BREC Air-cooled water chillers BREF Air-cooled water chillers with free-cooling system

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BREC Air-cooled water chillers BREF Air-cooled water chillers with free-cooling system 1602A - 1802A - 2202A - 2502A - 2802A3202A - 3602A - 4202A - 4802A R134a (400-1200 kW)

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Serie BRE

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Serie BRE

In BRE units, the inputs/outputs of the two circuits are divided into two boards connected with each other in a local area network.The two boards perform like a single controller to all intents and purposes.The microprocessor controller manages the unit’s operation autonomously. The microprocessor control boards contain the program and all the stored operating parameters which can be viewed and set on the user interface.

LAN 1 LAN 21

LAN 11

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Program Version

By pressing the key, you can see the version of the control program burnt in the Flash EPROM.

This information is essential when you want to add a new unit to a group of units connected in a Local Area Network because all the units connected with each other in a LAN must have the same software version.

Also, when contacting a service centre, it is important to quote the version of the control program contained in the Flash EPROM accurately.

Program VersionBIGCH 4.2 15-07-10

SCREW06ST021@L2042B2A00

Program VersionBIGCH 4.2 15-07-10

SCREW06ST021@L2042B2A00

Ver DateBIOS: 0422 00000BOOT: 0000 00000

Ver DateBIOS: 0422 00000BOOT: 0000 00000

BREF 1602 No PumpsComp.Fusheng R407CMech.exp.Valvef 50 Hz

BREF 1602 No PumpsComp.Fusheng R407CMech.exp.Valvef 50 Hz

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Normally the display uses the language that has been defined by the regulation program selected in the Flash memory: IT = Italian, EN = English, DE = German, FR = French , SP = Spanish and the possibility of selecting a different language at any moment , by pressing + in the same time.

Language Selection

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12:22 26.3°C 55%InizializzazioneAttendere...

LAN01

12:22 26.3°C 55%InizializzazioneAttendere...

LAN01

12:22 26.3°C 55%Initiating ...Please Wait

LAN01

12:22 26.3°C 55%Initiating ...Please Wait

LAN01

12:22 26.3°C 55%Einschaltung...Bitte warten

LAN01

12:22 26.3°C 55%Einschaltung...Bitte warten

LAN01

12:22 26.3°C 55%DEPART

Attendre s.v.p.LAN01

12:22 26.3°C 55%DEPART

Attendre s.v.p.LAN01

12:22 26.3°C 55%Inicio

Espere …LAN01

12:22 26.3°C 55%Inicio

Espere …LAN01

NOTEThe only exceptions to this rule are the masks for service engineers ("Hardware Configuration"),

which always appear in English language.

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Accessing the Parameters

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Serie BRE

When the unit is powered but not running, 3 fields are active on the user terminal display:

A. Time and date (only in units featuring a clock card);B. Outlet water temperature;C. One of the following messages indicating what has switched the unit off:

1. ON/OFF button;2. Remote control ;3. Supervision system;4. Timed switch-off - in units with clock card - indicating what time the next restart is programmed for;5. Automatic unit inversion cycle;6. Setback mode;7. Forced switch-off subsequent to water flow alarm;8. Forced switch-off subsequent to water flow alarm.

12:22 26.1°C ESTWater OUT: °C 23.0

C

12:22 26.1°C ESTWater OUT: °C 23.0

C

ABC

ABC

To Start UnitPress On KeyTo Start UnitPress On Key

Warning : Stoppedby Remote Control!Warning : Stoppedby Remote Control!

Warning : Stoppedby Supervisor !

Warning : Stoppedby Supervisor !

Programmed StopRestart at 13:15 LUProgrammed Stop

Restart at 13:15 LU

Warning : Stoppedon Standby !

Warning : Stoppedon Standby !

Programmed StopPress On Key

Programmed StopPress On Key

Warning : Unitin Set Back ModeWarning : Unitin Set Back Mode

Warning : Stoppedby Water Flow AlarmWarning : Stoppedby Water Flow Alarm

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Status screen with the unit running

When the unit is running, the STATUS SCREEN appears on the displayfeaturing 6 active fields:

A.Current time (only in units featuring a clock card), ambient temperature.

B. Functions in progress; the following messages are given depending on the working conditions:• COOLING, HEATING, RECOVERY HEAT;• PUMP-DOWN CIRC. 1, PUMP-DOWN CIRC. 2, PUMP-DOWN CIRC. 1-2;• DEFROST CIRC.1, DEFROST CIRC.2, DEFROST CIRC.1-2;• C.1 CONDENS LIMITS, C.2 CONDENS LIMITS, C.1-2 CONDENS LIMITS;• C.1 EVAPOR LIMITS, C.2 EVAPOR LIMITS, C.1-2 EVAPOR LIMITS;• C.1 COND.LOW PRESS., C.2 COND.LOW PRESS., C.1-2 COND.LOW PRESS.;• C.1 DISCH.HIGH T., C.2 DISCH.HIGH T., C.1-2 DISCH.HIGH T.• C.1 OIL LOW P., C.2 OIL LOW P., C.1-2 OIL LOW P.• DRIPPING..., QUICK START

C. Where applicable, it indicates automatic cycle operation override:• "MAN" in operating mode with manual control;• "FORCE" when switching on using manual forcing;• "WATCH" when the unit enters “setback mode” to keep temperature parameters within the set limits.• "LOWPW" request for partial circuit operation to reduce power consumption (request from digital input)

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Status screen with the unit running

D. indicates unit’s slave status, which can be one of the following:• "ON": if the unit was switched on by the user teminal• "REMOTE": to a remote contact;• "SUPERV.": to a Supervisor;• "CYCLE": to automatic cycle inverting standard units and standby units;• "TIME": to a programme for operation based on time bands.

E. indicates trouble status, which can be one of the following:• "ALARM" : when there is an alarm;• "SERV": when a meter totalling hours of operation exceeds the threshold.

F. identifies with "LAN01", "LAN02", … when a number of units are connected in LAN.In this case, if a shared user terminal is used, it is possible to scroll among the units on the same LAN by pressing + keys at the same time.

12:22 26.1°C ESTCOOLING

LAN 01


LAN 01 P


LAN 02


LAN 02 P

……

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Reading and Programming Modes

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Hour-Meter Reading and Programming

This part of the program is used to determine service intervals for the unit’s components: when the device in question exceeds the operating hours threshold indicated, the microprocessor reports the service request by activating the alarm condition and sending the “SERV” message up on the main form. There are also two forms featuring the number of times the compressor starts (with the option of resetting the count).

The forms give the number of hours accumulated and operating thresholds. To edit limits and/or reset the hour-meter, you must call up the subroutine in programming mode. The functions regard the following unit components: 1. Compressors; 2. Water circulation pumps; 3. Compressors starting number; 4. Command manual Defrost circuit;

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Hour-Meter Reading and Programming

For each device, it is possible to: • read the accumulated number of hours of duty; • set operating thresholds (Note: by setting the threshold to 0, the counter is disabled); • reset the hour-meter (RESET = "OK"), e.g. once the component has been serviced and/or replaced. Parameters can only be edited within the permissible setting ranges. Screens on the left feature the progressive number of starts of the unit’s compressors and pumps, with the option of resetting the count.

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Reading Input and Output States

This part of the software, which can be called up directly by pressing the I/O key, allows to check the state of the board’s inputs and outputs. The codes given on the display are the same ones used to identify components in the unit and in the relevant literature (electrical and refrigerant drawings).

DIGITAL INPUTS (ID1 - ID14): Remote On-Off = remote On-Off contactLP1 = circuit 1 low-pressure pressure switchAP1= circuit 1 high-pressure pressure switchTH1-2 = protector breaker compressor 1TH3-4 = protector breaker compressor 2THPE1 = thermo protectors for the water circulation pumpRSF = phase sequence relayFS = water flow-switchHeat Rec Req = start up contact of heat recoveryTHPES = thermo protectors for the water circulation pump Free-CoolingChange SETP. = commutation contact for the working setpointPower Reduc. = reduction contact of the absorbed powerRem. SUM/WIN = commutation contact for SUMMER/WINTER operationI.V.LimitSw.= contact switches valve Free-CoolingCompress.1 Integral Prot. = KRIWAN protection for compressor 1

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ANALOGUE INPUTS (B1 - B8):Supplies the readings of the TEMPERATURE and PRESSURE sensors connected to the board.

UpCOe Expansion Analogue inputs (B1 – B4)Supplies the readings of the sensors connected to the UpCOE expansion board.B1 = Rem Offset summer setpoint

ANALOGUE OUTPUTS DIGITAL OUTPUTS (C1 - C13):V3V1 (recovery) = 3-way valve 1 contactVIC1 = cycle inversion valve circuit 1CPE1 = pump contactor circuit 1CC1,CC2,CC3 = compressor contactorsETVR1 (recup.) = ECO system or liq. inject. system switch-onCPES = free-cooling pump contactorAl. type “A” = digital outputs of signaling alarm the type “A”ETF1 = circuit 1 freon solenoid valveETVC1 (rec.) = circuit 1 condensing valveCV1R/CV1D = fan 1 contactAl. type “B” = digital output of signalling alarm the type “B” ANALOGUE OUTPUTS (Y1-Y2)Y1 Fan 1 Signal = fan speed control;Y2 Anaout 2 = free-cooling valve contact.


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INPUT/OUTPUT TABLE FOR THE TWO UpCO1m BOARDS

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INPUT/OUTPUT TABLE FOR THE TWO UpCO1m BOARDS

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Configuring the unit

Unit’s configuration mode is accessible by keeping pressed the P programming key until you hear a short audible signal and then pressing the I/O key. Once you have entered the password (by factory: 121), the relevant form is called up, comprising three options: move the cursor vertically to the line you are interested in using the DOWN key and then call up the forms by pressing the ENTER key.

HARDWARE CONFIGURATION:The unit control program needs to be “configured”, i.e. adapted to the unit it is installed in. During this stage, you must define all elements making up the unit that the microprocessor will be required to control. This operation is generally only required when the controller is installed actually on the unit, in which case, therefore, it is performed at the factory during final testing. Nonetheless,. configuration may be required as a result of later changes made to the unitConsequently, forms concerning configuration appear in English and are intended for use by service engineers only.

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DEVICES CONNECTED TO THE UNIT:Allows to set: • set unit type depending on whether the unit in question is a:

- standard-version chiller - chiller with condensation heat recovery - chiller with free cooling

• Circulating pumps• Fan speed regulation

Only some of the following forms will be displayed, depending on the type of unit.

SIZE AND DEVICES CONFIGURATIONAllows to set:- the size of the unit- the type of compressors- the type of fans


UNIT Type:STD ChillerCircul Pumps: 2Fan Speed Regul: Y

UNIT Type:STD ChillerCircul Pumps: 2Fan Speed Regul: Y

Unit Size: 1602Compressor Type:FushengFans Type: STD

Unit Size: 1602Compressor Type:FushengFans Type: STD

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CONFIGURATION OF SCREW COMPRESSORS’ OPTIONSAllows the following options to be set:• Injection of liquid for additional cooling only necessary for high levels of compression (Bitzer Compressors);• Eco+Subcooling to obtain an increased sub-cooling of the liquid (available for both Bitzer and Fusheng compressors).

CONFIGURATION OF THE ELECTRONIC EXPANSION VALVEAllows to set:- the type of refrigerant gas- high temperature function- the presence of the electronic expansion valve-the type of electronic expansion valve

COOLING SETPOINT LIMITSAllows the minimum and maximum setpoint limits to be set.


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PUMP-DOWN CONFIGURATION:Allows pump-down mode to be activated and the maximum time for the procedure to be set.

FREQUENCY OF THE ELECTRIC NETWORK:This Screen allows the frequency of the electric network.

FAN REGULATION - STANDARD MODE:This Screen allows the fan modulation parameters to be set on the basis of the condensing pressure: by disabling the low-noise mode, the fan speed regulation on a 2 steps regulation, as illustrated in the diagram below.


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FAN REGULATION - LOW NOISE MODE:By enabling the low-noise mode, the fan speed regulation is based on a ramp of 3 steps. The Screen on the left allows the parameters related to the 2nd modulation step.


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MAXIMUM SPEED SETPOINT OF FANS IN FC MODEScreen 72 in the event of total free-cooling, allows the maximum fan speed to be set.

SETPOINT FREE-COOLING ACTIVATIONIn free-cooling units, this Screen appears which enables the activation delta T to be set. When the external air temperature is lower than the inlet water temperature, the unit enters free-cooling mode: the water circulation pump activates by means of the free-cooling coil and the compressor steps change in order to increase the efficiency of the air-water exchanger.


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FREE-COOLING ACTIVATION WITH UNIT IN STAND-BYThis Screen allows the intelligent free-cooling management to be activated. The hydraulic connections among chillers are required, as shown below.

Intelligent Free-Cooling

THE IDEA OF THE INTELLIGENT FREE-COOLING:exploiting the air/water exchangers of the unit/s in stand-by

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Direct expansion mode


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Mixed mode


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Free-cooling mode


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In the diagram shown below, an example is shown where unit 1 is in stand-by and units 2 and 3 are running and connected with intelligent free-cooling. If the external temperature is able to activate the free-cooling, the control system of the units running, controls the start-up of the fans of the unit in stand-by (1) and the start-up of the free-cooling pump (C) of the units which are running (2 and 3). In this way the water is sent to all of the available free-cooling coils.


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Units without onboard pump/s


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Units with onboard pump/s


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ISOLATING VALVEThis mask gives the possibility to manage an external motorized valve (at customer care) for the main water circuit.

NOTE: The installation of this valve is strictly recommended when there are external main water pumps.

There are two different ways to manage this valve:•Use the limit switch of the valve. In this case you can set a time within which the valve must be closed; if the valve doesn’t close its contact within this time, you get the alarm:

•Do not use the limit switch of the valve. In this case you can set a time which must take into account the time needed for the valve to be fully open; after this timing, the main pump is switched on. You don’t get any alarm regarding the valve.

AlarmIsolating Valve Not(Fully) Opened:CheckValve/Limit Switch

AlarmIsolating Valve Not(Fully) Opened:CheckValve/Limit Switch

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ANTI-FREEZE – ACTIVATION OF THE FC PUMP:This Screen gives the possibility to activate the circulation pump through the free-cooling coils in anti-freeze operation. If this function is activated in the standby unit, the FC pump is switched on as soon as the external temperature falls below 1,0°C; it turns off when it rises above 3,0°C.N.B.: Only a correct mix of glycol ensures that the coils do not freeze if the external temperature falls below zero: the function indicated cannot guarantee the integrity of the coil, above all in freezing temperatures.

REGULATION OF THE AMPEROMETRIC SENSORSThis mask defines the working range of TA1 and TA2. These thresholds and the multiplying factor change accordingto the type of compressor.


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MAXIMUM ABSORBED CURRENT REGULATIONThis screen allows the maximum absorbed current threshold of the compressor above which the cooling capacity is reduced.Usually it matches the FLA of the motor.


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READING RANGE REGULATIONThis screen allows the reading range of the high pressure transducer to be set.

READING RANGE REGULATIONThis screen allows the reading range of the low pressure transducer to be set.

SENSOR ADJUSTMENTThis screen and the following Screens allow the temperature sensors which can be found in the unit to be adjusted (“read value”), when there is a difference between the value measured by the probe and the actual temperature, measured by a precision instrument.

MONITORING OF THE REFRIGERANT LOADThis mask is managed by an algorithm which constantly monitors the sub-cooling value for both circuits.NOTE: the liquid temperature sensors are optional.


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REMOTE SETPOINTScreen 88 allows the relative control parameters of the remote modulating control of the unit operating values to be set.A high-precision (1/1000) 20Kohm resistor must be connected in series to terminal B1 the UpCOE board. Next, apply the 0-10V signal referred to the GND terminal (both terminals are located on the control card). The zero value is adjusted automatically using the “Hardware setup” function.

HEAT RECOVERYScreen 89 allows the maximum condensation temperature limit to be set above that which is prevented by the heat recovery.

OPTIONAL REMOTE SETPOINTThis mask means that, if presence of a LAN connection, the changing in the set-point is sent through the LAN; it is enough to install the contact for the changing in set-point in one unit only and then to enable this function.


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This mask allows to set the maximum pressure at which the heat recovery will be disabled.

It is possible to set the automatic or manual reset for the flow switch alarm. If set to automatic, it is possible to decise how many times (from 1 to 4) the alarm will be in automatic reset; after the this number of pre-alarms (within a time interval of one hour) the alarm becomes critical and stops the unit. It is then necessary a manual reset.

In case of a UPS power supply for the controller, it is necessary to enable this function in order to disregard some alarms which could appear because of the missing main power line. It takes the information from the RSF.


Heat RecoveryCond.Pressure Limit

60°C

Heat RecoveryCond.Pressure Limit

60°C

Water flow-Sw.AlarmReset: AWater flow-Sw.AlarmReset: A

Double Power SupplyN

Double Power SupplyN

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QUICKSTARTThis mask allows the Quick-Start function to be activated. If, following a return of supply (Power ON) the temperature of the water is above the summer SetP.+ the programmed set, the compressors will start-up in approx. 3 minutes, reducing all the standard timings.

BUZZER ACTIVATION TIMEThis screen allows the maximum activation time of the buzzer activation when an alarm is active to be set.

SETTING THE ACCESS PASSWORDSThis screen allows the access passwords to be set:- SETTINGS MENU is accessible with the default password “00000”-SERVICE MENU is accessible with the default password “00121”

Both passwords can be changed and it is recommended to write the new passwords down before changing the existing ones.

If the passwords have been lost, the access to SERVICE MENU is granted with password “00242”.


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PROGRAMME SETUPThis operation is performed automatically if the programme is replaced. It may prove useful if you find data (setpoints, configurations etc.) are “contaminated” as it allows you to clear the memory (including data concerning the unit’s HARDWARE configuration): all setpoints are automatically restored to their respective factory settings (see sectionentitled "DEFAULT VALUES").Following this operation, the controller must be reconfigured and you will need to adjust any setpoints that are to have a value other than the default value.

AL. PAGE CLEAR-UPBy clearing the alarm log, you erase the all alarm events stored in the memory.

HARDWARE SET-UPUsed to run an automatic procedure for detecting devices connected to the controller. This operation is useful when you want to add an option to the card, replace a sensor, or when the display features the "NC” message instead of the temperature sensor’s reading.


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Delay Settings

This screen concerns initial transient behavior and gives you the option to set:• delay before the unit restarts after a power cut (‘POWER ON DELAY’) - it is required to prevent simultaneous starts in multiple installations; in LAN-connected units, a progressive start sequence (unit 1, unit 2, …) is run automatically, with 5-second intervals between one unit and the next.• initial period - from when the compressor starts - during which the low-pressure switch reading is disregarded (‘LP-STAT DELAY’). It enables the compressor to start even in a harsh climate.• length of time between the unit switching on and control starting (‘START TRANS.’) - this is the initial period deemed necessary to give the control system time to stabilize. During this period, the FS water flow-switch reading is also disregarded. This allows the unit to start without generating the "Loss of Water Flow" alarm. • delay - from when the unit starts - before environmental condition alarms are reported (‘T Al Delay’).

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This Screen allows the anti-hunting time constant to be set to avoid excessive differences in temperature. The greater the heat inertia of the water circuit, the greater this value must be set.

This Screen allows the water flow-switch (FS) parameters to be set: the first parameter is the acquisition delay for the signal issued by the flow-switch when the unit is started, whilst the second parameter is the length of the delay before the alarm, if there is one, is reported after the pump starts. Lastly, the third parameter (only displayed if there are two pumps) is the rotation time for the pumps’ operation.

This Screen allows the compressor timing to be set: •minimum time between two starts for a single compressor; •minimum time each compressor stays on; •minimum time each compressor stays off; •minimum time between two consecutive starts by different compressors;

This screen allows the start-up delay of the free-cooling pump during opening of the water isolation valve to be set.

Delay Settings

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During regular operation, all components the unit is fitted with are managed automatically. Nonetheless, to make maintenance and adjusting work easier, or if there is an emergency, individual components can be switched on using the manual override feature, regardless of the control process. In particular, it is possible to: •switch the unit on/off in manual mode;•switch the compressors on/off;•swap the two pumps over;•switch on /off the FC pump; •control the ramp for the fans’ modulating control. The safety devices are always activated, also during manual operation.

Manual Control

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Manual Control

To alter the operating mode of a component, simply move the cursor onto the relevant line, press the UP or DOWN key to change from automatic ("No") to manual ("Yes") or vice versa, and confirm by pressing the ENTER key.

While using Manual Override mode, to start one or more devices, the label “MAN” will be displayed in

the main mask.

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EXV Parameters

The Screens shown on the left allow the read only data and some operating parameters of the electronic expansion valve on circuit 1 to be displayed.

The screens are the same for the valve on circuit 2, but it is necessary to enter the screen dedicated to “Circuit 2 Valves”

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This Screen allows the type of electronic expansion valve to be set.

Allows the superheating value to be set in the various operating modes.

Allows the Proportional Gain to be set in the various operating modes.

Allows the set point for the Integral Time to be set for different operating modes.

Allows the set point of the Derivative time and the maximum suctiontemperature to be set.

EXV Parameters

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Allows the maximum number of opening steps and the set point of the neutral band for the superheating.

Allows the relationship in % of the power of the electronic expansion valve and the cooling circuit to be set where it has been inserted in the various operating modes described.

These Screens allow the limits of low superheating to be set: integral time and temperature in the various operating modes.

EXV Parameters

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Allows the setpoints of the MOP and LOP to be set in chiller mode.

Allows the start up delay of the MOP and the integral time to be set.

Allows the integral time of the LOP to be set.

Allows the start and finish of the range of the evaporating pressuresensor to be set.

Allows the delay time regarding the activation of the followingparameter alarms to be set : Low subcooling, high suction temperature, LOP and MOP.

Allows the delay time regarding the activation of the “Pressure sensor failure” to be set for the compressor start-up and during normal operation.

EXV Parameters

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Remote Control and LAN Settings

As an alternative, the unit can be started and stopped by means of: 1. a remote contact (or "remote control"); 2. a "supervision system" connected to the microprocessor with a serial cable. The microprocessor nonetheless retains control of the unit’s resources. ON/OFF VIA REMOTE CONTACT: the closing of a remote contact is responsible for starting the unit. The N.O. contact is voltage-free and connected to the master card (see wiring diagram). In units with a standard control programme, digital input 1 is the one specifically used for the on/off contact.

SUPERVISION SYSTEM: a supervision system exchanges data via a serial cable with the unit’s master card, which is controlled and monitored from a remote location. An optional Serial Card is available for this purpose, used to enable optoisolated interfacing with an RS-485 network for data transfer.

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This Screen allows to establish whether the unit is slaved to a remote control. More specifically, you can set: • the remote on/off command via clean contact (‘I/O via Contact’); • the remote on/off command from a supervision system by means of RS-485 serial line (‘I/O via Serial’). Being mutually exclusive, if the setting is "I/O via Serial Yes" , the "I/O via Contact" option is automatically disabled. • Moreover, with Screen 140 it is possible to set (only in heat pumps) the activation of the SUMMER/WINTER changeover remotely by means of a contact connected to the digital input 14 (see the electrical diagram attached to the unit).


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SETTING TRANSMISSION PARAMETERS FOR SUPERVISION:Allows the basic parameters to be set (first three lines) for switching via supervision, i.e. •serial address of the unit connected to the serial supervision network (must match serial address set in supervision program); •data transfer rate (Ser. speed): 1200, 2400, 4800, 9600 and 19200 for RS-485. •protocol type (standard or Modbus). In addition, the fourth line (should the unit be ready for connection in a Local Area Network) is for setting the number of units connected in the LAN. Remember that to prepare the unit for connection in a LAN, it must be assigned a LAN address other than 0 as indicated in the relevant LAN guide.


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This Screen concerns parameters for automatic rotation between running units and standby units. Via said form, you can determine: • whether to activate this management feature (Yes/No). When automatic rotation is enabled, you have to press the ON/OFF key on the unit with the lowest address in the network. • automatic cycle time between one inversion and the next (‘CYCLE TIME’) - if it has the value zero (" 0 "), the controller runs a test, rotating units at two-minute intervals. • the number of units on standby (‘Num. UNIT STAND-BY’). Automatic rotation can be executed: • on a time basis (based on the above-mentioned cycle-time); • subsequent to a level-2 alarm, i.e. subsequent to an alarm for which AR or BR has been set in the alarm addressing forms (see relevant section herein).


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This Screen, which is only seen if the local network is configured, allows the temperature regulation to be set in three different ways:

•Independently: the unit independently controls the water temperature regulation;

•Connected: the unit control carries out the water temperature control by calculating the average temperature of the units which are operating;

•Cascading: the control carries out an off-set on the regulation set point according to the units connected in the network therefore allowing the units to be switched on in succession. Each unit maintains its own regulation timings.


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This screen, which is only displayed if the local area network is configured, allows the unit operation to be managed with the mean temperature value measured in the room or with the "local" value measured just by the sensor inside the unit: •Mode: Local Unit control is based on temperature and humidity values detected by sensors on the actual air-conditioner. •Mode: Media Unit control is based on mean temperature and humidity values detected by sensors on active units connected in the local area network. If the difference between the mean value and its own sensor reading exceeds the "MEDIA/LOC.DIFF." value (default setting 2°C), the controller automatically switches from "MEAN" mode to "LOCAL" mode.


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Working Parameters

COOLING SETPOINT:No settings can be made to this screen. It gives the delivery water temperature setpoint to which the unit is referring for control purposes. The third and fourth line feature a message, where applicable, indicating the origin of the setpoint value when it deviates from the standard setting: •Compens. T.ext.: indicates that the setpoint given on the second line is calculated based on external temperature (based on parameters set in the forms described further on); •SetPoint OpT.: indicates that the second setpoint is active by virtue of the contact at digital input 10 switching; •Setback Mode SetP.: indicates that the setback mode setpoint is active; •Active SetP.: indicates that the setpoint is calculated based on the offset read by analogue input 3 (option only possible if there is no evaporating pressure sensor connected).

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COOLING SETPOINT:Allows the main cooling setpoint to be set and, where applicable, the “second setpoint” is activated when a contact connected to digital input 10 switches.

Working Parameters

SUMMER COMPENSATION:Allows summer compensation to be set for the cooling setpoint depending on external temperature based on a ramp whose coordinates (of the two angular points P1 and P2) must be entered here.

BRAH

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ALARM THRESHOLDS:Allows the inlet water temperature alarm thresholds to be set. If the unit is in its heat pump version, the second line reads “Water Inlet Summer Temperature” to distinguish summer mode thresholds from winter mode ones, which can be set on the last Screen.

Working Parameters

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BASIC PARAMETERS:This Screen allows the setback mode to be enabled/disabled as well as the setpoint for operation whilst said mode is enabled.

CYCLIC PUMP START:This Screen determines operation of the fan water circulation pump whilst setback mode is enabled for a period of 120 seconds. If set to "Yes", the pump is switched on cyclically based on the set time interval.

Setback mode, which can be activated or deactivated via the keypad, consists in starting the unit automatically when it is idle - but powered - based on the setpoint settable for this operating mode. Basically, setback mode is activated to ensure that environmental conditions are regulated - though in a wider range - even when the system is off. Hence its activation does not depend on signals coming from remote control systems, which it takes priority over. Unit start as a result of setback mode is not considered an alarm condition.

Setback Mode

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LOW POWERThis screen allows the low absorption function of the compressors’ power supply to be set so reducing the cooling capacity.

It is possible to commute between four different options:1. OFF = always disabled2. ON = always enabled3. ON from Digital Contact = enabled from digital contact ID11 (see electrical drawing)4. ON from Supervision = enabled by means of BMS (see variables list)

Max absorption: determines the maximum threshold current not to be exceeded when the Low Power function is active.

Low Power

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Clock – Calendar – Time Bands

If the microprocessor features the optional clock card, the STATUS Screen displays the date, current time and day of the week. The following actions can also be associated with a particular time: • unit starting and stopping based on a timer program; • logging of alarm events. Current time and date are set, and time bands programmed, by means of the following forms:

CLOCK-CALENDAR SETUP:By means of the Screen 250, you can set: • time of day (hours, minutes); • date (day, month, year); • classification of the day of the week.

58

SETTING TIME BANDS:Using this device, you can set times (time bands) for automatic unit starting and stopping, achieving: • up to 3 on-off cycles a day, each with a start and stop time; • a weekly cycle with different daily cycles split into weekdays N (default setting from Monday to Friday), Saturdays P (default setting for Saturday, though it can be used for half-days etc.), and Sundays and holidays F (default setting for Sunday).

Entering Yes on the first Screen activates the time band device. Field D on the STATUS form will read “HOUR”. By using the Screen which follow you can program time cycles - featuring a start time (ON) and a stop time (OFF) - for normal days (N), Saturdays and pre-holidays (P), and Sundays and holidays (H). With the unit idle, the display reads “UNIT SWITCHED OFF – RESTART AT ” with the time and day of the week programmed for the next start. If you enter 00:00 in both the ON and OFF fields, the cycle is disregarded.


59

CLASSIFICATION OF DAYS OF THE WEEK:This is automatic, though it can be edited starting from the Screen on the left; the Screen is called up when the time band device is activated ("ENABLE:" YES.) The current day is identified - for the purpose of time band programming - as: - N: normal or week day; - P: Saturday or half-day; - F: Sunday or holiday;


60

WEEKDAY PROGRAMME OVERRIDE:Unless otherwise programmed, days are classified in the microprocessor’s memory as follows: • weekdays (N) all days during the week from Monday to Friday; • Saturdays or pre-holidays (P); • Sundays and holidays (H) The stored classification (N or P or H) appears under each day and can be edited by pressing key or until you reach the desired classification. Pressing the key then confirms the classification entered and you are moved on to the next day. If classification differs from the standard setting (override), the > symbol automatically appears in front of it. Time bands adopted when overriding will be the same as the ones for days with that classification.

The override condition is cancelled automatically once the day for which it was activated is over


61

Antifreeze

AntifreezeGlycol % 00Setpoint AF °C

2.0


2.0

In hardware configuration it is possible to set the percentage of glycol used in the water circuit. According to this percentage, the antifreeze set-point is automatically changed.

Here below the freezing temperatures in function of the percentage of glycol. The antifreeze limit is automatically set 2°C above the freezing temperature.

62

Antifreeze

#HOLD

The advanced feature checks for ice inside the evaporator, monitoring the delta between evaporating pressure and outlet water temperature.When ice-over conditions are detected, partial capacity operation is instantly implemented on the circuit involved, resulting in the pre-alarm:

If the situation is repeated 4 times within the space of an hour, the antifreeze alarm is generated, which stops both circuits (operator intervention needed):

AlarmCirc.1 AntifreezeCheck Evap.Cleaning/Refrigerant Charge


PreAlarmCirc.1 AntifreezeCheck Evap.Cleaning/Refrigerant Charge


AF Param.Afreeze SetP. °C 2.0AF delta Tw-Tev % 25AF1 – G - AF2 – G -

AF Param.Afreeze SetP. °C 2.0AF delta Tw-Tev % 25AF1 – G - AF2 – G -

It will be possible to access the following parameters:






2.0


2.0

63

Antifreeze

STEP 1 The evaporating temperature of any circuit must reach the lowest threshold of 2°C (Tuning parameter: AFreeze SetP. (ARAH, ERAH, LRAH)). Even if the tuning parameter is the evaporating temperature, the control algorithm works with the evaporating pressure which changes according to the refrigerant (2°C correspond to 3.9 bar for R407C, 7.5 bar for R410A);

STEP 2 Once the evaporating temperature has reached the value of 2°C, the

control also starts to read the value of the outlet water temperature and every 10 seconds calculates and stores three values of and then calculates the mean value;

STEP 3 If the evaporating temperature continues to remain below 2°C, every 10

seconds the control calculates and stores the value (and every time compares this result with the mean value calculated in STEP 2) in order to understand how fast this difference increases over time. On the other hand, if the evaporating temperature increases above -2°C for

a time longer than 6 minutes all the previous values are automatically reset.

ANTIFREEZE CONTROL LOGIC

64

Antifreeze

STEP 4 When the difference exceeds 25% (Tuning parameter: AF delta Tw-Tev (ARAH, ERAH, LRAH)) respect to the first mean value recorded for a time longer than 60 seconds, i.e. when:

the control sends an antifreeze pre-alarm and decreases the cooling

capacity.

STEP 5 At this point there are two possibilities:The evaporating temperature increases above 2°C and then decreases again below 2°C: the control will send another antifreeze pre-alarm. If this situation occurs 4 times within a few minutes, the antifreeze alarm is displayed and the unit is switched off;Even if the cooling capacity has been reduced, but the evaporating temperature decreases of 1.5°C more, the control sudden switches the unit off.

65

Alarm Addressing

The following section ("CONSULTING ALARMS") describes possible alarm events that may be detected by the controller, specifying the action taken by the controller for each. By using the Screens in this section, it is possible to assign a “type” to each of the alarms listed, i.e.: • type A: alarm is featured on the relay of digital output 8; • type AR: alarm is featured on the relay of digital output 8 and causes the standby unit to take over; • type B: alarm is featured on the relay of digital output 13; • type BR: alarm is featured on the relay of digital output 13 and causes the standby unit to take over

……

66

Alarms

ACTIVE ALARMSPressing the key silences the alarm buzzer and the description of the alarm is shown on the display.If the cause of the alarm has been eliminated, the last alarm message can be reset by holding down the key for a few seconds. If the cause of the alarm has not been eliminated, the audible buzzer warning is switched on again. ALARM LOG SEQUENCETo be able to reconstruct the sequence in which alarms occurred, the microprocessor keeps the last 100 events in its memory. All logged alarms can be consulted in series by pressing the key while you are on the STATUS Screen.

67

Alarms

Water flow alarm. It is enabled in all chillers without any on-board pump and it is activated when the flow switch opens. The unit is stopped.

Water flow alarm. It is enabled in all chillers with on-board pumps and it is activated when the flow switch opens. It can be due to a malfunctioning of the flow switch or the pump. The unit is stopped.

Warning which inform about a probable malfunctioning of the flow switch. This alarm appears when the unit starts (i.e. when the water flow rate reaches its nominal value) and the flow switch does still remain closed. When the unit is off and there is not any water flow rate, the flow switch must be open; when the unit starts, and the contact is found to be closed, that alarm appears informing there is something wrong on the water side. It doesn’t stop the unit. The reasons for this alarm could be two:•Faulty water flow switch with its contact permanently closed (in order to check this point, it is enough to stop the pump and check if the contact is open (refer to the electrical drawing and the I/O masks on the controller).•External pumps not activated by the unit’s controller.

AlarmLoss of Water FlowCheck Hydraulic

Circuit

AlarmLoss of Water FlowCheck Hydraulic

Circuit

AlarmFlowswitch FailureCheck Functionality/Elctr.Connections

AlarmFlowswitch FailureCheck Functionality/Elctr.Connections

AlarmLoss Of water FlowCheck Pump/Hydraulic

Circuit

AlarmLoss Of water FlowCheck Pump/Hydraulic

Circuit

68

Alarms

MAINS PHASE SEQUENCE ERROR OR LIMITS EXCEEDEDThe compressor must rotate the planned way or efficiency will be lost.The mains phase sequence may call for a direction of rotation other than the envisaged one in units with a three-phase power supply only. In this case, as soon as the unit is powered, the microprocessor immediately goes into an alarm state, impeding any other manoeuvre.In this case, disconnect the unit’s power supply and swap two of the supply phases over.

Circuit 1 low-pressure pre-alert. This re-sets automatically after 60 seconds. If it is activated for 4 times in a row within the period of one hour, the alarm is activated (it is necessary to reset it from the keyboard). Reporting the same for Circuit 2.

Circuit 1 low-pressure alarm. Reporting the same for Circuit 2.

AlarmMains Phase Error/Volt.Out of Limit

(Aut. Reset)

AlarmMains Phase Error/Volt.Out of Limit

(Aut. Reset)

PrealarmCirc. 1 Low PressureCheck Fridge CircuitRefrigerant Charge

PrealarmCirc. 1 Low PressureCheck Fridge CircuitRefrigerant Charge

AlarmCirc. 1 Low PressureCheck Fridge CircuitRefrigerant Charge

AlarmCirc. 1 Low PressureCheck Fridge CircuitRefrigerant Charge

69

Alarms





PrealarmCirc. 1 High Press.Check Fridge Circuit

And/Or Condenser

PrealarmCirc. 1 High Press.Check Fridge Circuit

And/Or Condenser

AlarmCirc. 1 High Press.Check Fridge Circuit

And/Or Condenser

AlarmCirc. 1 High Press.Check Fridge Circuit

And/Or Condenser

Circuit 1 High-pressure pre-alert. This re-sets automatically after 60 seconds. If it is activated for 4 times in a row within the period of one hour, the alarm is activated (it is necessary to reset it from the keyboard). Reporting the same for Circuit 2.

High pressure alarm for circuit 1 for the intervention of the high pressure switch with manual re-set. Reporting the same for Circuit 2.

Circuit 1 Antifreeze pre-alert. Reporting the same for Circuit 2.

Circuit 1 Antifreeze alarm. Reporting the same for Circuit 2.

Pump 1 thermal cut-out (or contactor fault) alarm. Reporting the same for Circuit 2.

Free-Cooling Pump thermal cut-out (or contactor fault) alarm.

AlarmPump 1 Not Running Check Safemotor/

Contactor

AlarmPump 1 Not Running Check Safemotor/

Contactor

AlarmPump FC Not Running

Check Safemotor/Contactor

AlarmPump FC Not Running

Check Safemotor/Contactor

70

Alarms

Compressor 1 thermal load alarm. Activated by opening of the thermo-magnetic contact switch IM (see attached electrical diagram).Reporting the same for the other compressors.

Compressor 1 integrated alarm protection. Activated by opening of the internal protection contact of the compressor. Checking of the electrical absorption or oil temperature.Reporting the same for the other compressors.

Heat recovery not possible alarm. The alarm indicates if the recovery request has caused the compressor operation to be outside the operating limits permitted of if the high pressure threshold has been exceeded 4 times in a row within the period of one hour.

Incorrect password entered alarm. Refers to an attempt to access the setting screen or configuration with the wrong password three times in a row.

AlarmCompress.1 Overload

Check Amperage

AlarmCompress.1 Overload

Check Amperage

AlarmComp.1 Integr.Prot.

Check Amperage/Oil Temp.

AlarmComp.1 Integr.Prot.

Check Amperage/Oil Temp.

AlarmHeat Recoverynot Possible

(Out of Limits)

AlarmHeat Recoverynot Possible

(Out of Limits)

AlarmAttempt to AccessWith Wrong Password(Min. 3 Occurences)

AlarmAttempt to AccessWith Wrong Password(Min. 3 Occurences)

71

Alarms

AlarmWater in Sensor

Failed/Disconnected:Check Sensor/Connect.

AlarmWater in Sensor


AlarmWater Out Sensor


AlarmWater Out Sensor


AlarmWater Tank Sensor


AlarmWater Tank Sensor


AlarmExt. Air temp. sensorFailed/Disconnected:Check Sensor/Connect.

AlarmExt. Air temp. sensorFailed/Disconnected:Check Sensor/Connect.

AlarmC.1 Discharge Sensor Failed/Disconnected:Check Sensor/Connect.

AlarmC.1 Discharge Sensor Failed/Disconnected:Check Sensor/Connect.

AlarmLiquid Refr.1 SensorFailed/Disconnected:Check Sensor/Connect.

AlarmLiquid Refr.1 SensorFailed/Disconnected:Check Sensor/Connect.

AlarmCirc.1 Evap.P.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmCirc.1 Evap.P.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmCirc.1 Cond.P.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmCirc.1 Cond.P.SensorFailed/Disconnected:Check Sensor/Connect.

Service Al.Pump 1

Exceeded 00000 RunHours

Service Al.Pump 1


Service Al.FC Pump


Service Al.FC Pump


Service Al.Compressor 1

Exceeded 00000 RunHour







Service Al.Pump 2


Service Al.Pump 2


Alarms for sensor failed/disconnected

Warnings for overshooting of the set hours of operation

AlarmEXV 1 Evap.T.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmEXV 1 Evap.T.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmEXV 1 Evap.P.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmEXV 1 Evap.P.SensorFailed/Disconnected:Check Sensor/Connect.

AlarmComp.1 Curr.Sensor


AlarmComp.1 Curr.Sensor


72

Alarms

AlarmC.1 Oil Low Press.:Check Delta Press.Condens.- Evap.

AlarmC.1 Oil Low Press.:Check Delta Press.Condens.- Evap.

Circuit 1 oil low pressure sensor fault alarm. Reporting the same for circuit 2.

Break in LAN warning.

Warning of Lan interruption between control boards 1 and 2

Service Al.Lan Interrupted

Units Not Connected:1,2,3,4,5,6,7,8,9,10

Service Al.Lan Interrupted

Units Not Connected:1,2,3,4,5,6,7,8,9,10

AlarmLAN: Circ.2 Board

Not Connected

AlarmLAN: Circ.2 Board

Not Connected

73

Alarms

AlarmCirc.1 EXV Driver:Not responding(Tlan failure)

AlarmCirc.1 EXV Driver:Not responding(Tlan failure)

Alarm activated following an error in the tLAN connection, between the driver EVD400 and the pCO1 control board.Reporting the same for circuit 2.

Alarm activated in conditions of excessive evaporation pressure, or rather when MOP is above the set threshold, for a time period longer than the Alarms Delay MOP. Reporting the same for circuit 2.

Alarm activated in conditions of low evaporation pressure, or rather when LOP is lower than the set threshold, for a time period longer than the Alarms Delay LOP.Reporting the same for circuit 2.

Alarm activated in conditions of low superheating, for a time period longer than the Alarms Delay Low SH.Reporting the same for circuit 2.

Alarm activated when the driver of the compressor in operation, remains without a power supply for more than 5 seconds. Reporting the same for circuit 2.

AlarmCirc.1 EXV Driver:

MOP Failed


MOP Failed


LOP Failed


LOP Failed

AlarmCirc.1 EXV Driver:Low Suct.SuperHeat

AlarmCirc.1 EXV Driver:Low Suct.SuperHeat

Alarm activated in conditions of low superheating, for a time period longer than the Alarms Delay Low SH.Reporting the same for circuit 2.

AlarmCirc.1 EXV Driver:Valve not closedBy Power Failure

AlarmCirc.1 EXV Driver:Valve not closedBy Power Failure

74

Alarms

AlarmCirc.1 EXV Driver:High Suction Temp.

AlarmCirc.1 EXV Driver:High Suction Temp.

Alarm activated following the aspiration temperature measured by the sensor of the EVD400 exceeding the value of the threshold set in High SH.Reporting the same for circuit 2.

Alarm activated when the compressor does not respect the minimum ON time corresponding to 300 seconds.Reporting the same for the other compressors.

Alarm activated when there is an interruption via tLAN between the pCO1 board and the pCOe board.

Alarm activated when compressor 1 exceeds the maximum set current threshold. Reporting the same for the other compressors.

AlarmCompressor 1

Minimun running timeNot Observe

AlarmCompressor 1

Minimun running timeNot Observe

AlarmpCOe:

Expansion boardNot Connected

AlarmpCOe:

Expansion boardNot Connected

AlarmHigh CurrentCompressor 1

AlarmHigh CurrentCompressor 1

75

Alarms

AlarmPls.Check Circuit 1Refrigerant Charge

AlarmPls.Check Circuit 1Refrigerant Charge

Alarm activated when the discharge temperature exceeds the condensation temperature by 40°C and at the same time the subcooling is lower than 3°C (5°C also taking into account the DP of the BTR). Reporting the same for the other compressors.

Alarm activated on opening of the thermal protection contact of the fans of circuit 1.Reporting the same for circuit 2.

AlarmFans Thermal Circ.1Check Electrical

Input

AlarmFans Thermal Circ.1Check Electrical

Input

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