Split Package Control System User`s Manual
Contents
1. 1 Pump Out The Pump Out cycle is used to evaporate any remaining refrigerant liquid from the coils The Liquid Valve is closed the Suction Valve if provided is open and the Fans are on If compressor monitoring is enabled the Pump Out cycle will terminate early once the compressor stops 2 Pre Defrost Pre Heat The Pre Defrost cycle may be used to open a Pre Hot Gas valve prior to Hot Gas Defrost For systems with Electric Defrost the Pre Defrost cycle may be used as a delay to allow the coil to warm up prior to energizing the Electric Defrost output The Pre Defrost timer may be set to zero to skip the Pre Defrost cycle 3 Defrost For systems with Electric Defrost the Defrost output is used to turn on the Defrost Heaters for systems with Hot Gas Defrost the Hot Gas valve is opened and for systems with Water Defrost the Defrost Water valve is opened The Defrost cycle may be set to run for a user programmable time period or until the early termination input is satisfied 4 Post Defrost Bleed The Post Defrost cycle may be used to open a Bleed equalization valve after a Hot Gas defrost cycle For systems with Electric Defrost or Water Defrost the Post Defrost cycle may be used as a delay to allow the coil to drip dry and to allow pressures to equalize prior to entering the Cool Coil state The Post Defrost timer may be set to zero to skip the Post Defrost cycle 5 Cool Coil The Cool Coil cycle is used to re freeze any remaini2. EPROM Modem Memory M1 512K RAM Fixed Analog Output Board Memory M2 8K EEPROM Fixed Analog Inputs ANALOG INPUTS SENSOR TYPE OFFSET CHAN NAME RANGE UNITS TYPE Gwer o i Zone mme s302 DG RD RTD Tempran 2 3 AU2DEFR TERM TEMP 58 122 DEGF 420 ma TYPE OFFST CHAN DESCRIPTION OUTPUT 0o LIQUIDSOL CLOSED SUCTION SOL CLOSED PRE DEFROST CLOSED DEFROST HEAT CLOSED 5 POST DEFROST CLOSED OUTPUT 5 6 AUI FAN OFF Fourpur_ 6 7 AU2FAN OFF OUTPUT 7 8 ALARM FAILURE NORMAL INPUT 8 9 COMPRESSOR RUNNING YES INPUT 9 10 HIGH PRESS CUT OUT NORMAL 11 LOW PRESS CUT OUT NORMAL OIL PRESS CUT OUT NORMAL 13 AU1 DEFROST TERM SW CLOSED AU2 DEFROST TERM SW CLOSED SHUTDOWN STANDBY CLOSED DEFROST INITIATE CLOSED Notes 1 120 VAC 5 Amp Form C mechanical relay 2 120 VAC Solid State Input Module 3 120 VAC Solid State Output Module 4 Normally energized Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used B 1 M amp M Systems Inc Refrigeration Split Package Controller Rev Appendix C Modbus Communications TBD Quality Note Please Verify This Document Is The Latest Revision Only the latest revision sho
3. amp SYSTEMS Coutrz ol Salaetcous M amp M Systems Inc Refrigeration Split Package Controller 1992 2006 M amp M Systems Inc All rights reserved Printed in the United States of America This manual is Copyright 1992 2006 by M amp M Systems Inc The information presented herein is proprietary to M amp M Systems Inc No part may be reproduced or translated in any form or by any means without the expressed written permission of M amp M Systems Inc Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used i Revision History Revision Date 5 10 06 Approval Description of Change Preliminary Release Comments TABLE OF CONTENTS 1 EQUIPMENT SUMMARY ssssssssssssssssissscsscssessessasssscssssoeeseasccsssseasesssosacsesessees saassesassecseseess sssessessesssesesceebesciseseeses 1 1 1 CONTROL SYSTEM COMPONENTS cccccccccecececscececececececececececececececececececececececececececececececececececececececececesecesesess 1 1 2 ENVIRONMENTAL SPECIFICATIONS ccccccecececececececececececececececeescecececececececececececececececececececececececececececesecesesess 1 123 CONTROL SOFTWARE s5 icsssshshssssessdosseessovevs de lonspooseanes
4. number G1 G4 Setpoint groups consist of a setpoint deadband and high and low alarms If heating is provided a heating setpoint is also provided Daily schedule times can be entered in any order and the SPCS will automatically reorder them in chronological order when the screen is saved The operator then assigns a daily schedule to each day of the week using the selectable field on the weekly schedule screen Each daily schedule is referred to by its schedule number SCH1 SCH3 A new day starts and schedules change at midnight The operator may also override the current schedule setpoint or disable scheduling all together The evaporator setpoint screen allows the operator to override the current control group and the current active daily schedule In addition scheduling may be disabled by the operator by selecting disable on the evaporator setpoint screen 2 1 4 Defrost Control A number of different defrost techniques are supported by the controller including Electric Hot Gas Water or Air The following table shows the valve configuration for each Defrost state Each state also includes a user programmable time which may be set to zero to bypass the state For example if the Pre Defrost valve is not used the Pre Defrost timer can be set to zero DEFROST LIQUID SUCTION PRE POST STATE SOL SOL DEFROST DEFROST DEFROST FANS NO DEFROST PUMP OUT The following list documents the detailed operation for each defrost state
5. state of the compressor to ensure that it is running when required An alarm will be generated if the compressor does not start within a user programmable time after the liquid valve opens The Compressor Running input may also be used to provide early termination of the Pump Out defrost state When this feature is enabled the Pump Out defrost cycle will be terminated when the compressor stops Three safety inputs have been provided High Pressure Cut Out Low Pressure Cut Out and Oil Pressure Cut Out These inputs are typically wired to pressure switches mounted in the equipment which will shutdown the compressor when a problem occurs The controller monitors these inputs and will change the evaporator state to Shutdown when active 2 3 Shutdown Standby Input The Shutdown Standby input is provided to allow external equipment to stop the evaporator The operator may select Shutdown or Standby operation for this input In either case the zone will be shutdown in an orderly fashion The primary difference between Shutdown and Standby operation is that a failure will be reported and zone high temperature alarms will remain enabled in the Shutdown state Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 6 3 Operator Interface TBD Quality No
6. Feed Runtime Demand Defrost or by operator input For Time of Day scheduling eight defrost cycles per day are supported Three different daily schedules may be assigned to each day of the week For Liquid Feed Runtime scheduling a defrost cycle will be performed when the Liquid valve has been open for a user programmable cumulative period of time The Demand Defrost input is provided to allow external devices to initiate a defrost cycle When the Defrost Initiate input contact is closed the zone will begin a defrost cycle 2 1 7 Defrost Queue When multiple zone controllers are configured in a network one controller is specified as a Master The Master controller handles the management of the Defrost Queue which ensures that only a specified number of zones are allowed to defrost at any given time When a zone requires defrosting a Defrost Request is entered into the Defrost Queue If the current number of zones defrosting is less than the maximum specified the zone is allowed to defrost If the maximum number of zones is already defrosting the zones will be defrosted on a first come first served basis Each zone can be designated as a Priority Defrost zone When the Defrost Queue is full zones with Priority Defrost will be entered at the top of the queue 2 2 Compressor Monitoring Compressor monitoring is an optional way to keep track of the operation and health of the compressor The Compressor Running input is used to monitor the
7. ed in any convenient location such as the rooftop by the condensing unit within the refrigerated space next to the evaporator or in a machinery room or hallway The application of the SPCS into various manufacturers equipment will determine what features and functions will be available for use by the plant personnel This document specifies all available functions and how they can be used Additional contactors sensors or wiring may be required in order to make full use of the capabilities of the SPCS 1 1 Control System Components The SPCS consists of the following components and sub systems 1 Control panel Microprocessor based controller board Memory RAM EPROM EEPROM Analog Input and Output Signal Conditioning Discrete Input Output Signal Conditioning Communications ports Power Supply Enclosure 2 Sensors and actuators e Analog sensors for temperature pressure etc e Form C relay outputs e Discrete contact inputs 3 Operator Interface Remote access via PC Optional remote access via modem Optional remote monitoring via Modbus RTU protocol Optional two line display with keypad 1 2 Environmental Specifications The SPCS will be designed to survive in an outdoor or indoor industrial environment under the following conditions Ambient Temperature 20 50 DEGC Operating 20 50 DEGC Non Operating Water Resistance NEMA 4 Power Input 110 220 VAC 50 60 Hz Agency Approvals UL 508A Listed Industrial Contr
8. elephone line are provided In either case all the functionality available with a local PC is available from the remote location If an open protocol is desired the Modbus RTU protocol is supported on an RS 422 RS 485 interface All real time analog discrete and state data are available as well as access to a limited number of control and monitoring setpoints Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 2 2 Detailed System Description 2 1 Evaporator Control Controlling the room temperature is the primary function of the SPCS and controlling the evaporator liquid valve is the minimum required control operation Compressors condensers and fans may or may not be controllable depending on how much additional wiring or contactors are added to the equipment The following paragraphs discuss controlling the liquid valve fans and defrost One or two coils can be controlled and each can have its own fan as long as they share the same liquid valve If the fans are not controllable then features such as fan cycling and fan sampling will not be available If defrost is required two methods are provided Air defrost simply stops refrigeration for a period of time to allow ice to melt from the coils Electric defrost also energizes elec
9. n for that particular zone When the temperature is above the cooling setpoint by half the deadband the liquid valve will open and when the temperature is below the cooling setpoint by half the deadband the liquid valve will close For example if the cooling temperature is set to 45 DEGF with a deadband of 2 DEGF the liquid valve will open at 46 DEGF and close at 44 DEGF The operator may select one of three fan cycling options for fan control while a zone is operating If No Fan Cycling NONE is selected the zone fans will remain running even when the zone is Satisfied If Temperature Fan Cycling TEMP is selected the zone fans will stop when the zone is Satisfied If Fan Sampling SAMP is selected the fans will stop when the zone is Satisfied but will restart periodically for a short period of time to mix the air in the room Fan On and Fan Off delays are also provided to allow fan staging when multiple fans are instrumented for an individual zone 2 Stop The Stop state is an operator selected state and is used to cancel all automatic control of an evaporator zone and shuts it down The fans turn off and the liquid valve closes An evaporator in the Stop state will still defrost based on the defrost schedule or by manual initiation of defrost via the manual override command Any defrost in progress when the operator selects the Stop state will run to completion Quality Note Please Verify This Document Is The Latest Revision Only the la
10. ng water on the coils and drip pan to prevent excess water from blowing into the room The Liquid valve is opened and the fans remain off for the duration of the Cool Coil cycle 6 Alarm Delay After the Cool Coil cycle normal refrigeration may resume The Alarm Delay cycle is used to inhibit zone temperature high alarms for a period of time after a defrost cycle in order to allow time for the room temperature to recover Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 5 2 1 5 Defrost Termination Early termination of a defrost cycle is provided as a user selectable option A temperature sensor or discrete contact closure may be used for each fan coil When termination on temperature is enabled the defrost cycle will be terminated when the coil temperature sensor rises above a user programmable setpoint When a discrete contact termination input is used the defrost cycle will be terminated when the termination contact closes When defrost termination is enabled an optional alarm may be generated if the defrost cycle is terminated on time instead of temperature The operator may enable or disable this feature 2 1 6 Defrost Scheduling A defrost cycle may be initiated in a number of different ways including Time of Day scheduling Liquid
11. odersneboessobevsSesodepvesenaedeverdnevenseoneve ds lonspoessnnesedeusnspeesguovelsee 2 1 4 REMOTE MONITORING cccccccecececececececececececececececececececececececececececececececececececececececececececececececececececececesecenens 2 2 DETAILED SYSTEM DESCRIPTION iscsccssssssoccsssssesessasssssesoessesssessoccesesssvonsessescesseseasssevseccosesssessbecdssessecsssess 3 2 1 EVAPORATOR CONTROL c ccccccecececececececececececececececececececececececececececececececesecececececececececececececeeeceseeecececececeeececens 3 2 1 1 LONE GON OL ANAE EE E ANE EE E AAE EA EEE E NASE A AE EEE E E A 3 2 1 2 VAAN WUT CA EEE EEE A EEA TE T EE T E ET A E E E E EE aces 4 2 3 Evaporator Setpoint Scheduling cccccccesccesecesecescesecesecuseeaseeseeeseesaeeseeeseeeseceseceaecaecsaecaaeeaecnaeenseeeaees 4 2 1 4 Defrost Control ssns nonis aarne e aa E EE E AE E A A E E N REA 5 2 1 5 Defrost Termination cccccccccccccesssecsssceenseceseceescecesceeescecsceesacecssceeeaeeceeeeeaaecsuceesaaecseceeeaaeceeeeseaeessaeeesaes 6 2 1 6 Defrost Scheduling onenean EE sageceante tgun gues song ovSbauagus EEA E EE 6 2 1 7 Defrost QUCUC rose srren ne E ERE REE E E E E E EE S 6 22 COMPRESSOR MONITORING a a a chagencd a a aa E saa E rara AE ETE EKEN 6 23 SHUTDOWN STANDB INPUT mecene E E EEE E EEE EE EEEE EEEE 6 3 OPERATOR INTERFACE sisssssssssssssscssssssssesssssesscseccssccssesecestevessesesssesssdeacsseasesasssvsses seseassasscboasssesesssseasssss
12. ol Panel UL File Number NITW E232237 cUL File Number NITW7 E232237 1 3 Control Software The Control Software executes from non volatile memory which requires no operator intervention in the event of a power failure The software is designed to provide control and monitoring functions to maintain the proper room temperature and to notify plant personnel that there is a problem with the system Also included are various optional safety controls and monitoring points to improve system performance For a detailed description of the Control Software see the Detailed System Description section below An optional local display and keypad is available to allow local monitoring and setpoint modification For a detailed description of the Operator Interface see the Operator Interface section below An interface is also provided for a PC Laptop or other hand held device to allow qualified maintenance personnel access to more advanced system functions System configuration historical log viewing graphing and report printing may all be performed through the PC interface The PC Monitor software is described in a separate document titled PC Monitor User s Manual 1 4 Remote Monitoring Several options are available for remote monitoring of real time data from the SPCS A PC may be permanently or temporarily connected to the one or more controllers through an RS 422 communications network In addition the PC may dial into the system if a modem and t
13. rator has the option of allowing the zone to restart immediately or to be restarted one at a time based on time and temperature The Master controller uses a user programmable power fail stage delay timer to restart zones after a power failure The zone whose temperature differential is highest from setpoint will be restarted until all zones have been restarted 2 1 2 Zones With Heat A zone with Heat uses a second zone control setpoint for use when the room temperature is too low Electric heat is typically used when a zone is instrumented for heating but any heating method can be used as long as it is controllable with a single output When a zone with heat is in the Satisfied state the setpoint will reflect whether the zone is in heating or cooling mode 2 1 3 Evaporator Setpoint Scheduling Each zone has four temperature setpoint groups which may be scheduled for use by the operator Each schedule consists of a weekly schedule and three daily schedules The operator can enter up to eight times into any one of the daily schedules The user also assigns the desired temperature setpoint group and fan cycling control to each time entered Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 4 Temperature setpoint groups are referred to by group
14. re Shutdown cancels automatic control of an evaporator zone and shuts it down The fans turn off and the liquid solenoid closes Any defrost in progress will be canceled An evaporator in the Shutdown state will not defrost based on the defrost schedule liquid feed runtime or by manual initiation of defrost via the manual override command When the condition that caused the shutdown is no longer active the control state will be restored to the previous state Defrosts which are cancelled by a Shutdown will not be re queued 7 Standby The Standby state is entered when the Shutdown Standby input is active and Standby operation has been programmed by the operator Standby is typically used when a zone needs to be stopped for washdown or cleanup operations Standby may also be used for Load Shedding by external control functions Standby cancels automatic control of an evaporator zone and shuts it down The fans turn off and the liquid valve closes An evaporator in the Standby state will still defrost based on the defrost schedule or by manual initiation of defrost via the manual override command Any defrost in progress will run to completion Zone high temperature alarms will be inhibited in the Standby state and for a user programmable time delay after the zone restarts 8 Power Fail The Power Fail state is used to reduce the demand power requirements for restarting evaporators after a power failure When power is restored to the system the ope
15. ssesecees 7 APPENDIX A ALARM AND FAILURE CONDITIONS ccssssscsssscccssssccssssscccsssscccsssccccssssccsessseccsesssceseses A 1 APPENDIX B HARDWARE REQUIREMENT G csssssssssssscsssccsessssccssssccccsssccscssceccessscccessaccsessccecsssscscssnees B 1 APPENDIX C MODBUS COMMUNICATIONS csssssccsssssscessscscssssccsensscccsssccessccccssssscecssssccscssccecessecsccesnes C 1 Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used iii M amp M Systems Inc Refrigeration Split Package Controller Rev 1 Equipment summary The M amp M Systems Spit Package Control System SPCS uses distributed methodology to control Heating Ventilation Air Conditioning and Refrigeration HVAC R equipment in the facility Control panels may be located close to the controlled equipment to reduce wiring costs An RS 422 multi drop serial communications network is used to connect multiple control panels to a Master control panel for alarm reporting data logging and interface to the PC based monitoring system The design of the SPCS has been ruggedized for use in indoor or outdoor applications Typical Split Package refrigeration systems consist of two primary components the Condensing Unit and the Evaporator The SPCS control panel may be mount
16. te Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 7 M amp M Systems Inc Refrigeration Split Package Controller Rev Appendix A Alarm and Failure Conditions The following table lists the system alarm and failure conditions Alarms are information only and will not cause the unit to shutdown Failures indicate that a particular piece of equipment has failed or a critical parameter has exceeded its failure setpoint Failures are categorized as fatal or non fatal to the operation of the unit Only failures will cause the unit or sub system to be shutdown Fatal failures for the unit are indicated in the following table by the letter F and non fatal failures use the letter N Low High High Other Other Inhibit Parameter Name Alarm Alarm Fail Alarm Fail conditions Alarm and Failure inhibit Conditions 1 Quality Note Please Verify This Document Is The Latest Revision Only the latest revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used A 1 M amp M Systems Inc Refrigeration Split Package Controller Rev Appendix B Hardware Requirements Hardware Version STARS Display Sub Assembly Memory M0 256K
17. test revision should be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used 3 3 Max Cool The Max Cool state cancels automatic control of an evaporator zone and leaves it running The fans turn on and the liquid solenoid opens An evaporator in the Max Cool state will still defrost based on the defrost schedule liquid feed runtime or by manual initiation of defrost via the manual override command 4 Satisfied The Satisfied state is when an evaporator zone is within its setpoints not cooling or heating The Fans may or may not be running depending on the Fan Cycling status 5 Defrost The Defrost state indicates that a zone is undergoing a defrost cycle The type of defrost to be performed is a function how the zone is instrumented Electric Water and Air defrost methods are supported A defrost cycle can be initiated manually through a time schedule or through liquid feed runtime Zones are defrosted on a first come first served basis by entering the zone in a defrost queue A zone can be identified as a priority defrost zone which allows it to be entered at the top of the queue 6 Shutdown The Shutdown state is entered when the Shutdown Standby input is active and Shutdown operation has been programmed by the operator Shutdown is typically used when dangerous conditions are detected such as a refrigerant leak or mechanical failu
18. tric heating elements to reduce the amount of time required to defrost the coils In practice other types of defrost may be supported as long as they can be initiated with a relay contact closure Defrost termination is also supported When used one or more discrete inputs or temperature sensors are used to signify that the timed defrost cycle may be terminated early 2 1 1 Zone Control Zone Temperature Control is the manipulation of the evaporator Liquid valve and fans to maintain the temperature of a refrigerated space This includes evaporator setpoint scheduling and zone defrost control The zone temperature is continuously monitored and controls are adjusted to maintain the current temperature setpoint The operator can change evaporator operating modes adjust fan cycling schedule control setpoints and adjust defrost parameters to match the individual needs of each refrigerated space Each Evaporator zone can operate in one of several different states including Cooling Stop Max Cool Defrost Stop Defrost Shutdown Satisfied Standby and Power Fail The function for each state in the evaporator zone is documented below 1 Cooling In the Cooling state the liquid valve is opened and closed in response to temperature changes On the evaporator zone setpoint screen the operator can set the cooling setpoint and a deadband for each of four control setpoint groups The cooling temperature is the value the controller will try to maintai
19. uld be used for development and testing Earlier printed revisions will be marked obsolete on the front and the pages damaged indicating they should not be used C 1
Download Pdf Manuals
Related Search