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Carel PRK300D0E0 User Manual Download Page 104

 CAREL INDUSTRIES - Headquarters

Via dell’Industria, 11 - 35020 Brugine - Padova (Italy)
Tel. (+39) 049.9716611 -  Fax (+39) 049.9716600
e-mail: [email protected] - www.carel.com

 Agenzia / Agency:

pR

ack +0300025EN r

e

l. 1.3 - 17.12.2015

Summary of Contents for PRK300D0E0

Page 1: ...H i g h E f f i c i e n c y S o l u t i o n s pRack pR300 NO POWER SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT compressor rack controller User manual...

Page 2: ......

Page 3: ...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 CA...

Page 4: ......

Page 5: ...s 26 4 START UP 27 4 1 Starting the rst time 27 5 USER INTERFACE 29 5 1 Graphic terminal 29 5 2 Description of the display 29 5 3 Password 31 5 4 Description menu 31 6 FUNCTIONS 33 6 1 Unit On O 33 6...

Page 6: ...6 ENG pRack 0300025EN rel 1 3 17 12 2015...

Page 7: ...inputs Available analog outputs Available digital outputs Small 5 8 4 8 Medium 8 14 4 13 Medium Driver 8 14 4 13 Large 10 18 6 18 Tab 1 b For each size the following versions are available with built...

Page 8: ...uction lines on board scroll or piston compressors 2 high pressure lines on the board I O I O I O I O pR300 Fig 1 c Example 4 2 suction lines on separate boards scroll or piston compressors 2 high pre...

Page 9: ...4 J5 J7 J8 J1 4 J10 J1 3 J1 2 J16 J1 7 J18 J15 J6 FieldBus card BMS card J11 pLAN J2 5BMS2 J2 6FBus2 4 3 2 1 4 5 1 6 2 3 3 3 8 9 7 8 10 13 14 11 12 15 pR300 16 18 17 Fig 2 b Legende Rif Description Ri...

Page 10: ...on 23 Valve driver analogue and digital inputs 11 pLAN plug in connector 24 Valve status signal LED 12 Reserved Voltage A 24 Vac or 28 to 36 Vdc Voltage B 230 Vac 50 60 Hz Tab 2 b pRack pR300 L C1 NO1...

Page 11: ...V insulating material PTI 175 Period of stress across the insulating parts long Type of action 1C 1Y for SSR versions Type of disconnection or microswitching microswitching Heat and re resistance cat...

Page 12: ...f 2 2 4 Power supply to probes and terminals Vdc can be used to power any active probes using the 24 21 Vdc 10 P 5 P 3 available at terminal VDC J2 The maximum current available is 150 mA protected a...

Page 13: ...IN DRIVER 1 3 4 6 7 8 9 11 12 13 Type of relay Type A Type A Type A Type A Type A Type A Type A LARGE NO 1 3 4 6 7 8 9 11 12 13 14 15 16 18 Type of relay Type A Type A Type A Type A Type A Type A Typ...

Page 14: ...ntact or transistor to GND Closing current 5mA maximum length 10 m Sonde Maximum length 10 m or less than 30 m with shielded cable S1 ratiometric pressure probe 0 to 5 V resolution 0 1 fs measurement...

Page 15: ...or digital inputs 13 and 14 negative pole for DC power supply J8 4 ID14 digital input no 14 24 Vac Vdc J8 5 ID14H digital input no 14 230 Vac S M L J9 8 pin telephone connector for connecting a displa...

Page 16: ...ansion modules not used S M L D J24 1 V term additional power supply terminal Aria not used J24 2 GND power supply common J24 3 5 Vref power supply for 0 5 V ratiometric probes J25 1 E E terminal for...

Page 17: ...230 Vac 0 Vac Vdc 24 Vac Vdc 0 Vac Vdc 24 Vac 230 Vdc 0 Vac Vdc pGDE pRack GND RS485 BMS connections 24 Vac 230 Vac 0 Vac Vdc 24 Vac 230 Vac 0 Vac Vdc U4 GND U5 GND J3 U1 U2 U3 GND VDC J2 OUT 4 OUT 3...

Page 18: ...card BMS card J11 pLAN J2 5BMS2 J2 6FBus2 4 3 2 1 Medium 24 Vac 230 Vdc 0 Vac Vdc 24 Vac 230 Vac 0 Vac Vdc 24 Vac 230 Vac 0 Vac Vdc GND RS485 BMS connections pGDE pRack 24 Vac Vdc 0 Vac Vdc 24 24 Vac...

Page 19: ...1 0 GND FieldBus card BMS card J23 FBus2 J11 pLAN J2 5BMS2 J2 6FBus2 4 3 2 1 NO 2 NO9 NO1 0 1 1 NO1 1 C9 C7 NO8 C8 NC8 J1 5 Large GND RS485 BMS connections 24 Vac 230 Vac 0 Vac Vdc 24 Vac 230 Vac 0 Va...

Page 20: ...U2 U3 GND VDC A B C D J27 1 3 2 4 J28 1 3 2 4 VBAT G0 G J30 GND VREF S1 S2 S3 S4 DI1 DI2 J29 giallo yellow giallo yellow verde green verde green marrone brown marrone brown bianco white bianco white s...

Page 21: ...G0 VBAT COMA NOA 1 3 2 4 Tx Rx GND DI1 S4 S3 S2 S1 GND DI2 VREF 2AT 24 Vac 230Vac 35VA TRADRFE240 Ultracap Technology G G0 VBAT G G0 VBAT COMA NOA 1 3 2 4 Sporlan SEI SEH SER DANFOSS ETS CCM CCMT ALCO...

Page 22: ...applications subject to considerable vibrations 1 5 mm pk pk 10 55 Hz secure the cables connected to the pRack pR300around 3 cm from the connectors using clamps if the product is installed in industr...

Page 23: ...rm GND 5 V REF Fig 3 a Hardware Version Terminals NTC probe cable S M D L GND 1 U1 U10 S2 S4 2 Tab 3 b Note the two wires of the NTC sensors are equivalent as they have no polarity therefore it is not...

Page 24: ...te connection of the analogue inputs The Sizes of the cables for the remote connection of the analogue inputs are shown in the following table Type of input Size mm2 for length up to 50 m Size mm2 for...

Page 25: ...ted from the rest of the module must have a maximum amplitude of 5V and a period between 8 ms and 200 ms The 0 10 V output voltage can be connected to a maximum load of 2 k with a maximum ripple of 10...

Page 26: ...5 8 A Tab 3 m If the product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 30 m This length shouldn t be exceeded in...

Page 27: ...the configuration in the list Fig 4 a This solution is used to choose between fourteen con gurations pre loaded in the pRack pR300 software For the description of the pre con gurations see the table...

Page 28: ...requirements The criteria applied for automatic association are described below Digital outputs pRack pR300 assigns in order Compressor outputs rst the SSR outputs for screw or Digital Scroll then the...

Page 29: ...rouped by screen but rather customised row by row on the display The basic structure comprises two screens that are scrolled by pressing Up and Down all the information can be con gured for display on...

Page 30: ...control EVS valves Percentage of valve capa city request from L2 Double line con guration In con gurations that feature control of two suction lines 4 di erent percentages can be shown from the values...

Page 31: ...assword can also be changed in the corresponding menu branch 5 4 Description menu Main menu Function tree The following general rules apply to the user interface The parameters are grouped by function...

Page 32: ...ettings b Line 2 f Generic func a Stages b Modulation c Alarms d Time bands e I O status g ChillBooster a Line 1 a I O status b Settings b Line 2 h DSS a I O status b Settings i EVS a Temperature cont...

Page 33: ...re considered as being common to all lines any speci c Situations are described on a case by case basis Below is a chart of the main functions described and their eld of application Function L1 suctio...

Page 34: ...Diff Diff Setpoint Regulation probe value Fig 6 e Inside the neutral zone the capacity request sent by the controller is constant except when there is a modulation device and modulation is enabled in...

Page 35: ...a g D b g When di erent pRack boards are used to manage the suction and condenser lines the backup suction pressure probe must be connected to the board that manages the suction line while the backup...

Page 36: ...h the same capacity and 4 load stages each 1 size Two lines line 1 with 2 screw compressors with the same capacity the rst with continuous modulation line 2 with 4 reciprocating compressors with two d...

Page 37: ...crease times If these times have already been con gured on the inverter the higher time set has priority Example 1 range of modulating device capacity variation higher than the capacity of the compres...

Page 38: ...vated on a maximum of 6 compressors 6 3 8 Liquid injection As an alternative to the economizer pRack pR300 can manage the injection of liquid into the compressors the two functions are alternative as...

Page 39: ...g procedure pRack pR300 can manage the speci c starting procedure for Digital Scroll compressors as represented as in the following gure 4s 180s 60s 50s 100s Request Valve Compressor Startup time Fig...

Page 40: ...scribed previously Note for further details on the series of compressors supported and the related pre con gured parameters contact Carel Envelope For screw compressors pRack pR300 can manage control...

Page 41: ...the neutral zone the compressors are switched o in sequence varying CRII capacity to achieve correct modulation The CRII compressor will go to 0 capacity before another compressor is shut down and can...

Page 42: ...n Pcond P3 Step3 o step2 Switch on P1 Pcond P2 step2 Keep o or switch o after 60 s 20s P2 Pcond P3 step2 Keep o or switch o after 180 s 20s Pcond P3 step2 Switch on P1 Pcond P2 step3 Keep o or switch...

Page 43: ...enabled and the related parameters set in main menu branch D a g D b g If speed up is enabled a start time can be set in which the fan speed is forced to 100 If the outside temperature sensor is used...

Page 44: ...can be applied to the suction pressure set point as shown in the gure Offset Probe value Offset min Lower value Upper value Offset max Fig 6 x 6 5 2 Floating suction pressure set point For the suctio...

Page 45: ...pRack pR300 Signals an alarm and stops the compressor Line oil management pRack pR300 features an alarm digital input for each line this is with Signal only that is has no e ect on the operation of th...

Page 46: ...re sent to the supervisory system The following generic functions are available for each board 5 stages 2 modulations 2 alarms 1 scheduler Each function can be enabled disabled by digital input and fr...

Page 47: ...ast the set time Activation ends when the request falls below a set threshold pRack pR300 can manage an alarm digital input from ChillBooster the e ect of which is to deactivate the device For details...

Page 48: ...wo drivers can be entered Fig 6 as The Driver is enabled automatically when the system selected in the Wizard is either Cascade or Pumped Note make sure that Fieldbus driver management re ects the log...

Page 49: ...igher priority therefore if a digital input is not active the corresponding action is not produced even if requested by the supervisor Two of the free digital inputs on pRack pR300 can be con gured fo...

Page 50: ...ently special days closing periods and daily time bands are ignored Silencer the function is only active with daily time bands there is no link to operating seasons special days and closing periods He...

Page 51: ...lt Unit OFF from digital IN Unit OFF from keypad Unit OFF manual mode Number of compressors on line 1 with unit ON con gurable 0 12 Compressor activation percentage on line 1 with unit ON con gurable...

Page 52: ...O Start up On Alarm O by time On by time Mod manual In pump down Countdown Digital ScrollTM compressor time count line 1 s 0 999 Compr Digital ScrollTM compressor status line 1 OFF ON Valve Digital S...

Page 53: ...ntrol with compensation applied line 2 Di erential Control di erential for pressure control line 2 Aa51 display only Pressure Condensing pressure line 2 Sat temp Saturated condensing temperature line...

Page 54: ...R Status Status of generic modulating function 1 0 0 100 0 Aaat display only Reg variable Control variable value for generic modulating function 2 Enable Enabling variable status for generic modulatin...

Page 55: ...set point for suction pressure control proportional control line 2 Actual setp E ective set point for suction pressure control proportional control with compensation applied line 2 Neutral zone Neutra...

Page 56: ...Delta relay DO Compressor 1 delta DO position and status On O display line 1 01 29 Logic DO logic to start compressor 1 line 1 NC NC NO Bac03 DO Compressor 1 unloader 1 DO position line 1 01 29 Status...

Page 57: ...ues C Compressors The I Os available depend on the selected con guration the following are just some examples For the complete list of I O positions available see Appendix A 5 Caa01 DI Alarm 1 for com...

Page 58: ...sor 12 remaining operating hours line 1 h 0 999999 Cac13 Compressor threshold working hours Compressor maintenance threshold hours line 1 88000 h 0 9999999 Cac14 Compressor hours reset Reset compresso...

Page 59: ...ction pressure tempe rature low alarm Type of low suction pressure temperature alarm threshold ABSOLUTE ABSOLUTE RELATIVE Threshold Low suction pressure temperature alarm threshold Cae27 Alarm di Low...

Page 60: ...in order to reach each capacity stage from previous for screw compressor 1 s 0 999 Caf23 Intermittent valve time Intermittent on o time for capacity control valves for screw compressor 1 10 s 0 99 Ca...

Page 61: ...ls see the corresponding parameters for line 1 above Cba01 DI Alarm 1 for compressor 1 DI position line 2 03 01 18 B1 B10 Status display only Status of alarm 1 for compressor 1 DI line 2 Closed Open L...

Page 62: ...eutral zone control condenser line 1 180 s 0 9999 Dad01 Enable condensing setpoint compensation Enable setpoint compensation condenser line 1 NO NO YES Dad02 Winter o set Enable setpoint compensation...

Page 63: ...06 Type Fans enabled with split condenser line 1 CUSTOM CUSTOM ODD EVEN GREATER THAN LESS THAN Only when enabling type is GREATER THAN or LESS THAN number of fans to consider for splitting line 1 0 0...

Page 64: ...f oil cooler pumps enabled line1 0 0 to 1 Analog output 0 to 2 Digital outputs Enable Aout pump Screw compressors enable AO for oil cooler pump line 1 YES NO Digital outputs YES Analog output Eaab08 S...

Page 65: ...1 NC NC NO Function display only Heat recovery pump status line 1 Not active Active Eeaa04 AO Heat recovery damper AO position line 1 01 29 Type Type of output PWM phase control for heat recovery dam...

Page 66: ...ic alarm function 1 management DISAB DISABLE ENABLE Gen alarm 2 Enable generic alarm function 2 management DISAB DISABLE ENABLE Efc06 Regulation variable Monitored variable for generic alarm function...

Page 67: ...shold valve 1 50 0 60 0 200 0 MOP thresh Maximum operating pressure protection threshold valve 1 50 0 60 0 200 0 Eia04 Setpoint SH PID control set point valve 2 11 0 K 40 0 180 0 LowSH thres Low super...

Page 68: ...REL NTC CAREL NTC 0 10V EXT SI GNAL NTC SPKP T0 CAREL NTC HT Alarm min Minimum probe S2 alarm threshold valve 2 50 0 C F 60 0 200 0 Alarm max Maximum probe S2 alarm threshold valve 2 105 0 C F 60 0 20...

Page 69: ...alarm delay valve 2 600 s 0 18000 Eid24 LowSH Low superheat alarm delay valve 2 300 s 0 18000 LOP Low operating pressure alarm delay valve 2 300 s 0 18000 MOP Maximum operating pressure alarm delay va...

Page 70: ...mon oil cooler pump line 2 YES NO Digital outputs YES digital input Ebba01 DO Subcooling valve DO position line 2 01 29 Status display only Status of subcooling valve DO line 2 Closed Open Logic Logic...

Page 71: ...er in a supervisory system network line 1 196 0 to 207 Protocol Supervisor communication protocol line 1 pRACK MANAGER CAREL SLAVE LOCAL CAREL SLAVE REMOTE MODBUS SLAVE pRACK MANAGER CAREL SLAVE GSM B...

Page 72: ...9 Gca05 Output alarms relays activation with Select alarm relay output activation for active alarms or alarms not reset Active alarms Active alarms Alarms not reset The following parameters refer to l...

Page 73: ...pressor 12 line 1 S1 S4 Ib20 Compressors sizes Compressors sizes line 1 SAME CAPACITY SAME CAPACITY DEFINE SIZES Ib21 S1 Enable size and size for compressor group 1 line 1 YES kW NO YES 0 0 500 0 S4 E...

Page 74: ...easure unit Unit of measure line 1 barg Refrigerant Type of refrigerant condenser line 1 R404A R22 R134a R404A R407C R410A R507A R290 R600 R600a R717 R744 R728 R1270 R417A R422D R413A R422A R423A R407...

Page 75: ...ing screen remains displayed until the Alarm button is pressed and held the alarm is saved in the log Semiautomatic acknowledgement is automatic until a maximum number of activations in set time If th...

Page 76: ...8 3 Pressure and prevent alarms pRack pR300 can manage pressure alarms from a pressure switch or probe according to the following diagram Alarms from pressure switch Low suction pressure High condens...

Page 77: ...If the number of activations is higher reset becomes manual Prevent by activating heat recovery The parameters corresponding to this function can be set in branch G b a G b b of the main menu if the...

Page 78: ...card BMS card J11 pLAN J2 5BMS2 J2 6FBus2 4 3 2 1 pR300 Fig 9 a The complete list of supervisor variables with the corresponding addresses and descriptions can be supplied upon request 9 2 Commissioni...

Page 79: ...names and contents Various types of les can be uploaded and downloaded and are distinguished by their extension File names In order to be recognised the names of the directories and les on the pendri...

Page 80: ...le memory UPLOAD the entire contents of the pRack Copy pRack upload After the description of the desired function various options are available 1 To copy the complete contents of the directory simply...

Page 81: ...rive 61 0 1 4 8 5 Fig 10 h 10 3 4 Upload in autorun mode Uploading in autorun mode is a special case of uploading in automatic mode Unlike automatic mode the user must wait for a speci c message to ap...

Page 82: ...medir_XY DirName_XY The pendrive then only needs to be plugged into each controller to run the upload con rming from the shared terminal 10 3 5 Manual upload To manually upload the contents of the pen...

Page 83: ...The purpose is to con gure the network Ethernet for pCOWeb RS485 for pCOnet when the respective card is installed for the rst time The remaining parameters alarms events etc can be con gured using the...

Page 84: ...ck Manager software 4 In the Connection settings panel set Baud rate to Auto and SearchDevice to Auto pLAN and select the COM port under PortNumber if necessary use the Wizard to detect the correct CO...

Page 85: ...n scroll piston 12 12 1 2 h 12 2 suction lines on separate boards scroll or piston compres sors 1 condenser line on a separate board 2 1 scroll piston scroll piston 12 12 1 2 3 d 13 2 suction lines on...

Page 86: ...iston compressors on line 2 1 condenser line on a separate board I O I O pLAN I O C1 NO1 NO2 NO3 C1 C4 NO4 NO5 NO6 C4 C7 NO7 C7 NO8 C8 NC8 G G0 U1 U2 U3 GND VDC V term GND 5 V REF U4 GND U5 GND VG VG0...

Page 87: ...C1 NO1 NO2 NO3 C1 C4 NO4 NO5 NO6 C4 C7 NO7 C7 NO8 C8 NC8 G G0 U1 U2 U3 GND VDC V term GND 5 V REF U4 GND U5 GND VG VG0 Y1 Y2 Y3 Y4 ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1 J1 J24 J2 J3 J4 J5 J1 4 J10 J1 3...

Page 88: ...be augmented by factors that are vital for this type of system such as variation in low temperature compressor rack cooling capacity and the trend in CO2 condensing pressure pRack only sends the contr...

Page 89: ...11 pLAN J2 5BMS2 J2 6FBus2 4 3 2 1 pR300 C1 NO1 NO2 NO3 C1 C4 NO4 NO5 NO6 C4 C7 NO7 C7 NO8 C8 NC8 G G0 U1 U2 U3 GND VDC V term GND 5 V REF U4 GND U5 GND VG VG0 Y1 Y2 Y3 Y4 ID1 ID2 ID3 ID4 ID5 ID6 ID7...

Page 90: ...e circuit control Medium temperature circuit control uses a pressure sensor installed on the low temperature receiver in order to exploit this sensor pRack needs to use an auxiliary control function a...

Page 91: ...esses 31 and 32 The default user terminal address is 32 so only if a second terminal is required must the address of this be set to 31 as described below The address of the terminal is also required w...

Page 92: ...G G0 U1 U2 U3 GND VDC V term GND 5 V REF U4 GND U5 GND VG VG0 Y1 Y2 Y3 Y4 ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1 J1 J24 J2 J3 J4 J5 J1 4 J10 J1 3 J1 2 J1 5 FieldBus card BMS card J11 pLAN J2 5BMS2 J2 6F...

Page 93: ...oftware o ers the option to automatically con gure the I Os choosing YES as described in par 4 1 4 If choosing NO each individual I O needs to be con gured manually at the end of the wizard In additio...

Page 94: ...ic Settable R1 Shutdown compressor ALB02 High condensing pressure from pressure switch Manual automatic Settable R1 Shutdown compressor ALB03 Low condensing pressure from probe Automatic Settable R1 F...

Page 95: ...hutdown compressor 4 line 2 ALC75 Alarm 3 compressor 4 line 2 Manual automatic Settable Settable Shutdown compressor 4 line 2 ALC76 Alarm 4 compressor 4 line 2 Manual automatic Settable Settable Shutd...

Page 96: ...stom envelope not con gured Automatic Not featured Not featured ALW09 Envelope warning suction or condensing probes not con gured Automatic Not featured Not featured ALW10 Low superheat warning Automa...

Page 97: ...7 Caa58 Alarm 6 compressor 5 line 1 Baa38 Caa59 Alarm 7 compressor 5 line 1 Baa39 Caa65 Alarm 1 compressor 6 line 1 Baa40 Caa66 Alarm 2 compressor 6 line 1 Baa41 Caa67 Alarm 3 compressor 6 line 1 Baa4...

Page 98: ...m 1 compressor 4 line 2 Baa99 cba66 Alarm 2 compressor 4 line 2 Baaaa Cba67 Alarm 3 compressor 4 line 2 Baaab Cba68 Alarm 4 compressor 4 line 2 Baaac Cba69 Alarm 5 compressor 4 line 2 Baaad Cba70 Alar...

Page 99: ...Caa74 Valve 2 compressor 6 line 1 Bac37 Caa75 Valve 3 compressor 6 line 1 Bac39 Caa76 Balancing valve compressor 6 line 1 Bac41 Caa80 Line relay compressor 7 line 1 Partwinding Star relay compressor 7...

Page 100: ...uction Bac73 Cba08 Relay line compressor 1 line 2 Partwinding Star relay compressor 1 line 2 Delta relay compressor 1 line 2 Bac74 Cba09 Valve 1 compressor 1 line 2 Bac75 Cba10 Valve 2 compressor 1 li...

Page 101: ...aaf Valve 1 compressor 12 line 2 Bacbq Cbaag Balancing valve compressor 12 line 2 Line 2 Condenser Baccn Dba20 Fan1 line 2 Bacco Dba21 Fan 2 line 2 Baccp Dba22 Fan 3 line 2 Baccq Dba23 Fan 4 line 2 Ba...

Page 102: ...a40 Backup condensing pressure probe line 2 Other Bab48 Dba38 Discharge temperature probe line 2 Bab49 Liquid temperature probe line 2 Bab14 Eeba05 Heat recovery outlet temperature probe line 2 Bab18...

Page 103: ...103 ENG pRack 0300025EN rel 1 3 17 12 2015...

Page 104: ...REL INDUSTRIES Headquarters 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 pRack 0300025EN rel 1 3 17 12 201...

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