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Daikin Hubbard GCU2040PXB1, Installation, Commissioning And Maintenance Manual

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Daikin Hubbard GCU2040PXB1 Installation, Commissioning And Maintenance Manual Download Page 6

 

 

 

 

 

 

 

 

 

Contents 

 

1.      Safety recommendations 

2.   Storage 

3. 

Description of the unit    

4. 

Application 

5.      Handling 

6. 

Post Transport Checks 

7. 

Overall Dimensions 

8. 

Serial plate Information 

9. 

Installation Spacing 

10.  External Pipe and Electrical Connections 

11.  Basic Component layout 

12.  Mechanical Safety of the system 

13.  Commissioning and Maintenance 

14.  Service and Maintenance 

15. Maximum Refrigerant Charge 

16. Estimation of Refrigerant and Oil Charge  

 

 

 

Page 6 of 172

Copyright HPL March 2021

P4114S Rev 03

Summary of Contents for Hubbard GCU2040PXB1

Page 1: ...Hubbard Products Ltd Hermetic R744 Condensing Units Model Number GCU2040PXB1 ESIE21 03 Installation Commissioning and Maintenance Manual CONTENTS Page 1 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 2: ...ty data Sheets 4 Wiring Schematics 5 Pipework Schematics P ID 6 Carel PR300T CO2 Controller manual and factory settings 7 ABB Inverter non default settings 8 Pressure Enthalpy Diagram 9 Commissioning...

Page 3: ...1 EC Declaration of Conformity Model GCU2040PXB1 Part Number A10145 04M Page 3 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 4: ...Page 4 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 5: ...Hubbard Hermetic Rotary R744 Units Installation Commissioning and Maintenance Manual Model No GCU2040PXB1 ESIE20 03 Page 5 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 6: ...Serial plate Information 9 Installation Spacing 10 External Pipe and Electrical Connections 11 Basic Component layout 12 Mechanical Safety of the system 13 Commissioning and Maintenance 14 Service an...

Page 7: ...nts Therefore the use of the unit in an explosion dangerous atmosphere is absolutely forbidden When maintenance requires operations on the cooling circuit drain the system and let it reach the atmosph...

Page 8: ...tallation and servicing of all electrical and refrigeration components A safe exit path must be provided in the event of a mishap During installation the space must be adequately ventilated to remove...

Page 9: ...d and system flanges rotalock valves and flexible connections are secure Where flexible hose lines are used please ensure that the outer material is not subject to rupture due to contact with other su...

Page 10: ...7 Dimensions and w eights Models GCU2040PXB1 7 1 Packaged Unit 7 2 Unit Dimensions Page 10 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 11: ...t Dry weight 155 kg 8 Serial Plate Information The unit is supplied with necessary warning and attention plates Serial plate is supplied with the weight of the unit and other information as showing be...

Page 12: ...External Pipe and Electrical connections Liquid and Suction Line positions are shown as below Both liquid and suction line are sealed to avoid any moister entering the pipes The unit is delivered with...

Page 13: ...suction pipew ork It is really important to ensure a good oil return on the compressor Suggested connections for suction and liquid line are shown below Industry recognised design standards for pipewo...

Page 14: ...e setting by discharging the valve Valves should be removed before testing to a value in excess of 80 of the valve setting Should the need to replace a valve arise this can be achieved by shutting off...

Page 15: ...ues e g LP switches and the system design maximum operating pressures The maximum operating pressures of the high and low side of the system will be stated on the serial plate note however that safety...

Page 16: ...ove procedure then prove the system The system should be held at test pressure for at least 15 minutes If the pressure has not significantly reduced then the system can be slowly vented to the leak te...

Page 17: ...into the System Initial charging should only be completed once the system has been proven to be leak free and after proper vacuum The charging point is located on the liquid line adjacent to the drier...

Page 18: ...following electrical items should be checked 1 Sub fuses circuit breakers correct 2 Main fuses circuit breakers are correct and balanced 3 Main compressor fuses and circuit breakers are correct 4 All...

Page 19: ...valve position The role of bypass valve is very critical for the rotary compressor operation especially when the compressor is getting the signal to run The valve is fully open when the unit is switc...

Page 20: ...in the oil separator The oil then passes into the separator oil reservoir section The oil reservoir section retains enough oil to supply the compressor oil level regulators under all conditions From t...

Page 21: ...d out is in accordance w ith your companies working practices and that the required equipment PPE is available and used WARNING Pipew ork associated with the condenser w ill be at extreme temperatures...

Page 22: ...valve by either removing the system charge on assemblies fitted with single relief valves or via a dual shut off valve assembly in which the pressure relief valve is mounted 3 During installation of...

Page 23: ...be capable to accommodate all the refrigerant charge kg holding in the system Also it is really important to avoid to overcharge the system which can cause issues in compressor operation and efficienc...

Page 24: ...unt of oil into the system ensures the compressor reliability and increase the lifetime of the system The GCU2040PXB1 unit is delivered with 1 15 kg of oil The additional oil required for varies pipe...

Page 25: ...ntroller 2 Close valve 1 at the suction line 3 Vent gas from service ports S n 2 and n 3 1 4 SAE until suction pressure drops near to 0 barg check on controller display 4 Charge required amount of oil...

Page 26: ...re 5 000 Long term exposure limit 8 hours 15 000 Short term exposure limit 10 min 30 000 Discomfort breathing difficulties headache dizziness etc 100 000 Loss of consciousness death 300 000 Quick deat...

Page 27: ...escue workers This product is a colorless odorless liquid that transforms to white crystalline particles when discharged from its container The gas is slightly acidic and may be felt to have a slight...

Page 28: ...EASURES SKIN Promptly flush skin with water until all chemical is removed If there is evidence of frostbite bathe do not rub with lukewarm not to exceed 105 F 41 C water If water is not available cove...

Page 29: ...spill Flakes of carbon dioxide will form at pressures below 67 psig 461 95 kPa and fall as snow Shut off leak if you can do so without risk Ventilate area or move container to a well ventilated area T...

Page 30: ...confined space where the concentration may be above the PEL use a self contained NIOSH approved breathing apparatus or supplied air respirator For escape use the former or a NIOSH approved gas mask wi...

Page 31: ...uses respiratory depression High concentrations result in narcosis Symptoms in humans are as follows CONCENTRATION EFFECT 1 Breathing rate increases slightly 2 Breathing rate increases to 50 above the...

Page 32: ...s in ill health should be restricted from working with or handling OTHER EFFECTS OF OVEREXPOSURE Damage to retinal or ganglion cells and central nervous system may occur MEDICAL CONDITIONS AGGRAVATED...

Page 33: ...t Act of 1986 Proposition 65 PENNSYLVANIA Carbon Dioxide is subject to the Pennsylvania Worker and Community Right to Know Act 16 OTHER INFORMATION CURRENT ISSUE DATE May 2015 PREVIOUS ISSUE DATE Apri...

Page 34: ...e safety data sheet Company Idemitsu Kosan Co Ltd Address 1 1 3 Chome Marunouchi Chiyoda ku Tokyo 100 8321 Japan Telephone 81 3 3213 3143 Telefax 81 3 3211 5343 1 4 Emergency telephone number 44 0 123...

Page 35: ...SECTION 3 Composition information on ingredients 3 2 Mixtures Hazardous components Chemical name CAS No EC No Registration number Classification Concentration w w GLYCOLS POLYPROPYLENE DIMETHYL ETHER...

Page 36: ...1 Extinguishing media Suitable extinguishing media Use extinguishing measures that are appropriate to local circumstances and the surrounding environment 5 2 Special hazards arising from the substanc...

Page 37: ...alue type Form of exposure Control parameters Basis 2 6 di tert butyl p cresol 128 37 0 TWA 10 mg m3 GB EH40 Further information Where no specific short term exposure limit is listed a figure three ti...

Page 38: ...ata available Density 0 9973 g cm3 15 C Solubility ies Water solubility insoluble Partition coefficient n octanol water No data available Auto ignition temperature No data available Decomposition temp...

Page 39: ...classified based on available information Product Remarks According to the classification criteria of the European Union the product is not considered as being an eye irritant Respiratory or skin sen...

Page 40: ...mulative vPvB at levels of 0 1 or higher 12 6 Other adverse effects Product Additional ecological information There is no data available for this product SECTION 13 Disposal considerations 13 1 Waste...

Page 41: ...49 2012 of the European Parliament and the Council concerning the export and import of dangerous chemicals Not applicable Seveso II Directive 2003 105 EC amending Council Directive 96 82 EC on the con...

Page 42: ...ernational Maritime Dangerous Goods IMO International Maritime Organization ISHL Industrial Safety and Health Law Japan ISO International Organisation for Standardization KECI Korea Existing Chemicals...

Page 43: ...32450621 DAPHNE HERMETIC OIL PZ68S Revision Date 15 03 2017 10 10 Page 43 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 44: ...4 Wiring Schematics Model GCU2040PXB1 Part Number D4155S Page 44 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 45: ...le IF IN DOUBT ASK Date PCO AN 25 02 2019 4HP MT CCU WIRING DIAGRAM SHORT FORM 1 7 Bluestem Road Ransomes Europark Suffolk Ipswich IP3 9RR TEL 01473 890522 FAX 01473 890687 Sheet 1 2 D4155S 05 Page 45...

Page 46: ...le IF IN DOUBT ASK Date PCO AN 25 02 2019 1 7 Bluestem Road Ransomes Europark Suffolk Ipswich IP3 9RR TEL 01473 890522 FAX 01473 890687 Sheet 2 2 4HP MT CCU WIRING DIAGRAM SHORT FORM D4155S 05 Page 46...

Page 47: ...5 Pipework Schematics P ID Model GCU2040PXB1 Part Number D4129 Page 47 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 48: ...ROM GAS COOLER TO GAS COOLER RECEIVER S GAS COOLER FILTER DRIER MT SUCTION S 2 STAGE DISCHARGE 1 STAGE SUCTION OIL SEPERATOR OIL RETURN LINE SIGHT GLASS CAPILLIARY TUBE 3 8 1 2 3 8 3 8 3 8 3 8 3 8 1 2...

Page 49: ...6 Carel PR300T CO2 Controller manual Page 49 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 50: ...o l u t i o n s pRack pR300T NO POWER SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT pRack pR300T user manual for the management of CO2 systems in transcritical conditions Page 50 of 172 Copyright...

Page 51: ...eys or any other accessory in the CAREL product portfolio CARELadoptsapolicyofcontinualdevelopment Consequently CARELreservestherighttomakechangesand improvements to any product described in this docu...

Page 52: ...s 24 3 7 pLAN electrical connections 25 4 START UP 26 4 1 Starting the first time 26 4 2 Wizard 26 4 3 Example of system configuration using the Wizard 26 4 4 Advanced configuration 28 5 USER INTERFAC...

Page 53: ...ms 84 9 SUPERVISORY AND COMMISSIONING SYSTEMS 86 9 1 PlantVisor PRO and PlantWatch PRO supervisory systems 86 9 2 Commissioning software 86 10 SOFTWARE UPDATE AND CONFIGURATION 87 10 1 Smart Key opera...

Page 54: ...omatic and manual management Configurable compressor alarms Double Signal on digital outputs for high or low priority alarms Log from application Supervisor protocol Carel Modbus Tab 1 a 1 2 Component...

Page 55: ...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 6FBus2 4 3 2 1 pR300T Fig 1 a Example 2 2 suction lines o...

Page 56: ...1 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 pR300T 16 18 17 Fig 2 b Key Ref Description Ref Description 1 Power su...

Page 57: ...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 pR300T L C1 NO1 NO2 NO3 C1 C4 NO4...

Page 58: ...sulating 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 fire resistance catego...

Page 59: ...wer 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 against shor...

Page 60: ...11 12 13 14 15 16 18 Type of relay Type A Type A Type A Type A Type A Type A Type A Type A Type A LARGE NC 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 Ty...

Page 61: ...D Closing current 5mA maximum length 10 m Probes 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 error 2 fs massimo 1 typ...

Page 62: ...mmon for 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...

Page 63: ...ply common J24 3 5 Vref power supply for 0 5 V ratiometric probes J25 1 E E terminal for RS485 connection BMS2 J25 2 E E terminal for RS485 connection BMS2 J25 3 GND GND terminal for RS485 connection...

Page 64: ...c 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 OUT 2 OUT 1 Ntc Pt1000 ID U1 U2 U3 GND VDC U1 U2 U3...

Page 65: ...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 V Vac ac V Vdc dc 0 0 Va Vac c Vd Vdc c 0 Vac Vdc 24 Vac Vdc 24 Vac Vdc...

Page 66: ...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 Vac Vdc pGDE pRack 24 Vac Vdc 0 Vac Vdc 0 Vac Vdc 0 Vac Vdc 24 Vac Vdc 24 Vac...

Page 67: ...9 NTC driver A ratiometric pressure transducer driver A NTC driver B ratiometric pressure transducer driver B giallo yellow giallo yellow verde green verde green marrone brown marrone brown bianco whi...

Page 68: ...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 EX5 6 EX7 8 3 5 4 1 3 3 2 5 5 6 4 1 NT...

Page 69: ...as follows Address 15 Ext no off set Baud 19 2 K Prot CAREL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 with offset no offset 19 2 K 9 6 K 38 4 K 57 6 K CAREL Modbus ON OFF Address Ext Prot Baud Fig 2 k The...

Page 70: ...er and enters terminal G0 this applies to all the devices connected to the pRack PR300T do not secure the cables to the terminals by pressing the screwdriver with excessive force to avoid damaging the...

Page 71: ...e PT1000 sensor each sensor wire needs to be connected to a dedicated terminal as shown in Fig 3 b Note the two wires of the PT1000 sensors are equivalent as they have no polarity therefore it is not...

Page 72: ...tal inputs The pRack PR300T features digital inputs for connecting safety devices alarms device status and remote switches These inputs are all optically isolated from the other terminals They can wor...

Page 73: ...st 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 100 mV The 4 20 mA current output ca...

Page 74: ...M 10 3 8 12 13 13 L 13 5 8 12 13 14 15 18 Tab 3 l 3 6 4 Remote connection of the digital outputs The Sizes of the cables for the remote connection of the digital outputs are shown in the following tab...

Page 75: ...the same procedure making sure the Carel default values have been reset After having restored the defaults the 7 segment display will show the number 88 the same as when first starting the controller...

Page 76: ...must be answered YES Wizard Ib43 Compressor config Configure another suction line YES Fig 4 h Answer YES to the next question which asks if a dedicated pRack board is present this way the pRack pR300...

Page 77: ...the board s inputs and outputs with the various functions Forthewizardonly afterhavingconfiguredthelines automaticassociation can be chosen as an option If choosing not to use this function the I Os...

Page 78: ...enu branch A a by pressing button The information relating to the main values Fig 5 a shown on the main screen when first starting vary according to the system configuration one line two lines two lin...

Page 79: ...ntify the order of the screen inside the menu for example screen Bab01 is the first screen in menu B a b Note The information on the screens may vary according to the password level used to access the...

Page 80: ...ne 1 a I O status b Settings 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 F S...

Page 81: ...n be performed using one of the system configurations described hereafter Configuration 1 a pRack pR300T board for managing both suction lines and control of the high pressure part this configuration...

Page 82: ...nit to shutdown Configuration of some parameters e g inputs outputs configuration of compressors inverter parameters Installation of default parameters Manual management 6 3 Control pRack PR300T can m...

Page 83: ...ed times For control in Neutral zone the parameters shown in the figure must be set NZ timings Setpoint Regulation probe value Decrease zone Increase zone Neutral zone Diff Decr Diff Incr Diff Diff Mi...

Page 84: ...e same modulation device is used on each line The maximum number of compressors and load stages per line varied according to the type of compressor Compressors and modulation devices Compressors Maxim...

Page 85: ...a f C b f and C a g C b g The modulating device is always the first to start and the last to stop irrespective of the type of rotation the other devices start or stop according to the type of rotation...

Page 86: ...ed when exceeding a set threshold As the economizer tends to increase the condensing pressure this needs to be controlled to ensure the high condensing pressure alarm is not generated In addition the...

Page 87: ...e manufacturer to achieve maximum COP or to a higher value to increase resolution of the capacity delivered a higher cycle time implies greater continuity in the effective capacity that can be deliver...

Page 88: ...ing a parameter in main menu branch D a b D b b in this case the fans only start if at least one compressor is on This setting is ignored if the fans are controlled by a dedicated pRack PR300T board a...

Page 89: ...d parameters set in main menu branch D a g Split condenser can be used to exclude from rotation fans whose index is even odd higher than a settable value lower than a settable value The function can b...

Page 90: ...on that can be set by a parameter for a fixed time which is also settable by a parameter in order to be able to quickly raise the pressure in the tank This procedure is reactivated whenever the unit g...

Page 91: ...wed for the HPV valve output Eib28 Minimum HPV valve regulation setpoint Enable low temp control lower proportional zone 6 7 RPRV valve management Management of the RPRV valve which is a PI regulation...

Page 92: ...energy saving functions by adjusting the suction and condensing pressure set points The suction and condensing pressure set points can be applied with two different offsets one for the closing period...

Page 93: ...gement per individual compressor or per line Individual compressor oil cooling oil injection Line common oil receiver The functionalities can be enabled and the relative parameters can be set from mai...

Page 94: ...e placed between the oil separator and receiver Once these two I Os have been enabled a pressure differential threshold can be set between the oil receiver pressure and the suction line pressure from...

Page 95: ...time line 2 Delay for oil level valve pulsing at startup line 2 Maximum pulsing time for the oil level valve line 2 Tab 6 f Summary of inputs outputs and oil receiver level parameters Mask Descriptio...

Page 96: ...et temperature is between Tmin and T23 see the control parameters screen Eib05 in this zone defined as subcritical the HPV set point would be calculated based on subcooling This minimum set point can...

Page 97: ...cooler pressure alarm Sign of life Prevent active A unit of measure and description can be associated to each generic function The following shows the operation of 4 types of generic functions Stages...

Page 98: ...system configurations The function that prevents contemporary starts can be enabled and a delay time can be set for compressor starts belonging to different lines Forcing the medium temperature line F...

Page 99: ...y active output is deactivated when all the compressors are off and no compressor can be started due to alarms or time settings despite the control request or when the unit is OFF As soon as at least...

Page 100: ...6 ax Increasingthereceiversetpointresultsintheflashgasvalve RPRV closing The parallel compressor is not affected by a decrease in the opening of the RPRV valve however remains active until parallel c...

Page 101: ...only based on the operating seasons and consequently 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 opera...

Page 102: ...N line 1 0 12 Compressor activation percentage with unit ON line 1 0 100 Number of fans on with unit ON line 1 0 16 Fan activation percentage with unit ON line 1 0 100 L2 Suction Suction pressure or t...

Page 103: ...ON OFF Valve Status Digital Scroll TM valve line 1 ON OFF Cap Req Capacity requested Digital Scroll TM compressor line 1 0 100 ActualCapac Actual capacity Digital Scroll TM compressor line 1 0 100 Aa2...

Page 104: ...only F1 Power delivered from fan 1 of line 2 a to the right of the value means that some form of power forcing is active 0 100 F8 Power delivered from fan 8 of line 2 a to the right of the value mean...

Page 105: ...heat reclaim request HR 1 Status Status of first heat reclaim request ON OFF Water temp Water temperature with HR1 regulated by temperature C F Valve Status of first heat reclaim valve Open Closed Pu...

Page 106: ...N OFF from keypad Manual Funct work Prevent from HP On off from keypad line 1 OFF OFF ON Ac02 L1 L2 Unit status display only OFF da tastiera see Ac01 above On off from keypad line 1 OFF OFF ON On off...

Page 107: ...06 Status display only Modulating device output value line 1 0 0 0 100 0 Bb01 Suction L1 Suction line 1 in manual mode Disabled Disabled abled Suction L2 Suction line 2 in manual mode Disabled Disabl...

Page 108: ...line 1 01 18 Part winding DO Star relay DO Compressor 1 part winding star DO position and status On Off display line 1 01 18 Delta relay DO Compressor 1 DO position and status On Off display line 1 0...

Page 109: ...compressor Number of alarms for each compressor line 1 1 4 0 4 7 Cae02 Alarm 1 descr Selection of first compressor alarm description Generic Overload High pressure Low pressure Oil line 1 Not availabl...

Page 110: ...disable enable Discharge temp Enable Digital Scroll discharge temperature alarm line 1 enable disable enable Caf90 Different sizes Enable compressors of different sizes line 1 NO NO YES Different numb...

Page 111: ...me on Minimum integrated parallel compressor ON time 30 s 0 999 Min time off Minimum integrated parallel compressor OFF time 120 s 0 999 Min time on same compr Minimum time between starts of same inte...

Page 112: ...ion condensing line 1 90 s 0 9999 Dab15 Power reduction to 0 min time Minimum time to decrease capacity request to 0 dead zone regulation condensing line 1 30 s 0 9999 Power reduction to 0 max time Ma...

Page 113: ...deactivation for high pressure prevent line 1 0 h 0 24 Dag10 Silencer Enable silencer line 1 Disabled Disabled Abled Max output Maximum possible request when silencer is active line 1 75 0 0 0 100 0 C...

Page 114: ...differential line 1 10 0 C C F Delay Common oil high temperature alarm delay line 1 0 s 0 32767 Eaab10 Enable oil lev Enable oil level management line 1 NO NO YES Num oil level alarms Number of compre...

Page 115: ...0 C Differential Liquid injection differential line 1 5 0 Eeaa02 DI HR Enable Activation Digital input to activate heat reclaim 01 18 U1 U10 Status Status HR DI display only Open Closed Logic Logic H...

Page 116: ...ime to byp Evaluation time to start GC bypass 30 s Max receiver press To allow byp Max receiver pressure to allow bypass 60 0 barg Eeab28 HPV valve modul Setp min Min HPV setpoint with heat reclaim to...

Page 117: ...Generic probe A position B1 U1 U10 Generic probe A type 4 20 mA display only Generic probe A value Max limit Generic probe A maximum limit 30 0 barg Min limit Generic probe A minimum limit 0 0 barg C...

Page 118: ...eat recovery 5 barg barg 0 100 IHR Integral time for the proportional integral regulation of the HPV valve with heat recovery 60 s 0 9999 Eib08 Enable HPV setpoint filter Enabling of the filter action...

Page 119: ...a HPV Min steps Minimum valve step number 50 step 0 9999 Max steps Maximum valve step number 480 step 0 9999 closing steps Valve closing steps 500 step 0 9999 Nom step rate Valve nominal speed 50 step...

Page 120: ...less than Fan capacity under which the ChillBooster is deactivated line 2 95 0 100 Tab 7 f Mask index Display description Description Def U of M Values F settings Faaa01 Summer Winter Enable summer w...

Page 121: ...t line 1 0 0 barg 0 0 99 9 Gba04 Enable ChillB as first prevent step Enable ChillBooster as first stage for condensing HP prevent line 1 NO NO YES Chill offset Offset between ChillBooster and prevent...

Page 122: ...s sizes line 1 Same size Same size Define sizes Ib21 S1 Enable size and size for compressor group 1 line 1 YES kW NO YES 0 0 500 0 S4 Enable size and size for compressor group 4 line 1 NO kW NO YES 0...

Page 123: ...s of measure Units of measure line 1 barg Refrigerant Type of refrigerant condensing line 1 R744 R22 R134a R404A R407C R410A R507A R290 R600 R600a R717 R744 R728 R1270 R417A R422D R413A R422A R423A R4...

Page 124: ...p probe malfunction Automatic 60 s R2 Related functions disabled ALA34 Suction pressure backup probe malfunction line 2 Automatic 60 s R2 Related functions disabled ALA35 Common oil temperature probe...

Page 125: ...ble ChillBooster ALH02 ChillBooster fault line 2 Automatic Config R2 Disable ChillBooster ALO02 pLan malfunction Automatic 60 s R1 Shutdown unit ALT01 Compressor maintenance request Manual Not present...

Page 126: ...aa65 Alarm 1 compressor 6 line 1 Baa40 Caa66 Alarm 2 compressor 6 line 1 Baa41 Caa67 Alarm 3 compressor 6 line 1 Baa42 Caa68 Alarm 4 compressor 6 line 1 Baa43 Caa69 Alarm 5 compressor 6 line 1 Baa44 C...

Page 127: ...4 line 2 Baa89 Cba46 Alarm 7 compressor 4 line 2 Baa91 Cba53 Alarm 1 compressor 3 line 2 Baa92 Cba54 Alarm 2 compressor 3 line 2 Baa93 Cba55 Alarm 3 compressor 3 line 2 Baa94 Cba56 Alarm 4 compressor...

Page 128: ...compressor 4 line 1 Partwinding Star relay compressor 4 line 1 Delta relay compressor 4 line 1 Bac22 Caa48 Valve 1 compressor 4 line 1 Bac23 Caa49 Valve 2 compressor 4 line 1 Bac24 Caa50 Valve 3 compr...

Page 129: ...compressor 4 line 1 Eaaa28 Oil cooling compressor 5 line 1 Eaaa31 Oil cooling compressor 6 line 1 Eaaa54 Common oil level valve line 2 Ebaa01 Subcooling valve line 1 Baceh Sign of life Bacem Normal al...

Page 130: ...a23 Fan 4 line 2 Baccr Dba24 Fan 5 line 2 Baccs Dba25 Fan 6 line 2 Bacct Dba26 Fan 7 line 2 Baccu Dba27 Fan 8 line 2 Baccv Dba28 Fan 9 line 2 Baccw Dba29 Fan 10 line 2 Baccx Dba30 Fan 11 line 2 Baccy...

Page 131: ...rature probe line 2 Bab64 Suction pressure probe compensation line 2 Con Bab08 Dba39 Condensing pressure probe line 2 Bab10 Dba40 Condensing pressure backup probe line 2 Altre funzioni Bab48 Dba38 Dis...

Page 132: ...cknowledgement they re reactivated as soon as the alarm condition ceases 8 1 3 Log The alarm log can be accessed from branch G a of the main menu by pressing the Alarm button and then Enter when there...

Page 133: ...pressure High condensing pressure Alarms from probe Low suction pressure High suction pressure Low condensing pressure High condensing pressure One possible example for the low pressure alarms is sho...

Page 134: ...action is to force all the fans on at maximum and switch all the compressors off except for the minimum capacity stage ignoring the control times but observing the compressor protection times The mini...

Page 135: ...ding addresses and descriptions can be supplied upon request 9 2 Commissioning software pRack Manager is configuration and real time monitoring software used to check the operation of pRack PR300T for...

Page 136: ...shing The key has detected the pRack and is checking the access rights start On steady Pressing the start button will start writing the software to the pRack start On steady Pressing the start button...

Page 137: ...Choose 1 connessione locale local connection 2 baud rate Auto 3 ricerca dispositivo find device Auto pLAN As for the port number follow the Wizard s instructions for the port to be identified automat...

Page 138: ...BIN download reserved nomeApplicativo DEV ApplicationName DEV nomeApplicativo GRT ApplicationName GRT upload only from which the GRP file is extracted nomeApplicativo IUP ApplicationName IUP nomeAppli...

Page 139: ...ntents 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 write the name of the director...

Page 140: ...run mode is a special case of uploading in automatic mode Unlike automatic mode the user must wait for a specific message to appear on the display to start or disable the operation described in the co...

Page 141: ...upload the contents of the pendrive the user must access the management menu from the system screens selecting UPLOAD and then MANUAL The files are selected by pressing ENTER when the cursor is on th...

Page 142: ...FORMATION and then PCOWEB NET Konfig Then select PCOWEB settings to configure pCOWeb parameters or PCONET settings to configure pCOnet parameters Configuring pCOWeb When you select PCOWEB settings the...

Page 143: ...played the display is cleared and a message similar to the one below is shown Display address changed Fig A c If the terminal detects inactivity of the entire pLAN network that is it does not receive...

Page 144: ...Page 144 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 145: ...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 PR300T 0300018EN rel 1 5 02 05 2017 Page 145 of 172 Copyri...

Page 146: ...tion probe fault 0 Cad05 L1 Function for setpoint compensation by digital input enabled suct cond 0 NO Ffa04 L1 FANS Dab01 L1 Fans regulation type 0 PROPORTIONAL BAND Dab01 L1 Fans control mode 1 TEMP...

Page 147: ...Maximum suction setpoint 40 Cbb03 L2 Suction setpoint 12 Cba04 L2 uct Regulation type P P I PID 0 PROP INT Cba04 L2 uct Integral time 0 s Cbb05 L2 Suction differential 0 Cbb08 L2 Increasing zone diffe...

Page 148: ...arm 5 of compressor start delay 0 s Cbe28 L2 Compressor alarm 5 type 0 Auto 1 Manual 0 AUT Cbe28 L2 Compressor alarm 5 priority 0 Light 1 Serious 1 SERIOUS Cbe31 L2 Compressors alarm 6 delay 0 s Cbe31...

Page 149: ...ompressor 6 0 Bab64 L1 Auxiliary pressure probe 0 Bab65 C Bab58 barg Bab59 C Input Digitali MaskIndex Va esc VarValue Type Channel Baa56 L1 Common low pressure from pressostat 0 NC Baa57 L1 Common hig...

Page 150: ...L2 Alarm 3 of compressor 4 0 NC Baa86 L2 Alarm 4 of compressor 4 0 NC Baa87 L2 Alarm 5 of compressor 4 0 NC Baa88 L2 Alarm 6 of compressor 4 0 NC Baa89 L2 Alarm 7 of compressor 4 0 NC Baa91 L2 Alarm...

Page 151: ...sor 1 unloader 2 0 NC Bac05 L1 Compressor 1 unloader 3 0 NC Bac06 L1 Compressor 1 unloader 4 0 NC Bac07 L1 Compressor 1 equalization valve 1 NO DO 04 Bac08 L1 Compressor 2 line relay 0 NO Bac08 L1 Com...

Page 152: ...ader 3 0 NC Bac83 L2 Compressor 2 unloader 4 0 NC Bac84 L2 Compressor 2 equalization valve 0 NO Bac86 L2 Compressor 3 line relay 0 NO Bac86 L2 Compressor 3 delta relay 0 NO Bac86 L2 Compressor 3 star...

Page 153: ...y L2 Fan 12 status 0 NO Baccz L2 Fan 13 status 0 NO Bacda L2 Fan 14 status 0 NO Bacdb L2 Fan 15 status 0 NO Bacdc L2 Fan 16 status 0 NO Bacde L2 Heat reclaim pump on off 0 NO Bacdf L2 Chillbooster sta...

Page 154: ...nverter non default settings ABB inverters are factory set and tested on these units Further details on ABB installation and set up available on request Page 154 of 172 Copyright HPL March 2021 P4114S...

Page 155: ...s In1 Start NoUnit 0 23 In1 Start In2 Dir 4 Ext1 in2 source Always off NoUnit DI2 12 Run enable 1 source DI2 NoUnit Selected 21 Start stop mode 1 Start mode Automatic NoUnit 0 2 Const time 2 Magnetiza...

Page 156: ...60 27 54 31 Fault functions 11 Fault reset selection Not used NoUnit Not used 12 Autoreset selection 0x0807 NoUnit 0x0000 0xffff 0x0000 14 Number of trials 5 NoUnit 0 5 0 15 Total trials time 60 0 s...

Page 157: ...uency reference 8 kHz NoUnit 4 12 4 kHz 98 User motor parameters 2 Rs user 0 02713 p u 0 00000 0 50000 0 00000 6 Ld user 0 36092 p u 0 00000 10 00000 0 00000 7 Lq user 0 54159 p u 0 00000 10 00000 0 0...

Page 158: ...4 4 2 5 2020 11 51 AM Index Name Value Unit Min Max Default 10 Motor nominal power 3 30 kW 0 00 10000 00 11 00 Drive composer pro v 2 2 0 1 Page 158 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 159: ...side Use it if the conductivity of the shield is not sufficient for the protective grounding or there is no symmetrically constructed grounding conductor in the cable d 360 degree grounding of the cab...

Page 160: ...ile MB TCP ABB C Ethernet IP 51 02 Protocol Profile EIP ABB Pro CANopen BCAN 11 58 01 Protocol enable CANopen Warning Fault Description A2A1 2281 Warning Current calibration is done at the next start...

Page 161: ...8 PRESSURE ENTHALPY DIAGRAM FOR R744 REFRIGERANT Page 161 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 162: ...1 2 3 4 5 6 7 8 9 10 4HP Condensing Unit 1st discharge 2nd suction are internally There is no intercooler in this unit Expansion Evaporator Page 162 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 163: ...R744 CO2 P h Diagram Subcritical 1 2 3 4 5 Gas cooler Evaporator 2nd stage 1st stage P h produced by Coolpack Page 163 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 164: ...R744 CO2 P h Diagram Transcritical 1 2 4 5 Gas cooler Evaporator 2nd stage 1st stage P h produced by Coolpack 7 6 10 Page 164 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 165: ...9 Commissioning Form Page 165 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 166: ...et point Ambient temp C HPV correct operation RPRV correct operation Discharge pressure Bar Gas cooler probe position Gas cooler pressure Bar Gas cooler outlet temp C MT discharge temp C Receiver set...

Page 167: ...Name Signature Date CO2 Hermetic Rotary Condending Unit COMMISSIONING FORM Additional Comments Page 167 of 172 Copyright HPL March 2021 P4114S Rev 03...

Page 168: ...city PB 5 83 kW Rated power input DB 2 7 kW Rated COP COPB 2 160 Parameters at full load and ambient temperature 15 C Point C Rated cooling capacity PC 4 82 kW Rated power input DC 1 6 kW Rated COP CO...

Page 169: ...ork near the condensing unit in a safe location this PRV must be securely clamped in position not just connected to the pipework MEDIUM TEMPERATURE Rotary Condensing Units MT 2 HP Rotary CCU GCU2020PX...

Page 170: ...140PXB1 LT 20 HP CCU 120 bar g 80 Bar g 80 Bar g 67 Bar g MODEL DESCRIPTION DISCHARGE PRV INTERMEDIATE PRESSURE PRV MAXIMUM RUNNING RATING MAXIMUM LIQUID RUNNING PRESSURE GCU2020PXB1 MT 2 HP CCU None...

Page 171: ...pework Valves etc MUST have a MINIMUM PS rating MODEL LIQUID LINE EXPANSION VALVE LIQUID LINE COMPONENTS SUCTION PRV REQUIRED SUCTION PRV RATING HCU2020PXB1 HCU2040PXB1 GCU2020PXB1 GCU2040PXB1 90 Bar...

Page 172: ...ipework Valves etc MUST have a MINIMUM PS rating MODEL LIQUID LINE EXPANSION VALVE LIQUID LINE COMPONENTS SUCTION PRV REQUIRED SUCTION PRESSURE RATING HCU2020PXB1 HCU2040PXB1 GCU2020PXB1 GCU2040PXB1 9...

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