure The MOP protection threshold is applied as a saturated evaporation temperature value so that it can be easily compared against the technical specifications supplied by the manufacturers of the compressors The protector is activated so as to prevent too high evaporation temperatures from causing an excessive workload for the compressor with consequent overheating of the mot
55. ignal from an external controller Parameter description Def Configuration Main contro multiplexed Superheat control cabinet multiplexed cabinet cold room cold room cabinet cold room with on board compressor perturbed cabinet cold room cabinet cold room with sub critical CO R404A condenser for sub critical CO air conditioner chiller with plate heat exchanger air conditioner chiller with tube bundle heat exchanger air conditioner chiller with finned coil heat exchanger air conditioner chiller with variable cooling capacity perturbed air conditioner chiller Special control EPR back pressure hot gas bypass by pressure hot gas bypass by temperature transcritical CO gas cooler analogue positioner 4 to 20 mA analogue positioner 0 to 10 V O Note R404A condensers with subcritical CO refer to superheat control for valves installed in cascading systems where the flow of R404A or other refrigerant in an exchanger acting as the CO condenser needs to be controlled perturbed cabinet cold room or air conditioner chiller refer to units that momentarily or permanently operate with swinging condensing or evaporation pressure Tab 5 a Auxiliary control features the following settings Parameter description Def Configuration Auxiliary control Disabled Disabled High condensing temperature protection on 53 Modulating therm
56. ings around the activation threshold or immediate reactivation of the protector LowSH low superheat The protector is activated so as to prevent the return of liquid to the compressor due to excessively low superheat valves from Parameter description Def Min Max UOM CONTROL LowSH protection threshold 5 40 72 set point K R superheat LowSH protection integration 15 0 800 S time ALARM CONFIGURATION Low superheat alarm delay 300 10 18000 5 LowSH 0 alarm disabled Tab 7 0 EVD evolution 030222041 rel 1 0 01 06 2008 28 CAREL 7 PROTECTORS When the superheat value falls below the threshold the system enters low superheat status and the intensity with which the valve is closed is increased the more the superheat falls below the threshold the more intensely the valve will close The LowSH threshold must be less than or equal to the superheat set point The low superheat integration time indicates the intensity ofthe action the lower the value the more intense the action The integration time is set automatically based on the type of main control A SH Low_SH_TH ee A iI i ON t Low_SH i OFF AE i 1 1 gt 1 1 ON 1 1 t R 1 I OFF p i EN 1 1 r r E B t lt gt Fig 7 a Key SH Superheat A Alarm Low SH TH Low SH protection threshold D Alarm delay Low SH Low SH protectio
57. ir conditioner chiller with variable cooling capacity Perturbed air conditioner chiller EPR back pressure Hot gas bypass by pressure Hot gas bypass by temperature Transcritical CO2 gas cooler Analogue positioner 4 to 20 mA Analogue positioner 0 to 10 V Analogue positioner 0 to 10 V A Sensor S2 CAREL NTC CAREL NTC HT high temp Combined NTC SPKP TO 10V external signal A Auxiliary control Disabled High condensing temperature protection on 53 Modulating thermostat on S4 Backup sensors on 53 amp 54 1 1 un 142 CARELNTC 17 144 Disabled 1 1 co 145 31 EVD evolution 030222041 rel 1 0 01 06 2008 Parameter description Def Min Max UOM Type CAREL SVP Modbus CAREL Notes gt luser Sensor 53 Ratiometric OUT 0 to 5 V 1 to 4 2 barg 04 to 92 barg 1 to 9 3 barg 0 to 17 3 barg 0 4 to 342 barg 0 to 34 5 barg 0 to 45 barg Electronic OUT 4 to 20 mA 0 5 to 7 barg 0 to 10 barg 0 to 18 2 bar 0 to 25 barg 0 to 30 barg 0 to 44 8 barg remote 0 5 to 7 barg remote 0 to 10 barg remote O to 18 2 barg remote 0 to 25 barg remote 0 to 30 barg remote 0 to 44 8 barg Ratiometric 1 to 9 3 barg oO gt Relay configuration Disabled Alarm relay open when alarm active Solenoid valve relay open in standby Valve relay alarm open in sta
58. iring see paragraph 2 7 General connection diagram Backup sensors on 53 amp S4 In this case pressure sensor 53 and temperature sensor S4 will be used to replace sensors 51 and S2 respectively in the event of faults on one or both so as to guarantee a high level of reliability of the controlled unit EVD evolution Key CP Compressor EEV Electronic expansion valve C Condenser V__ Solenoid valve L Liquid receiver E Evaporator F Dewatering filter P Pressure sensor transducer S Liquid indicator T_ Temperature sensor For the wiring see paragraph 2 7 General connection diagram 23 EVD evolution 030222041 rel 1 0 01 06 2008 6 1 Inputs and outputs Analogue inputs The parameters in question concern the choice of the type of pressure sensor S1 and 53 and the choice of the temperature sensor S2 and 54 as well as the possibility to calibrate the pressure and temperature signals As regards the choice of pressure sensor S1 see the chapter on Commissioning Inputs S2 S4 The options are standard NTC sensors high temperature NTC combined temperature and pressure sensors and 0 to 10 Vdc input For S4 the 0 to 10 Vdc input is not available When choosing the type of sensor the minimum and maximum alarm values are automatically set See the chapter on Alarms The auxiliary sensor S4 is associated with the Modulating thermostat function or can be used as a back
59. iver RESET all the parameters on the driver are restored to the default ccessful ay saves all the values of the parameters on the splay copies all the values of the parameters to the values See the tab e of parameters in chapter 8 A Important the procedure must be carried out with driver powered DO NOT remove the display from the driver during the UPLOAD DOWNLOAD RESET procedure the parameters ca target driver have i nnot be downloaded if the source driver and the ncompatible firmware 11 EVD evolution 030222041 rel 1 0 01 06 2008 2 7 General connection diagram X UE am E GO I Sporlan I DANFOSS I ALCO I WE SE SEH SER ETS EX5 6 I EX7 8 I EVD e Power supply module 2AT 230 Vac 24Vac E A 3a E 30VA 2AT 230 Vac 24 Vac 8 9 2AT c op pco 30VA og m m gt son ES shield x us gt a l a PLAN EC vi g oO poses shield o dores Modbus O shield RS485 gt EVDOOOOEO tLAN version EVDO0000E1 pLAN version EVD0000E2 RS485 version Fig 2 j Key white A Connection to EVBAT200 300 2 yellow B Connection to electronic pressure sensor SP
60. ld must be greater than the rated evaporation temperature of the unit otherwise it would be activated unnecessarily The MOP threshold is often supplied by the manufacturer of the compressor It is usually between 10 C and 15 C A Important if the closing of the valve also causes an excessive increase in the suction temperature S2 the valve will be stopped to prevent overheating the compressor windings awaiting a reduction in the refrigerant charge At the end of the MOP protection function superheat control restarts in a controlled manner to prevent the evaporation temperature from exceeding the threshold again HiTcond high condensing temperature To activate the high condensing temperature protector HiTcond a pressure sensor must be connected to input S3 as much as possible Normal operating conditions will not resume based The protector is activated so as to prevent too high evaporation on the activation of the protector but rather on the reduction in the temperatures from stopping the compressor due to the activation of the refrigerant charge that caused the increase in temperature The system high pressure switch will therefore remain in the best operating conditions a little below the threshold until the load conditions change ON Def Min Max UOM Parameter description Def Min Max UOM HiTcond threshold 80 60 200 C CF CONTROL 76 3992 pr
61. lers air conditioners and refrigerators the latter including subcritical and transcritical CO2 systems It features low superheat high evaporation pressure MOP low evaporation pressure LOP and high condensing temperature protection and can manage as an alternative to superheat control special functions such as the hot gas bypass the evaporator pressure control EPR and control of the valve downstream of the gas cooler in transcritical CO2 circuits Together with superheat control it can manage an auxiliary control function selected between condensing temperature protection and modulating thermostat As regards network connectivity the driver can be connected to either of the following apCO programmable controller to manage the driver via pLAN a pCO programmable controller or PlantVisorPRO supervisor for supervision only via tLAN or R5485 Modbus respectively In this case On Off control is performed via digital input 1 The second digital input is available for optimised defrost management Another possibility involves operation as a simple positioner with 4 to 20 mA or 0 to 10 Vdc analogue input signal EVD evolution comes with a LED board to indicate the operating status or a graphic display accessory that can be used to perform installation following a guided commissioning procedure involving setting just 4 parameters refrigerant valve pressure sensor type of main control chiller Showcase etc The procedure c
62. limits corresponding to the range of measurement of the sensor EVD evolution 030222041 rel 1 0 01 06 2008 38 CAREL Parameter description Def Min Max UOM SONDE Pressure 1 MINIMUM alarm 1 20 290 51 AL MAX barg value 51 AL MIN psig Pressure 1 MAXIMUM alarm 193 151 AL 200 2900 barg value 51 AL MAX psig Temperature S2 MINIMUM 50 60 52 AL MAX C F alarm value S2 AL MIN Temperature S2 MAXIMUM 105 S2 AL 200 392 C F alarm value 52 Pressure 3 MINIMUM alarm 1 20 3 AL MAX barg value 53 psig Pressure 3 MAXIMUM alarm 193 153 AL 200 2900 barg value 53_AL_MAX psig Temperature 54 MINIMUM 50 60 S4_AL_MAX C F alarm value S4 AL MIN Temperature S4 MAXIMUM 105 S4 AL M 200 392 C CF alarm value S4 MAX Tab 9 c The behaviour of the driver in response to sensor alarms can be configured using the manufacturer parameters The options are no action control continues but the correct measurement of the variables is not guaranteed forced closing of the valve control stopped valve forced to the initial position control stopped use the backup sensor valid only for sensor 51 and S2 alarms control continues Parameter description Def CONFIGURATION Sensor 51 alarm management Valve in fixed posi
63. m value C 193 calibration offset 0 60 870 60 870 barg psig A 35 34 C Pressure 3 MINIMUM value 1 20 290 Pressure 3 barg psig A 33 32 MAXIMUM value C Pressure 53 MAXIMUM value 93 Pressure 53 200 2900 barg psig A 31 30 MINIMUM value C Pressure 53 MINIMUM alarm value 20 290 Pressure S3 barg psig A 40 39 MAXIMUM alarm value C Pressure S3 MAXIMUM alarm value 93 Pressure 53 200 2900 barg psig A 38 37 MINIMUM alarm value C 154 calibration offset 0 20 36 20 36 C F A 42 41 C Temperature S4 IMUM alarm value 50 60 76 Temperature F A 47 46 S4 MAXIMUM alarm value C Temperature 54 MAXIMUM alarm value 105 Temperature 200 392 C CF A 45 44 54 MINIMUM alarm value CONTROL A Superheat set point 11 LowSH thre 180 324 K R A 50 49 shold A_ Valve opening at start evaporator valve capacity ratio 50 0 100 96 37 164 C Valve open in standby 0 0 1 D 231 22 0 disabled valve closed 1 enabled valve open 25 C Start delay after defrost 10 0 60 min 140 167 Hot gas bypass temperature set point 10 60 76 200 392 C CF A 28 27 A_ Hot gas bypass pressure set point 3 20 290 200 2900 barg psig A 62 61 A EPR pressure set point 3 5 20 290 200 2900 barg psig A 29 28 C_ PID proportional gain 15 0 800 A 48 47 C_ PID integration time 150 0 1000 5 38 165 C_ PID derivative time 5 0 800 5 A 49
64. ming mode the superheat set point otherwise keep the value recommended by CAREL based on the application and the protection thresholds LOP MOP See the chapter on Protectors 4 4 Other functions By entering Service programming mode other types of main control can be selected transcritical CO hot gas bypass etc as well as so called special control functions which do not involve the superheat activating auxiliary controls that use sensors S3 and or 54 and setting the suitable values for the control set point and the LowSH LOP and MOP protection thresholds see the chapter on Protectors which depend on the specific characteristics of the unit controlled By entering Manufacturer programming mode finally the operation of the driver can be completely customised setting the function of each parameter If the parameters corresponding to PID control are modified the driver will detect the modification and indicate the main control as Customised 17 EVD evolution 030222041 rel 1 0 01 06 2008 5 1 Main and auxiliary control EVD evolution features two types of control main auxiliary Main control is always active while auxiliary control can be activated by parameter Main control defines the operating mode of the driver The first 10 settings refer to superheat control the others are so called special settings and are pressure or temperature settings or depend on a control s
65. more intense the action will be The integration time in summary represents the intensity of he reaction of the valve especially when the superheat value is no near the set point the derivative action is linked to the speed of variation of the superhea FEN value that is the gradient at which the superheat changes from instan o instant It tends to react to any sudden variations bringing forward P he corrective action and its intensity depends on the value of the ime Td derivative time Parameter description Def Min Max UOM CONTROL Superheat set point 11 LowSH soglia 180 320 K CR Key proportianaligaiti e E 800 V1 Solenoid valve E Evaporator PID integration time 150 0 1000 5 va lh E Ive TE PID derivative time 5 0 800 3 ermostatic expasnion valve ectronic valve Tab 5 c E i For the wiring see paragraph 2 7 General connection diagram See the EEV system guide 030220810 for further information on This involves PID control without any protectors LowSH LOP MOP HiTcond see the chapter on Protectors without any valve unblock procedure and without auxiliary control Control is performed on the calibrating PID control O Note when selecting the type of main control both superheat pressure sensor value read by input 51 compared to the set point EPR control and special modes the PID c
66. n No action 27 154 Language Italiano English Italiano Unit of measure C K barg F R psig C K barg 21 148 EVD evolution 030222041 rel 1 0 01 06 2008 32 CAREL o 3 Parameter description Def Min Max UOM e m 3 Notes E SONDE C S1 calibration offset 0 60 870 60 160 870 60 barg psig A 34 33 mA CST calibration gain 4 to 20 mA 1 20 20 A 36 35 C Pressure S1 MINIMUM value 20 290 Pressure S1 barg psig A 32 31 MAXIMUM value C Pressure S1 MAXIMUM value 93 Pressure S1 200 2900 barg psig A 301 29 MINIMUM value C Pressure S1 MINIMUM alarm value 20 290 Pressure S1 barg psig A 39 38 MAXIMUM alarm value C Pressure S1 MAXIMUM alarm value 93 Pressure S1 200 2900 barg psig A 37 36 MINIMUM alarm value C 192 calibration offset 0 20 290 20 120 290 20 C F volt A 41 40 C_ S2 calibration gain 0 to 10 V 20 20 A 43 42 C Temperature 52 MINIMUM alarm value 50 60 Temperature C F A 46 45 52 alarm MA XIMUM value C Temperature 52 MAXIMUM alarm value 105 Temperature 200 392 C F A 44 43 52 MINIMUM alar
67. n t Time B Automatic alarm reset LOP low evaporation pressure LOP Low Operating Pressure The LOP protection threshold is applied as a saturated evaporation temperature value so that it can be easily compared against the technical specifications supplied by the manufacturers of the compressors The protector is activated so as to prevent too low evaporation temperatures from stopping the compressor due to the activation of the low pressure switch The protector is very useful in units with compressors on board especially multi stage where when starting or increasing capacity the evaporation temperature tends to drop suddenly When the evaporation temperature falls below the low evaporation temperature threshold the system enters LOP status and is the intensity with which the valve is opened is increased The further the temperature falls below the threshold the more intensely the valve will open The integration time indicates the intensity of the action the lower the value the more intense the action Parameter description Def Min Max UOM CONTROL LOP protection threshold 50 60 72 Protection MOP C F threshold LOP protection integration time 0 0 800 S ALARM CONFIGURATION Low evaporation temperature 300 0 18000 S alarm delay LOP 0 alarm disabled Tab 7 c The integration time is set automatically based on the type of main control O Note the LOP t
68. n valve GC Gas cooler EV Electronic valve E Evaporator IHE Inside heat exchanger VI Solenoid valve For the wiring see paragraph 2 7 General connection diagram This involves PID control without any protectors LowSH LOP MOP HiTcond see the chapter on Protectors without any valve unblock procedure and without auxiliary control Control is performed on the gas cooler pressure sensor value read by input S1 with a set point depending on the gas cooler temperature read by input S2 consequently there is not a set point parameter but rather a formula CO gas cooler pressure set point Coefficient A Tgas cooler 52 Coefficient B The set point calculated will be a variable that is visible Analogue positioner 4 to 20 mA The valve will be positioned linearly depending on the value of the 4 to 20 mA input for analogue valve positioning read by input S1 There is no PID control nor any protection LowSH LOP MOP HiTcond see the chapter on Protectors no valve unblock procedure and no auxiliary control gt gt EVD evolution a D cz 5 2 9 I 1 Do M 4 A 100 0 gt mA Fig 5 f Key Ev_ Electronic valve A Valve opening For the wiring see paragraph 2 7 General connection diagram Forced closing will only occur when digital input DI1 opens thus switching between control status and standby The pre positioning and repositi
69. nal management of power failures with valve closing if the EVBAT200 EVBAT300 accessory is fitted advanced alarm management Series of accessories for EVD evolution Display code EVDISO0 0 Easily applicable and removable at any time from the front panel of the driver during normal operation displays all the significant system variables the status of the relay output and recognises the activation of the protection functions and alarms During commissioning it guides the installer in setting the parameters required to start the installation and once completed can copy the parameters to other drivers The models differ in the first settable language the second language for all models is English EVDISOO 0 can be used to configure and monitor all the control parameters accessible via password at a service installer and manufacturer level Fig 1 a USB tLAN converter code EVDCNVOOEO The USB tLAN converter is connected once the LED board cover has been removed to the service serial port underneath Fitted with cables and connectors it can connect EVD evolution directly to a computer which using the VPM program can configure and program the driver VPM can also be used to update the driver and display firmware See appendix Fig 1 b EVD evolution 030222041 rel 1 0 01 06 2008 CAREL Battery module code EVBAT EVBAT00200 is an electronic device that guarantees temporary power to
70. ndby amp control alarms Alarm relay 139 Sensor 54 CAREL NTC CAREL NTC HT high temperature Combined NTC SPKP TO CAREL NTC 20 47 Configuration of DI2 Disabled Optimise valve control after defrost Disabled 37 Variable 1 on display Valve opening Valve position Current cooling capacity Control set point Superheat Suction temperature Evaporation temperature Evaporation pressure Condensing temperature Condensing pressure Modulating thermostat temperature EPR pressure Hot gas bypass pressure Hot gas bypass temperature CO gas cooler outlet temperature CO gas cooler outlet pressure CO gas cooler pressure set point Sensor S1 reading Sensor S2 reading Sensor 53 reading Sensor S4 reading 4to 20 mA input Oto 10V input Superheat 45 72 Variable 2 on display vedere variable 1 on display Valve ope ning 46 173 Sensor 1 alarm management o action orced valve closing alve in fixed position se backup sensor 3 cmn Valve in fixed position 24 151 NIC ensor S2 alarm management o action orced valve closing alve in fixed position se backup sensor 4 lt Valve in fixed position 25 152 NIC ensor 53 alarm management o action orced valve closing alve in fixed position xc cm No action 26 153 Nn ensor S4 alarm management o action Forced valve closing Valve in fixed positio
71. ng temperature reaches excessive values to prevent the compressor from shutting down due to high pressure The condensing pressure sensor must be connected to input 53 Modulating thermostat This function is used by connecting a temperature sensor to input S4 to modulate the opening of the electronic valve so as to limit the lowering of the temperature read and consequently reach the control set point This is useful in applications such as the multiplexed cabinets to avoid the typical swings in air temperature due to the ON OFF control thermostatic of the solenoid valve A temperature sensor must be connected to input S4 located in a similar position to the one used for the traditional temperature control of the cabinet In practice the close the controlled temperature gets to the set point the more the control EVD evolution 030222041 rel 1 0 01 06 2008 22 CAREL function decreases the cooling capacity of the evaporator by closing the expansion valve By correctly setting the related parameters see below a very stable cabinet temperature can be achieved around the set point without ever closing the solenoid valve The function is defined by three parameters set point differential and offset Parameter description Def Min Max UOM SPECIAL odulating thermostat set point 0 60 200 C CF 76 392 odulating thermostat differential 0 1 0 1 100 COP 02 180 odula
72. o meaning as there is no flow of refrigerant and the effective control phase Control The control request can be received by the closing of digital input 1 or via the network pLAN The solenoid or the compressor are activated when the valve following the pre positioning procedure has reached the calculated position The following figure represents the sequence of events for starting control of the refrigeration unit Control delay after defrost Some types of refrigerating cabinets have problems controlling the electronic valve in the operating phase after defrost In this period 10 to 20 min after defrosting the superheat measurement may be altered by the high temperature of the copper pipes and the air causing excessive opening of the electronic valve for extended periods in which there is return of liquid to the compressors that is not detected by the sensors connected to the driver In addition the accumulation of refrigerant in the evaporator in this phase is difficult to dissipate in a short time even after the sensors have started to correctly measure the presence of liquid superheat value low or null The driver can receive information on the defrost phase in progress via digital input 2 The Start delay after defrost parameter is used to set a delay when control resumes so as to overcome this problem During this delay the valve will remain in the pre positioning point while all the normal sensor alarms procedures e
73. oning procedures are not performed Manual positioning can be enabled when control is active or in standby Analogue positioner 0 to 10 Vdc The valve will be positioned linearly depending on the value of the 0 to 10V input for analogue valve positioning read by input S1 There is no PID control nor any protection LowSH LOP MOP HiTcond no valve unblock procedure and no auxiliary control with corresponding forced closing of the valve and changeover to standby status AAA EVD evolution a 9 E E gt 9 100 in display mode Control is direct as the pressure increases the valve on opens Fig 5 g Parameter description Def Min Max UOM Kev SPECIAL R Transcritical CO2 coefficient A 33 100 800 Ev_ Electronic valve A Valve opening Transcritical CO2 coefficient B 22 7 100 800 sia A x CONTROL For the wiring see paragraph 2 7 General connection diagram PID proportional gain 15 0 800 A NES E PID derivative time 150 0 1000 s Important the pre positioning and repositioning procedures PID integration time 5 0 800 Is are not performed Manual positioning can be enabled when control is active or in standby EVD evolution 030222041 rel 1 0 01 06 2008 5 4 Auxiliary control Auxiliary control can be activated at the same time as main control and uses the sensors connected to inputs 53 and or S4 Parameter description Def C
74. ons and main characteristics In summary electrical connections by plug in screw terminals serial card incorporated in the driver based on the model tLAN pLAN RS485 Modbus compatibility with various types of valves and refrigerants activation deactivation of control via digital input 1 or remote control via pLAN from pCO programmable controller superheat control with protection functions for low superheat MOP LOP high condensing temperature configuration and programming by display accessory by computer using the VPM program or by PlantVisor PlantVisorPro supervisor and pCO programmable controller commissioning simplified by display with guided procedure for setting the parameters and checking the electrical connections multi anguage graphic display with help function on various parameters management of different units of measure metric imperial parameters protected by password accessible at a service installer and manufacturer level copy the configuration parameters from one driver to another using the removable display ratiometric or electronic 4 to 20 mA pressure transducer the latter can be shared between a series of driver useful for multiplexed applications possibility to use 53 and S4 as backup sensors in the event of faults on the main sensors S1 and S2 4 to 20 or 0 to 10 Vdc input to use the driver as a positioner controlled by an external sig
75. ontrol values suggested by CAREL pressure set point Control is direct as the pressure increases the valve will be automatically set for each application opens and vice versa Parameter description Def Min Max UOM CONTROL EPR pressure set point 3 5 20 290 200 2900 barg psig Protector control parameters proportional gain 15 0 800 integration time 150 0 1000 5 See the chapter on Protectors Note that the protection thresholds are set Teena 5 0 300 by the installer manufacturer while the times are automatically set based on the PID control values suggested by CAREL for each application Ios Parameter description Def Min Max UOM CONTROL LowSH protection threshold 5 40 72 superh K R set point LowSH protection integ time 15 0 800 5 LOP protection threshold 50 60 76 MOP CDF threshold LOP protection integ time 0 0 800 S 19 EVD evolution 030222041 rel 1 0 01 06 2008 Hot gas bypass by pressure This control function can be used to control cooling capacity If there is no request from circuit B the compressor suction pressure decreases and the bypass valve opens to let a greater quantity of hot gas flow and decrease the capacity of the circuit EVD evolution Key CP_ Compressor Vl Solenoid valve C Condenser V2 Thermostatic expasnion valve L Liquid receiver EV Electronic valve F D
76. or and possible activation of the thermal protector The protector is very useful in units with compressor on board if starting with a high refrigerant charge or when there are sudden variations in the oad The protector is also useful in multiplexed systems showcases as allows all the utilities to be enabled at the same time without causing problems of high pressure for the compressors To reduce the evaporation emperature the output of the refrigeration unit needs to be decreased This can be done by controlled closing of the electronic valve implying superheat is no longer controlled and an increase in the superheat emperature The protector will thus have a moderate reaction that tends o limit the increase in the evaporation temperature keeping it below the activation threshold while trying to stop the superheat from increasing threshold The more the evaporation temperature increases with reference to the MOP threshold the more intensely the valve will close The integration time indicates the intensity of the action the lower the value the more intense the action T EVAP A MOP_TH MOP TH 1 ini 1 1 OFF i I MOP ON LJ l E t PID i m OFF d N t ALARM 1 1 D t Fig 7 c Key T EVAP Evaporation temperature MOP TH MOP threshold PID PID superheat control ALARM Alarm MOP MOP protection t Time D Alarm delay A Important the MOP thresho
77. ostat on S4 Backup sensors on 53 amp 54 Tab 5 b A Important the High condensing temperature protection and Modulating thermostat auxiliary settings can only be enabled if the main control is superheat control first 10 settings On the other hand Backup sensors on 53 54 can always be activated once the related sensors have been connected The following paragraphs explain all the types of control that can be set on EVD evolution EVD evolution 030222041 rel 1 0 01 06 2008 18 CAREL 5 CONTROL 5 2 Superheatcontrol The primary purpose of the electronic valve is ensure that the flow rate of refrigerant that flows through the nozzle corresponds to the flow rate required by the compressor In this way the evaporation process will take place along the entire length of the evaporator and there will be no liquid at the outlet and consequently in the branch that runs to the compressor As liquid is not compressible it may cause damage to the compressor and even breakage if the quantity is considerable and the situation lasts some time Superheat control The parameter that the control of the electronic valve is based on is the superheat temperature which effectively tells whether or not there is liquid at the end of the evaporator The superheat temperature is calculated as the difference between superheated gas temperature measured by a temperature sensor located at t
78. otection threshold 50 Protection LOP 200 C F HiTcond integration time 20 0 800 5 threshold 392 ALARM CONFIGURATION protection integration time 20 0 800 s High condensing temperature alarm delay 600 O 18000 s ALARM CONFIGURATION HiTcond High evaporation temperature 600 0 18000 s 0 alarm disabled alarm delay MOP Tab 7 6 0 alarm disabled Tab 7 4 The integration time is set automatically based on the type of main The integration time is set automatically based on the type of main control When the evaporation temperature rises above the MOP threshold the system enters MOP status superheat control is interrupted to allow the pressure to be controlled and the valve closes slowly trying to limit the evaporation temperature As the action is integral it depends directly on the difference between the evaporation temperature and the activation 29 control Note the protector is very useful in units with compressors on board if the air cooled condenser is undersized or dirty malfunctioning in the more critical operating conditions high outside temperature the protector has no purpose in multiplexed systems showcases where the condensing pressure is maintained constant and the status of the individual electronic valves does not affect the pressure value EVD evolution 030222041 rel 1 0 01 06 2008 CAREL To reduce the condensing temperature the output of the refrigeration unit
79. ower the value The driver in pLAN or tLAN configura tion does not start control and the valve remains closed Check the pLAN tLAN connections Check that the pCO application connected to the driver where featured correctly manages the driver start signal Check that the driver is NOT in stand alone mode The driver in stand alone configuration does not start control and the valve remains closed Check the connection of the digital input Check that when the control signal is sent that the input is closed correctly Check that the driver is in stand alone mode LOP protection disabled Set a LOP integration time greater than 0 s LOP protection ineffective Make sure that the LOP protection threshold is at the required saturated evaporation temperature between the rated evaporation temperature of the unit and the corre sponding temperature at the calibration of the low pressure switch and decrease the value of the LOP integration time Solenoid blocked Check that the solenoid opens correctly check the electrical connections and the operation of the relay Insufficient refrigerant Check that there are no bubbles in the sight glass upstream of the expansion valve Check that the subcooling is suitable greater than 5 C otherwise charge the circuit The valve is connected incorrectly rotates in reverse and is open Check the movement of the valve by placing it in manual control and closing or ope nin
80. project has been created to transfer the list of configuration parameters to another driver read the list of parameters from the source driver with the Read command remove the connector from the service serial port connect the connector to the service port on the destination driver write the list of parameters to the destination driver with the Write command A Important the parameters can only be copied between controllers with the same code Different firmware versions may cause compatibility problems 12 4 Setting the default parameters When the program opens select the model from the range and load the associated list of parameters go to Configure device the list of parameters will be shown with the default settings connect the connector to the service serial port on the destination driver during the write procedure the LEDs on the converter will flash The driver parameters driver will now have the default settings 12 5 Updating the driver and display firmware The driver and display firmware must be updated using the VPM program on a computer and the USB tLAN converter which is connected to the device being programmed see paragraph 2 5 for the connection diagram The firmware can be downloaded from http ksa carel com See the VPM On line help 45 EVD evolution 030222041 rel 1 0 01 06 2008 CAREL
81. r the corresponding terminals Loosen each screw and insert the cable ends then tighten the screws and lightly tug the cables to check correct tightness separate as much as possible at least 3 cm the sensor and digital input cables from the power cables to the loads so as to avoid possible electromagnetic disturbance Never lay power cables and sensor cables in the same conduits including those in the electrical panels avoid installing the sensor cables in the immediate vicinity of power devices contactors circuit breakers etc Reduce the path of the sensor cables as much as possible and avoid enclosing power devices 5 avoid powering the driver directly from the main power supply in the panel if this supplies different devices such as contactors solenoid valves etc which will require a separate transformer Case 1 multiple drivers connected in a network powered by the same transformer Typical application for a series of drivers inside the same electrical panel 230Vac 2 5 Connecting the USB tLAN converter remove the LED board cover by pressing on the fastening points plug the adapter into the service serial port connect the adapter to the converter and then this in turn to the computer Fig 2 d Case 2 multiple drivers connected in a network powered by different transformers GO not connected to earth Typical application for a series of drivers in different
82. returns to the com pressor only when starting the controller after being OFF The valve opening at start parameter is set too high Check the calculation in reference to the ratio between the rated cooling capacity of the evaporator and the capacity of the valve if necessary lower the value The superheat value swings around the set point with an amplitude greater than 4 C The condensing pressure swings Check the controller condenser settings giving the parameters blander values e g increase the proportional band or increase the integration time Note the required sta bility involves a variation within 0 5 bars Ifthis is not effective or the settings cannot be changed adopt electronic valve control parameters for perturbed systems The superheat swings even with the valve set in manual control in the position cor responding to the average of the working values Check for the causes of the swings e g low refrigerant charge and resolve where pos sible If not possible adopt electronic valve control parameters for perturbed systems The superheat does NOT swing with the valve set in manual control in the position corresponding to the average of the working values As a first approach decrease by 30 to 50 96 the proportional factor Subsequently try increasing the integration time by the same percentage In any case adopt parameter settings recommended for stable systems The s
83. rogramming operations on the driver It displays the operating status the significant values for the type of control that the driver is performing e g superheat control the alarms the status of the digital inputs and the relay output Finally it can save the configuration parameters for one driver and transfer them to a second driver see the procedure for upload and download parameters For installation remove the cover pressing on the fastening points fitthe display board as shown the display will come on and if the driver is being commissioned the guided configuration procedure will start press Fig 3 b A Important the driver is not activated if the configuration procedure has not been completed The front panel now holds the display and the keypad made up of 6 buttons that pressed alone or in combination are used to perform all the configuration and programming operations on the driver 13 3 2 Display and keypad The graphic display shows 2 system variables the control status of the driver the activation of the protectors any alarms and the status of the relay output D Surriscaldam 4 9 K Apertura valvola 44 x Rele i Prg Esc Fig 3 c Key 1__ 1st variable displayed 2 2nd variable displayed 3 relay status 4 alarm press HELP 5 protector activated
84. ssure and temperature and the suction temperature variables 3 press UP DOWN the variables are shown on the display 4 press Esc to exit display mode EVD evolution 030222041 rel 1 0 01 06 2008 For the complete list of the variables shown on the display see the chapter Table of parameters 3 4 Programming mode display The parameters can be modified using the front keypad Access differs according to the user level Service Installer and manufacturer Modifying the Service parameters IThe Service parameters as well as the parameters for commissioning the driver also include those for the configuration of the inputs the relay output the superheat set point or the type of control in general and the protection thresholds See the table of parameters Procedure 1 press Esc one or more times to switch to the standard display 2 press Prg the display shows a screen with the PASSWORD request 3 press ENTER and enter the password for the Service level 22 starting from the right most figure and confirming each figure with ENTER 4 if the value entered is correct the first modifiable parameter is displayed network address press UP DOWN to select the parameter to be set press ENTER to move to the value of the parameter press UP DOWN to modify the value press ENTER to save the new value of the parameter repeat steps 5 6 7 8 to modify the other parameters 0 press Esc to exit th
85. start control If during standby a control request is received before starting control the valve is moved to a precise initial position Parameter description Def Min Max UOM Control Valve opening at start evaporator valve 50 0 100 capacity ratio Tab 6 i 25 3 10 33 If the capacity request is 100 Opening Valve opening at start up If the capacity request is less than 100 capacity control Opening Valve opening at start up Current unit cooling capacity where the current unit cooling capacity is sent to the driver via pLAN by the pCO controller If the driver is stand alone this is always equal to 100 O Note this procedure is used to anticipate the movement and bring the valve significantly closer to the operating position in the phases immediately after the unit starts ifthere are problems with liquid return after the refrigeration unit starts or in units that frequently switch on off the valve opening at start up must be decreased If there are problems with low pressure after the refrigeration unit starts the valve opening must be increased Wait When the calculated position has been reached regardless of the time taken this varies according to the type of valve and the objective position there is a constant 5 second delay before the actual control phase starts This is to create a reasonable interval between standby in which the variables have n
86. suitable greater than 5 C otherwise charge the circuit The valve is significantly undersized Replace the valve with a larger equivalent Stator broken or connected incorrectly Disconnect the stator from the valve and the cable and measure the resistance of the windings using an ordinary tester The resistance of both should be around 36 ohms Otherwise replace the stator Finally check the electrical connections of the cable to the driver Valve stuck closed Use manual control after start up to completely open the valve If the superheat remains high check the electrical connections and or replace the valve The cabinet does not reach the set temperature despite the value being opened to the maximum for multiple xed cabinets only Solenoid blocked Check that the solenoid opens correctly check the electrical connections and the operation of the relay Insufficient refrigerant Check that there are no bubbles of air in the liquid indicator upstream of the expansion valve Check that the subcooling is suitable greater than 5 C otherwise charge the circuit The valve is significantly undersized Replace the valve with a larger equivalent Stator broken or connected incorrectly Disconnect the stator from the valve and the cable and measure the resistance of the windings using an ordinary tester The resistance of both should be around 36 ohms Otherwise replace the stator Finally
87. tc managed Parameter description Def Min Max UOM Control Start delay after defrost 10 0 60 min Tab 6 j Important if the superheat temperature should fall below the set point control resumes even if the delay has not yet elapsed EVD evolution 030222041 rel 1 0 01 06 2008 Key A Control request W Wait S Standby T1 Pre positioning time P__ Pre positioning T2 Start delay after defrost R__ Control Time Positioning change cooling capacity This control status is only valid for the pLAN driver If there is a change in unit cooling capacity of at least 10 sent from the pCO via the pLAN the valve is positioned proportionally In practice this involves repositioning starting from the current position in proportion to how much the cooling capacity of the unit has increased or decreased in percentage terms When the calculated position has been reached regardless of the time taken this varies according to the type of valve and the position there is a constant 5 second delay before the actual control phase starts Note if information is not available on the variation in unit cooling capacity this will always be considered as operating at 100 and therefore the procedure will never be used In this case the PID control must be more reactive see the chapter on Control so as to react promptly to variations in load that ar
88. tegration time 0 0 800 5 protection threshold 50 LOP 200 392 C CF soglia OP protection integration time 20 0 800 5 SPECIAL HiTcond threshold 80 60 76 200 392 C CF HiTcond integration time 20 0 800 5 ALARM CONFIGURATION Low superheat alarm delay LowSH 300 O 8000 S 0 alarm disabled Low evaporation temperature alarm 300 O 8000 S delay LOP 0 alarm disabled High evaporation temperature alarm 600 0 8000 S delay MOP 0 alarm disabled High condensing temperature alarm 600 O 8000 S delay HiTcond 0 alarm disabled Low suction temperature alarm 50 60 76 200 392 C F hreshold Low suction temperature alarm 300 0 18000 5 delay 9 5 motor alarm n the event of incorrect connection or damage to the valve motor an alarm will be signalled see the table of alarms and the driver will go into wait status as it can longer control the valve The alarm is indicated by he LED NET and is reset automatically after which control will resume immediately Important after having resolved the problem with the motor it is recommended to switch the driver off and on again to realign the position of the valve If this is not possible the automatic procedure for synchronising the position may help solve the problem nonetheless correct control will not be guaranteed until the next synchronisation EVD evolution 030222041 rel 1 0 01 06 2008
89. the driver in the event of mains power failures Supplied with a 12 Vdc lead battery it delivers 22 Vdc to the driver for the time required to completely close the electronic valve being controlled while during normal operation the battery is recharged The complete module with batteries code EVBAT00300 and the box for batteries code EVBATBOX 0 are available EVBATOO300 Batteria 12 V Valve cable E2VCABS 00 IP67 Shielded cable with built in connector for connection to the valve motor The connector code E2VCONOOO0 IP65 can also be purchased on its own to be wired Fig 1 d EVD evolution 030222041 rel 1 0 01 06 2008 8 CAREL 2 INSTALLATION 2 1 DIN rail assembly and dimensions 2 3 Connection diagram superheat control EVD evolution is supplied with screen printed connectors to simplify wiring The shield is connected with a spade terminal CAREL EXV 5 230 Vac 24 Vac 2AT 30VA 08 a O th E 3 E FE 3 2 4 58 5 Power Supply E V connection UUUUUUUUUUU A fp x green yellow brown white personal computer for configuration USB tLAN converter adapter ratiometric pressure transducer evaporation pressure Dp CEP D 9 NTC suction temperature a M m gt 10 digital input 1 to enable control 5 A 8 G A cn ww 11 free contact
90. ting thermostat superheat set 0 0 0 1100 K CR point offset 0 function disabled 180 Tab 5 i The first two should have values similar to those set on the controller for the cabinet or utility whose temperature is being modulated The offset on the other hand defines the intensity in closing the valve as the temperature decreases the greater the offset the more the valve will be modulated The function is only active in a temperature band between he set point and the set point plus the differential A Important the Modulating thermostat function should not be used on stand alone refrigeration units but only in centralised systems In fact in the former case closing the valve would cause a lowering of the pressure and consequently shut down the compressor Examples of operation S4 set point diff set point 1 offset too low or function disabled ON 54 set point diff set point t 3 2 offsettoo high ON F OFF t S4 set point diff set point t 3 offsetcorrect ON F OFF t Key diff differential F modulating thermostat function S4 temperature CAREL EV evolution LE rus EI Fig 5 i Key CP_ Compressor EEV Electronic expansion valve C Condenser V Solenoid valve L Liquid receiver E Evaporator F Dewatering filter P Pressure sensor transducer S Liquid indicator T Temperature sensor For the w
91. tion o action orced valve closing alve in fixed position se backup sensor 53 ensor 2 alarm management o action orced valve closing alve in fixed position se backup sensor S4 ensor 3 alarm management o action orced valve closing alve in fixed position ensor 54 alarm management o action Forced valve closing Valve in fixed position CONTROL Valve opening at start evaporator valve capacity 50 ratio C n Valve in fixed position C No action n lt No action n Tab 9 d 9 4 Control alarms These are alarms that are only activated during control Protector alarms The alarms corresponding to the LowSH LOP MOP and HiTcond protectors are only activated during control when the corresponding activation threshold is exceeded and only when the delay time defined by the corresponding parameter has elapsed If a protector is not enabled integration time 0 s no alarm will be signalled If before the expiry of the delay the protector control variable returns back inside the corresponding threshold no alarm will be signalled Note this is a likely event as during the delay the protection function will have an effect If the delay relating to the control alarms is set to O s the alarm is disabled The protectors are still active however The alarms are reset automatically Low suction temperature alarm The low suction temperature alarm is not link
92. tion temperature alarms This is because following such alarms the user may want to protect the unit by stopping the flow of Key refrigerant or switching off the compressor L Phase The LOP alarm is excluded as in the event of low evaporation temperature N Neutral closing the solenoid valve would worsen the situation COMI NOI Alarm relay output Parameter description Def Relay configuration Alarm Disabled relay Alarm relay open when alarm active Solenoid valve relay open in standby 9 3 Sensor alarms Valve relay alarm open in standby amp control alarms The sensor alarms are part of the system alarms When the value measured by one of the sensors is outside of the field defined by the parameters corresponding to the alarm limits an alarm is activated The limits can be O Note if configured as an alarm relay to send the alarm signal to a set independently of the range of measurement Consequently the field remote device siren light connect a relay to the output according to outside of which the alarm is signalled can be restricted to ensure greater the following diagram safety of the controlled unit Note the alarm limits can also be set outside of the range of measurement avoid unwanted sensor alarms In this case the correct operation of he unit or the correct signalling of alarms will not be guaranteed by default after having selected the type of sensor used the alarm imits will be automatically set to the
93. tion to a supervisory system via RS485 and to a pCO controller via pLAN tLAN Modbus Parameter description Def Min Max UOM Configuration Network address 198 1 207 Tab 4 a Refrigerant The type of refrigerantis essential for calculating the superheat In addition itis used to calculate the evaporation and condensing temperature based on the reading of the pressure sensor Parameter description Def Configuration Refrigerant R404A R22 R134a R404A R407C R410A R507A R290 R600 R600a R717 R744 R728 R1270 R417A R422D Tab 4 b Valve Setting the type of valve automatically defines all the control parameters based on the manufacturer s data for each model In Manufacturer programming mode the control parameters can then be fully customised see the paragraph valve parameters if the valve used is not in the standard list In this case the driver will detect the modification and indicate the type of valve as Customised Parameter description Def Configuration Valve CAREL CAREL ExV Alco EX4 Alco EX5 Alco EX6 Alco EX7 Alco EX8 330Hz sugge sted by CAREL Alco EX8 500Hz specified by Alco Sporlan SEI 0 5 11 Sporlan SER 1 5 20 Sporlan SEI 30 Sporlan SEI 50 Sporlan SEH 100 Sporlan SEH 175 Danfoss ETS 25B Danfoss ETS 50B Danfoss ETS 1008 Danfoss ETS 250 Danfoss ETS 400 Tab 4 c Pressure sensor S1 Setting the type of pressure sensor S1 de
94. up parameters will not need to be set and confirmed n fact the application running on the pCO will manage the correct values based on the unit controlled Consequently simply set the pLAN LAN or Modbus address for the driver as required by the application on the pCO and after a few seconds communication will commence between the two instruments and the driver automatically be enabled for control The main screen will shown on the display which can then be removed and control will be commence when requested by the pCO controller or digital input DI1 The pLAN driver is the only version that can start control with a signal from the pCO controller over the pLAN If there is no communication between the pCO and the driver see the paragraph pLAN error alarm the driver will be able to continue control based on the status of digital input 1 The tLAN and RS485 Modbus drivers can be connected to a pCO controller but only in supervisor mode Control can only start when digital input 1 closes 15 4 2 Guided commissioning procedure display After having fitted the display Configurtion Hetwork address O the first parameter is displayed O press UP DOWN to modify the network address value press Enter to move to the value of the parameter Configurtion Hetwork address Y Prg We press UP DOWN to move to the next parameter refrigerant press Enter to
95. up sensor for the main sensor S2 Type CAREL code Range CAREL NTC 10 at 25 C NTCO HP00 NTCO WFOO NTCO HF00 50T105 C CAREL NTC HT HT SOKO at 25 C NTCO HTOO 0T120 C 150 C per 3000 h Combined NTC SPKP TO 40T120 C A Attention in case of combined NTC sensor select also the parameter relevant to the corresponding ratiometric pressure sensor Parameter description Def CONFIGURATION Sensor 52 CAREL NTC CAREL NTC CAREL NTC HT high T Combined NTC SPKP TO 0 10 V external signal Sensor S4 CAREL NTC CAREL NTC CAREL NTC HT high T Combined NTC SPKP TO Tab 6 a Input S3 The auxiliary sensor S3 is associated with the high condensing temperature protection or can be used as a backup sensor for the main sensor S1 If the sensor being used is not included in the list select any 0 to 5 V ratiometric or electronic 4 to 20 mA sensor and then manually modify the minimum and maximum measurement in the manufacturer parameters corresponding to the sensors Important sensors 3 and S4 appear as NOT USED if the auxiliary control parameter is set as disabled If auxiliary control has any other setting the manufacturer setting for the sensor used will be shown which can be selected according to the type Auxiliary control Variable displayed High condensing temperature protection 53 Modulating thermostat 54 Backup sensors
96. up to 230 Vac 12 solenoid valve Oo JO Un joo N2 Fig 2 b 13 alarm signal Terminal Description O Note G GO Power supply the use of the driver for the superheat control requires the use of the mE So supply evaporation pressure sensor 51 and the suction temperature sensor 52 which will be fitted after the evaporator and digital input 1 to enable 1 3 2 4 Stepper motor power supply control As an alternative to digital input 1 control can be enabled via COM1 NO1 Alarm relay remote signal tLAN pLAN RS485 For the positioning of the sensors GND Earth for the signals relating to other applications see the chapter on Control VREF Power to active sensors inputs 51 52 are programmable and the connection to the terminals 51 Sensor 1 pressure or 4 to 20 mA external signal depends on the setting of the parameters See the chapters on 52 Sensor 2 temperature or 0 to 10 V external signal Commissioning and Functions EE sensor pressure sensor S1 in the diagram is ratiometric See the general 4 Sensor 4 temperature DH Digital input 1 connection diagram for the other electronic sensors 4 to 20 mA or DI2 Digital input 2 combined E Terminal for tLAN pLAN RS485 Modbus connection Terminal for tLAN pLAN RS485 Modbus connection Terminal for pLAN RS485
97. uperheat set point is too low Increase the superheat set point and check that the swings are reduced or disappear Initially set 13 C then gradually reduce the set point making sure the system does not start swinging again and that the unit temperature reaches the control set point In the start up phase with high evaporator tempe ratures the evaporation pressure is high MOP protection disabled or ineffective Activate the MOP protection by setting the threshold to the required saturated eva poration temperature high evaporation temperature limit for the compressors and setting the MOP integration time to a value above 0 recommended 4 seconds To make the protection more reactive decrease the MOP integration time Refrigerant charge excessive for the system or extreme transitory conditions at start up for cabinets only Apply a soft start technique activating the utilities one at a time or in small groups If this is not possible decrease the values of the MOP thresholds on all the utilities 41 EVD evolution 030222041 rel 1 0 01 06 2008 PROBLEM CAUSE CAREL SOLUTION In the start up phase the low pressure protection is activated only for units with compressor on board The Valve opening at start up parameter is set too low Check the calculation in reference to the ratio between the rated cooling capacity of the evaporator and the capacity of the valve if necessary l
98. valve position 0 0 9999 step Tab 6 k Control is placed on hold all the system and control alarms are enabled however neither control nor the protectors can be activated Manual positio ning thus has priority over any status protection of the driver Note the manual positioning status is NOT saved when restarting after a power failure in for any reason the valve needs to be kept stationary after a power failure proceed as follows remove the valve stator in Manufacturer programming mode under the configuration parameters set the PID proportional gain 0 The valve will remain stopped at the initial opening position set by corresponding parameter CAREL Recover physical valve position Parameter description Def Min Max UOM Valve Synchronise valve position in opening 1 0 1 Synchronise valve position in closing 1 0 1 Tab 6 1 This procedure is necessary as the stepper motor intrinsically tends to lose steps during movement Given that the control phase may last continuously for several hours it is probable that from a certain time on the estimated position sent by the valve driver does not correspond exactly to the physical position of the movable element This means that when the driver reaches the estimated fully closed or fully open position the valve may physically not be in that position The Synchronisation procedure allows the driver to perform a certain number of steps
99. ven prior to purchase from the website www carel com Each CAREL product in relation to its advanced level of technology requires setup configuration programming commissioning to be able to operate in he best possible way for the specific application The failure to complete such operations which are required indicated in the user manual may cause the final product to malfunction CAREL accepts no liability in such cases Only qualified personnel may install or carry out technical service on the product The customer must only use the product in the manner described in the documentation relating to the product n addition to observing any further warnings described in this manual the ollowing warnings must be heeded for all CAREL products prevent the electronic circuits from getting wet Rain humidity and all ypes of liquids or condensate contain corrosive minerals that may damage he electronic circuits In any case the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual do not install the device in particularly hot environments Too high emperatures may reduce the life of electronic devices damage them and deform or melt the plastic parts In any case the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual do not attempt to open the device in any way other than described in t
100. y Decrease the value of the Valve opening at start parameter on all the utilities making sure that there are no repercussions on the control temperature Liquid returns to the com pressor only after defrosting for multiplexed cabinets only The pause in control after defrosting is too short ncrease the value of the valve control delay after defrosting parameter The superheat temperature measured by the driver after defrosting and before reaching operating conditions is very low for a few minutes Check that the LowSH threshold is greater than the superheat value measured and that he corresponding protection is activated integration time gt 0 s If necessary decrease he value of the integration time The superheat temperature measured by the driver does not reach low values but there is still return of liquid to the compres sor rack Set more reactive parameters to bring forward the proportional factor to 30 increase the integration vative time to 10 sec closing of the valve increase the ime to 250 s and increase the deri Many cabinets defrosting at the same time Stagger the start defrost times If this is not possib two points are not present increase the superhea by at least 2 C on the cabinets involved e if the conditions in the previous set point and the LowSH thresholds The valve is significantly oversized Replace the valve with a smaller equivalent Liquid
101. y protectors LowSH LOP MOP HiTcond see the chapter on Protectors without any valve unblock procedure and without auxiliary control Control is performed on the hot gas bypass temperature sensor value read by input S2 compared to the set point Hot gas bypass temperature set point Control is reverse as the temperature increases the valve closes Parameter description Def Min Max UOM CONTROL Hot gas bypass temperature set point 10 60 200 C CF 76 392 PID proportional gain 15 0 800 PID derivative time 150 0 1000 s PID integration time 5 0 800 5 Tab 5 9 CAREL Transcritical CO2 gas cooler This solution for the use of CO in refrigerating systems with a transcritical cycle involves using a gas cooler that is a refrigerant air heat exchanger resistant to high pressures in place of the condenser In transcritical operating conditions for a certain gas cooler outlet temperature there is pressure that optimises the efficiency of the system Set A T B Set pressure set point in a gas cooler with transcritical CO T gas cooler outlet temperature Default value A 3 3 B 22 7 In the simplified diagram shown below the simplest solution in conceptual terms is shown The complications in the systems arise due to the high pressure and the need to optimise efficiency 1 EVD evolution V1 v2 Fig 5 e Key CP Compressor V2 Thermostatic expasnio

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