Product manual
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1. Any systems that are on defrost force off to refrigeration using the following items Note CPST CPLT EP6A and EPLx only support JTL network initiated defrosting No defrost interface cards can be used with these types SYSTEM CPSA CPxS CP2x All other types FUNCTION R 0 Normal X 1 Forced Refrigeration Rg E g R P g g Q R N Rg g R y g g COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 19 One system at a time force defrosts on and off 1 at a time using the following items 425 1 Forced Defrost Check all the outputs as appropriate 3 11 5 Drain Down System If drain down boards are used then on returning from forced defrost condition to normal refrigeration each drain down output should energise COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 202. FUNCTION ITEM 30 MTEM31 ITEM32 ITEM 33 CONDENSER 1 XOCC Note 1 X x don t care c closed O open SW2 May use wire links TYPES CP5H CPLT CPST LEGACY INTERFACE IF1 IF4 PROGRAMMABLE INTERFACE IF11 IF14 FUNCTION ITEM 30 ITEM31 ITEM32 ITEM 33 CONDENSER XOCC X don t care X c closed O open SW2 May use wire links Dot showing closed TYPES EP6x EPLX PROGRAMMABLE INTERFACE IF11 1F14 FUNCTION ITEM 30 ITEM 31 ITEM 32 ITEM 33 conpenseroureurst 7 Jo fa deo h conpenserovrputse ra fo ds to Available on later firmware enhancements Note IF4 and IF14 are for use with variable speed condenser fan controllers COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 7 3 1 3 Defrost ALL TYPES EXCEPT EP6x EPLX e e CPLT CPST eua INTERFACE IF3 PROGRAMMABLE INTERFACE IF13 FUNCTION ITEM30 ITEM31 ITEM32 ITEM 33 Defrost system 1 7 afe XOCC Note 2 x don t care Defrost system 8 14 c closed Defrost system 15 21 PE OS eee a Defrost system 22 28 ls SW2 May use E wire links Drain down valve 1 7 Drain down valve 8 14 Drain down valve 15 21 E a TYPES EP6U amp CP5H LEGACY INTERFACE IF3 PROGRAMMABLE INTERFACE IF13 FUNCTION pee ITEM 30 ITEM31 ITEM32 ITEM33 Defrost system 8 14 2 O open SW2 May use Drain down valve 1 7 XOOC Dot showing i closed Drain down valve 8 14 2 Drain down valve 15 21 Note EPLT EPLA EP6A CPLT a
3. data has already been set up for this installation If the data is sensible do not erase it and start again as this may involve a lot of unnecessary work Note Ifthe controller has been despatched direct from JTL Systems it will contain the standard default data To check if the data is sensible check the following using the hand unit on items as shown CPxS CP2x CPSA EP6x CP5x CP4x EPLT CPLT CPST No of detoststems__ 200 wo lw ___ If the items are in agreement with the actual equipment it is reasonably safe to assume that the data has already been set up sensibly If it has not been set up the bitswitches on the main controller as follows PACK TYPE SWITCH POSITION FUNCTION x don t care CPCS CPRS CPSA XXXC LT pack c closed dot showing XXXO HT pack O open XCCC LT pack gas XXCO HT pack gas XXOC LT pack electric XX00 HT pack electric XOCC LT pack migros All other controllers all types Perform an initiation sequence with the maintenance unit as follows can RVC COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 10 3 4 DISPLAY TEST Check the JTL displays are functioning sensibly If there is garbage on displays check the display type on the maintenance unit When there is a display splitter for up to 4 displays or a 4 way display panel then the display type selected should be LED2 If there is a display splitter for only 2 displays then the display type is LED1
4. follows COMPRESSOR CPxS CP2x CPSA CP4x CP5x EP6X CPLT EPLX a poo o w o Note CPxS CP2x CP3x and CP4x support up to 3 steps compressor CP5x and EP6x support up to 4 steps compressor CPLT and EPLx support 1 step compressor CPSA supports 2 steps compressor CPST has an analogue 4 20mA output per compressor COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 15 3 10 3 Type of Compressor Set the type of compressor using the item no in the table as follows COMPRESSOR CP2x CP3x CP4x CP5x EP6X DISPLAY eal CPST EPLx O Not Controlled 1 LT Compressor 2 HT Compressor 3 Satellite 3 10 4 Defrost System Set Up No further set up is required for setting 3 11 ELECTRICAL TESTING WITHOUT LOAD Before electrical testing check a All commons to interface card fault inputs are definitely connected to neutral b All line and load outputs from interface and main controller cards have correct polarity LN or LINE must be to the ac supply side and LD or LOAD must be connected directly or indirectly to the output load Remove all necessary output fuses or isolate any necessary circuit breakers Arrange to defeat any electrical fault circuits pressure switches etc that may not allow the equipment the equipment to run 3 11 1 Condenser Use the forced function to stage the condenser 1 stage at a time PACK TYPE ITEM FUNCTION CPxS CP2x Set to O for Auto Set to 1 13 for f
5. required This should be applied across each coil SEGREGATION Ideally the JTL pack controller should be in a different section to the interface cards This requirement is satisfied by the use of the JTL enclosure for the pack controller however it is still recommended that the interface cards are mounted with the control equipment and not with the main controller HEAT RECLAIM AND LIQUID DIFFERENTIAL VALVES Specific care should be taken with the heat reclaim and liquid differential valves If these are not directly driven by JTL control equipment they must be suppressed SUPPRESSOR TYPE Suppressors should be series resistor capacitor type JTL can provide information on procurement or supply suitable parts from stock CABLE SCREENING EMC guidlines indicate in some circumstances that screens of cables should be earthed at both ends to ensure EMC capability This should only be done when the earth is guaranteed to be perfect low independance to all frequences at both ends of the screened cable If the earth is not perfect then connection of the screen at both ends will cause severe problems Connections of the screen should be made to the earth terminals shown or specified on the installation documents COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 4 2 7 EARTH CONNECTION Earth connections must be copper or aluminium to earth Steel plates trunking armouring forming part of the earth system are no
6. 7 Note Telephone cable and other low voltage insulated cables are not permitted 1 2 3 JTL Controllers to JTL Comms Unit The recommended cable for the purpose is a twin core cable Equivalent to BICC type 7 2 2A to DEF STAN 61 12 part 4 Possible Suppliers FES Order Code 030704E RS Order Code 362 897 Note Telephone cable and other low voltage insulated cables are not permitted COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 2 ELECTRICAL NOISE SUPPRESSION amp EMC REQUIREMENTS 2 1 2 2 2 3 2 4 2 5 2 6 PRINCIPLES All JTL controllers have built in suppressors to suppress electrical interference that is generated by relays solenoids and contactors when power to such devices is removed The suppressor provides a path for the stored energy in the coil and thus prevents high voltages and sparks which generate the interference OUTPUTS The JTL pack controller comprises 2 fundamental parts the main pack controller and the interface cards With the exception of the liquid differential pressure valve all power outputs are driven by the interface cards Where the valves are driven directly by the JTL cards the built in suppression is adequate Problems arise where the JTL output indirectly drives the valves which are therefore unsuppressed Where these indirectly driven valves are controlled by equipment mounted in the same section as the JTL pack controller then extra suppression is
7. IGNAISGROUNDS 4 Se ee ee Sa Ba ee Go i ie SO id 5 PACK COMMISSIONING 0 0 0 00 0 cece nee eb eben eben ene bees 6 3 1 INTERFACE CARD ADDRESSING oo 6 S44 COMPRESOR ee ite we eS a a SO en aoe iah 6 Do YCONGENSERS a hake Sle ager PAA Oe Are nal pole ali eS cel len Sak 7 B15 O ics cee gn ated Rennie ee Dah ati chalets andy ta eRe logy alate EEN 8 3 2 WATCHDOG DEFAULT SETTINGS S ssa taa 288 bask oud ar died tl E 9 3 3 INIFIAL SETTINOS caret ted tl Ua ee Oe oe 10 3 4 DISPLAY TEST Susi rd o ia eure akan A 11 3 5 PRESSURE TRANSDUCERS TEST 0 0 00000 cece nee e eae 12 3 6 TEMPERATURE SENSORS 0 02200 c ce eee be ee bbe ee bbe bans beens 12 3 7 AUTOUNP UI Tis cain oh Be etre ds ete es es aye eae Tea cota date 13 3 8 LOW LIQUID OR REFRIGERANT LEAK INPUT o 13 3 9 PACK COMMUNICATIONS ta ts 5 Anaad trestle dat a di td fai 14 3 10 INSTALLATION SERUP at Mit a aes Ros 15 S110 SGONGENSESR a atl OG ea det ety tate ad eh ee ae 15 3 10 2 Number of steps per compressor 0 00 15 3 10 3 Type of Compressor eee 16 3 10 4 Defrost System Set Up noaua 16 3 11 ELECTRICAL TESTING WITHOUT LOAD oohun 16 SNAN CONGENSE wis Sent a E Et IS E oan so 16 3 11 2 Compressor Type CPxS CP2x CP3x CPSA 0 0 eee ee 17 3 11 3 Compressor type CP4x CP5x EP6x CPLT CPST EPLX 18 SACs DERROST SYSTEMN arsu nada E OE 19 3 11 5 Drain Down SYSTEMY secina t adian eee 20 TABLE OF CONTENTS COMP PACK INSTALL MANUAL WPD Doc N
8. JTL SYSTEMS LIMITED COMPRESSOR PACK INSTALLATION MANUAL FOR ALL CONTROLLER TYPES GV JTL Systems Limited A1 Kingfisher Court Hambridge Road NEWBURY Berkshire RG14 5SJ Tel 01635 263646 Fax 01635 263647 After Sales Support Line 0870 321 HELP 4357 INSTALLATION PRACTICE a pida tele ai ats See AL lg hth at Mehta age ata Sambar ade fs 1 1 1 CABLE INSTALLATION REQUIREMENTS 0 0 1 44 4 CAE CUA ION A A ts 1 DUI A A A A 1 TAS Powerand Control Cables iii ld da GG aio 2 MAA HIgh Voltaje Testing 1 in ek be ee bd ae a 2 1 1 5 Cable Installation Within Enclosures 00 00 0 aa 2 1 1 6 External Cable to JTL Control Equipment site wiring 2 1 2 CABLE SPECIFICATION score aa elas oo alta des e ie A ia aetna dinates 3 1 2 1 Pressure Transducer Cable o tia rinri a a ee 3 1 2 2 Temperature Sensor Extension Cable 0 0 0 00 c eee 3 1 2 3 JTL Controllers to JTL Comms Unit 00 000000 a 3 ELECTRICAL NOISE SUPPRESSION amp EMC REQUIREMENTS 0 00 00 00 c cece eee 4 2 1 PRINCIPLES tit A tl rin Ande Me 4 2 2 OW TIPS a o o Pd tat aan Mpa ct E atten tanec 4 2 3 SEGREGATION ste 0 ths atestado tata tie ed aligh a ia aches alias dra ado tet 4 2 4 HEAT RECLAIM AND LIQUID DIFFERENTIAL VALVES 0 0 0000000 eee eee 4 2 5 SUPPRESSOR TYPE axsete coun antgny key aa pe oe A El IE Cte eho Ba ot 4 2 6 GABLESGREENING o Toca tae 4 2 7 FEARTA CONN E OTON aia ad Aion ads aden om ee Kft 5 2 8 S
9. The display type is selected using the maintenance unit by setting the following items PACK TYPE ITEM FUNCTION CPxS CP2x CP3x CPSA CP4x CP5x EP6U CPLT CPST EPLX EP6A MEN LED2 ONLY Once the display is selected correctly it can be tested by setting item 99 to 1 COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 11 3 5 PRESSURE TRANSDUCERS TEST There are four types of pressure transducer associated with the JTL equipment PT1 G PT1 O 100 psi gauge PT2 G PT2 O 200 psi gauge PT3 G PT3 O 300 psi gauge PT1A G PT1A 15 85 psi gauge The discharge pressure is always a PT3 G PT3 The HT suction pressure is always a PT1 G PT1 The LT and satellite suction pressures can use either PT1 G PT1 or PT1A G PT1A The LT and satellite suction pressure transducers can thus be selected by the maintenance unit item numbers PACK TYPE SATELLITE FUNCTION 1 PT1A G CP4x CP5x EP6x CPST CPLT EPLx 126 129 Connect the transducers or transducer simulators one at a time to the pack wiring The correct pressures should be indicated on the displays The supply voltage of 8 0 2 Vdc should be checked from the to the The output from the transducer should be checked to the O ura mao G lav 75V Papel psi a ae E ero fav fev fos fo ero w fev wow lo 3 6 TEMPERATURE SENSORS The 7 temperature sensor readings are indicated on items 31 37 respectively Un
10. f Defrost Interface not fitted CP4x CP5x EP6x CPSA On Drain Down Interface fitted Off Drain Down Interface not CP4x CP5x EP6x ied Each of the interface cards should now be communicating with the main controller The red LED indicators on each interface board should be on and stay on continuously This indicates that each board is receiving the message The reply communications status is indicated on the alarm status function on the maintenance unit INTERFACE TYPE ITEM DISPLAY CIR no faut Condenser 98 88 CPSA only COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 14 3 10 INSTALLATION SET UP 3 10 1 Condenser The condenser can be sequenced in 7 simple steps or a more complex sequence for up to 12 fans If simple steps up to 7 are required set the number of fans to the number of steps For 8 10 or 12 fans with summer winter solenoid set 8 10 or 12 OR 9 11 or 13 The sequence varies depending on the value set Output 7 is used to control the summer winter solenoid When half the selected fans are running the summer winter output is energised and the fan control outputs revert to 1 or O fans depending on whether 8 10 12 or 9 11 13 are selected see the CP4X manual for details 3 10 2 Number of steps per compressor The JTL controller supports up to 4 steps per compressor using 3 unloading stages For each compressor set the number of steps using the item no in the table as
11. her connectors connected to JTL equipment within the enclosure should be bootlace ferruled with the correct ferrule using an appropriate crimp tool Signal cables should be identified if possible JTL manufacture cables for all DIN connectors in various lengths to the above standards Signal cables are separated in to 2 groups common ground and RS485 communication cables Common ground cables must obey the above rules totally RS485 communication cables are more tolerant of problems so some relaxation may be allowed No signal cable should be run in trunking with power cables COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 1 1 1 3 Power and Control Cables All JTL controllers which drive electrical equipment have specified ratings For full details see appropriate manuals Generally however the following rules apply Max ac voltage 230 V de voltage 50 V Max ac dc current 1 A continuous resistive All ac outputs are suppressed internally on the controller This is done by the use of a resistor capacitor network connected from the LOAD to the neutral It is ESSENTIAL that the relays are wired correctly and all relay terminals are marked LN for line LD for load C for line common NO for load normally open NC for load normally closed As suppressors are internally connected to neutral it is ESSENTIAL that LINE L NEUTRAL N polarity is observed on all power connections If this polari
12. nd CPST do not support defrost amp drain down interfaces COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 8 3 2 WATCHDOG DEFAULT SETTINGS All interface cards have a built in watchdog which checks the communications link If no messages are received after 90 seconds then the watchdog times out When the power is first applied the red LED indicator on the card is on and the watchdog is healthy When the power to the card is on and the indicator is off the watchdog has timed out In this mode the default switches SW1 programmable interface or SW3 legacy interface active There is a switch on SW3 equivalent to every relay When the switch is closed the relay is energised This mode can be used to check the full electrical connections to the output relays from the JTL equipment prior to the full sequence testing To do this set all the default switches on all interface cards to open Disconnect the power to the main controller and power up all the interface cards Use the appropriate bit of default switch to operate the appropriate relay After commissioning these switches should be left in the appropriate position for operating the equipment in the event of a main controller failure COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 9 3 3 INITIAL SETTINGS Once the electrical tests are complete the main controller should be set up if necessary Care should be taken to see if the
13. o 00948 Issue 7 Nov 2004 JTL Systems Ltd 1 INSTALLATION PRACTICE 1 1 CABLE INSTALLATION REQUIREMENTS When installing JTL Systems controllers into equipment it is essential that the following requirements are observed 1 1 1 Cable Segregation All JTL controllers are fitted with plugs and sockets for all connections so that units may be unplugged for servicing Connections are divided in to two groups i Power Control ii Signal It is essential that the cable connections to these groups be segregated For full information about which connection is which see the relevant wiring diagram which if is not supplied with the controller may be obtained from JTL Systems or your supplier As a guide the following applies Circular DIN Audio connectors are always signal 2 part Klippon connectors are generally power connections but not always Exceptions to this rule are the voltage free inputs to coldstore and cabinet controllers and monitors in the product ranges RC and EC 1 1 2 Signal Cables Low voltage signals should be run in multicore cable to minimise EMC problems and to avoid any confusion with power cables during installation or subsequently Signal cables should have a minimum insulation voltage of 250 V ac Signal cables must have a minimum cross section of 0 2 mm and be flexible with a minimum of 7 strands Telephone cable is not permitted under any circumstances Flexible cables connected to JTL screw connectors and ot
14. orced stages CP3x All other types Check the outputs on the electrical equipment sequence correctly At each stage check the confirmation back to each input on condenser card COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 16 3 11 2 Compressor Type CPxS CP2x CP3x CPSA If there is an auto manual switch for each compressor then select 1 compressor at a time and turn it to auto Check the compressor is ready to run with the following items COMPRESSO CPSA CPxS CP2x CP3x DISPLAY R rdy ready O not ready COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 17 3 11 3 Compressor type CP4x CP5x EP6x CPLT CPST EPLX Use the forced number of stages item 102 to sequence up stages on that compressor 1 at a time Check the outputs sequence correctly and repeat for each compressor Select auto on any auto manual switch for all compressors Check the compressors are ready to run ao Je e _ Use the forced number of stages for each compressor to sequence the compressors COMPRESSOR FORCED FORCED OFF DISPLAY STAGES CP En Enabled C OFF Disabled Check the outputs sequence correctly for each compressor Note CPST has an analogue output for minimum stages set 1 and maximum set 127 COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 18 3 11 4 Defrost System Check each system using the forced functions
15. t acceptable 2 8 SIGNAL GROUNDS Signals and signal grounds must be run in the same cable Under no circumstances should the ground be run in a seperate cable to the signal COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 5 3 PACK COMMISSIONING 3 1 INTERFACE CARD ADDRESSING The main controller communicates with the interface cards via a 4 wire serial data bus 2 wires are for transmit and 2 wires for receive Each interface card has an address which is specified by switches or item numbers on the interface card These settings must be correct position for the pack to work 3 1 1 Compressors ALL TYPES EXCEPT CPLT EPLX LEGACY INTERFACE TYPES IF1 amp IF2 PROGRAMMABLE INTERFACE IF11 amp IF12 COMPRESSOR ITEM 30 MMEM31 TEM32 ITEM 33 X don t care c closed O open SW2 May use wire links Dot showing closed E TYPE CPLT EPLx LEGACY INTERFACE TYPE IF1 PROGRAMMABLE INTERFACE IF11 COMPRESSOR ITEM 30 ITEM31 TEM32 ITEM 33 1 7 1 XC00 X don t care 1 c closed 1 o open 3 See Dot showing closed note Note For true legacy support set item 32 to O For the recommended enhanced control strategy set item 32 to 1 see relevant product manual interface user guide COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 6 3 1 2 Condensers ALL TYPES EXCEPT EP6x EPLX CP5H CPLT CPST LEGACY INTERFACE IF1 1F4 PROGRAMMABLE INTERFACE IF11 1F14
16. ty is not observed data corruption or processor mis operation may occur 1 1 4 High Voltage Testing No JTL controllers should be connected in circuit during high voltage flash testing 1 1 5 Cable Installation Within Enclosures Within the enclosure separation must occur with a minimum of 150 mm between parallel runs of power and signal cables These must not be run in common trunking 1 1 6 External Cable to JTL Control Equipment site wiring A minimum spacing of 350 mm must be maintained between parallel runs of power and signal cables These must not be run in common trunking Where separation of 350 mm is not possible the signal cable should be screened and run in conduit or separate section steel trunking All external cables should be clearly identified as to destination COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 2 1 2 CABLE SPECIFICATION 1 21 Pressure Transducer Cable The recommended cable for the purpose is a 4 core cable with overall Screen Equivalent to BICC type 7 2 4C to DEF STAN 61 12 4 Posssible Suppliers FES Order Code 030701X Farnell Order Code 140 481 RS Order Code 367 454 Note Telephone cable and other low voltage insulated cables are not permitted 1 22 Temperature Sensor Extension Cable The recommended cable for the purpose is a twin core cable Equivalent to BICC type 7 2 2A to DEF STAN 61 12 part 4 Possible Suppliers FES Order Code 030704E RS Order Code 362 89
17. used sensors can be de selected PACK TYPE ITEM FUNCTION CPxS CP2x CP3X 103 109 O Disable 1 Enable CPSA 4 only 103 106 All other types 131 137 COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 12 3 7 AUTO INPUT To enable full operation of the pack the auto input must be enabled A contact closure must be made on P1 of the main controller This may be a simple wire link as auto manual changover is not often fitted PACK TYPE ITEM DISPLAY CPxS CP2x CPSA CP3x n OFF Manual AUTO Auto All other types It should display auto when the input is closed 3 8 LOW LIQUID OR REFRIGERANT LEAK INPUT Check the input on IP2 of the main controller A closed input is OK An open input is an alarm condition after 30 minute time delay PACK TYPE ITEM DISPLAY CPxS CP2x CPSA CP3x CLr No alarm Lo Li Open input All other types 172 173 CLr No alarm reF L Open input COMP PACK INSTALL MANUAL WPD Doc No 00948 Issue 7 Nov 2004 JTL Systems Ltd 13 3 9 PACK COMMUNICATIONS All interface boards communicate with the main JTL controller If the main controller was initialised above using the Item 9 function then program in the number of compressors fans and defrost systems as listed in that section On some pack types defrost stub and drain down interfaces can be de selected using the following item numbers PACK TYPE ITEM DISPLAY CPSA 209 On Defrost Interface fitted Of
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