Dixell Xc440c User manual

Electronic Controller for

Compressor Racks

XC440C

Instructions Manual

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Operating instructions cod. 1592001300

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INDEX

1. GENERAL WARNING 4

PLEASE READ BEFORE USING THIS MANUAL 4

SAFETY PRECAUTIONS 4

2. GENERAL DESCRIPTION 4

3. FIRST INSTALLATION 5

3.1 HOW TO SET THE KIND OF GAS 5

3.2 HOW TO SET THE RANGE OF THE PRESSURE PROBES 5

3.3 HOW TO SET THE KIND OF DISPLAY: RELATIVE OR ABSOLUTE PRESSURE 6

4. USER INTERFACE 7

4.1 DISPLAYING 7

4.2 KEYBOARD 7

4.3 THE ICONS 8

5. HOW TO SEE AND MODIFY THE SET POINT 8

5.1 HOW TO SEE THE SET POINT OF COMPRESSORS OR FANS 8

5.2 HOW TO MODIFY THE SET POINT OF COMPRESSORS OR FANS 8

6. PARAMETERS PROGRAMMING 9

6.1 HOW TO ENTER THE “PR1” PARAMETER LIST 9

6.2 HOW TO ENTER IN PARAMETERS LIST “PR2” 9

6.3 HOW TO CHANGE PARAMETER VALUES 9

7. HOW TO DISABLED AN OUTPUT 10

7.1 HOW TO DISABLED AN OUTPUT DURING A MAINTENANCE SESSION.10

7.2 OUTPUT DISABLED SIGNALLING.10

7.3 REGULATION WITH SOME OUTPUTS DISABLED.10

8. RUNNING HOURS OF LOADS 10

8.1 HOW TO DISPLAY THE RUNNING HOURS OF A LOAD.10

8.2 HOW TO RESET THE RUNNING HOURS OF A LOAD.11

9. ALARM MENU 11

9.1 HOW TO SEE THE ALARMS 11

10. USE OF THE PROGRAMMING “HOT KEY “ 12

10.1 HOW TO PROGRAM A HOT KEY FROM THE INSTRUMENT (UPLOAD) 12

10.2 HOW TO PROGRAM AN INSTRUMENT USING A HOT KEY (DOWNLOAD) 12

11. KEYBOARD LOCKING 12

11.1 HOW TO LOCK THE KEYBOARD 12

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11.2 TO UNLOCK THE KEYBOARD 12

12. LIST OF PARAMETERS 13

12.1 PLANT DIMENSIONING AND TYPE OF REGULATION.13

12.2 PROBES CONFIGURATION 14

12.3 OTHERS INPUTS CONFIGURATION 14

12.4 DISPLAY AND MEASUREMENT UNIT 15

12.5 COMPRESSORS REGULATION 15

12.6 FANS REGULATION 16

12.7 ALARMS – COMPRESSOR SECTION 16

12.8 ALARMS – FANS SECTION 16

12.9 OTHER 17

13. TYPE OF REGULATION 18

13.1 DEAD BAND – ONLY FOR COMPRESSORS 18

13.2 PROPORTIONAL BAND – FOR COMPRESSORS OR FANS 19

14. MOUNTING & INSTALLATION 20

15. ELECTRICAL CONNECTIONS 21

15.1 PROBES CONNECTION 21

16. RS485 SERIAL LINK 21

17. TECHNICAL FEATURES 22

18. ALARM LIST 22

18.1 TYPES OF ALARMS AND SIGNALLING MANAGED 22

18.2 ALARM MUTING 24

18.3 ALARM CONDITIONS – SUMMARY TABLE 24

19. WIRING CONNECTIONS 25

20. DEFAULT VALUE 26

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1. General warning

1.1 Please read before using this manual

•This manual is part of the product and should be kept near the instrument for easy and

quick reference.

•The instrument shall not be used for purposes different from those described hereunder. It

cannot be used as a safety device.

•Check the application limits before proceeding.

1.2 Safety Precautions

•Check the supply voltage is correct before connecting the instrument.

•Do not expose to water or moisture: use the controller only within the operating limits

avoiding sudden temperature changes with high atmospheric humidity to prevent formation

of condensation

•Warning: disconnect all electrical connections before any kind of maintenance.

•The instrument must not be opened.

•In case of failure or faulty operation send the instrument back to the distributor or to

“DIXELL s.r.l.” (see address) with a detailed description of the fault.

•Consider the maximum current which can be applied to each relay (see Technical Data).

•Ensure that the wires for probes, loads and the power supply are separated and far enough

from each other, without crossing or intertwining.

•Fit the probe where it is not accessible by the end user.

•In case of applications in industrial environments, the use of mains filters (our mod. FT1) in

parallel with inductive loads could be useful.

2. General description

The XC440C is designed to manage compressors or fans in a condensing system such as a

pack.

The compressors can be simple, multistage or with different capacities.

Control is by means of a neutral zone or proportional band and is based on the pressure or

temperature sensed in the LP suction (compressors) or HP (condenser) circuits. A special

algorithm

balances the run hours of the compressors to distribute the work load uniformly.

The controllers can convert pressure and display it as temperature.

The front panel offers complete information on the system’s status by displaying the suction

and condenser pressure (temperatures), the status of the loads, possible alarms or

maintenance conditions.

Each load has its own alarm input that is able to stop it when activated.

By means of the HOT KEY the controller can be easy programmed at power on.

The controller can be connected to the XJ500, controlling and monitoring system, thanks to the

serial TTL output, using the standard ModBus RTU protocol.

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3. First installation

At first installation, it’s necessary the following:

1. Select the kind of gas.

2. Set the range of the pressure probes.

In the following paragraph a short cut for the above operations.

Chapters 6 Parameters programming and 12 List of parameters will explain in detail these

operations.

3.1 How to set the kind of gas

The controller has memorised the relation between temperature and pressure for some gases.

The pre-set gases is: r404.

If another gas is used, act as in the following:

1. Enter the Programming mode by pressing the Set and DOWN key for 3s.

2. Select the “Pr2” parameter. Then enter the password 3 –2 1.

3. Select the FtyP, kind of gas, parameter.

4. Press the “SET” key: the value of the parameter will start blinking.

5. Use “UP” or “DOWN” to change the gas amount the following: . Select the gas among the

following: r22= R22; r404=R404A; 507=R507; 134=134; r717= ammonia.

6. Press “SET” to store the new value and move to the following parameter.

To exit: Press SET + UP or wait 30s without pressing a key.

NOTE: the set value is stored even when the procedure is exited by waiting the time-out to

expire.

3.2 How to set the range of the pressure probes

According to the part number a controller is pre-set to work with the following pressure probes:

XC440C – xxxxA, or XC440C – xxxxE: PP11: -0.5÷11 bar (-7÷160 PSI) - relative pressure;

XC440C – xxxxB: PP30: 0÷30 bar (0÷435PSI) - relative pressure

If the probes you’re using have a different range act as in the following:

To set the pressure range of the Probe use the parameters:

PA04: Adjustment of read out corresponding to 4mA

PA20: Adjustment of read out corresponding to 20mA

Practically these parameters has to be set with the start and end scale of the probe range.

WARNING: set a value correspondent to absolute pressure.

E.I. PP11 relative pressure transducer, range -0.5÷11.0 bar. PA04=0.50; PA20=12.00.

PP30 relative pressure transducer, range: 0÷30bar. PA04=1.00; PA20=31.00.

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How to do:

1. Enter the Programming mode by pressing the Set and DOWN key for 3s.

2. Select the “Pr2” parameter. Then enter the password 3 –2 1.

3. Select the PA04, adjustment of read out corresponding to 4mA, parameter.

4. Press the “SET” key: the value of the parameter will start blinking.

5. Set the lower value of the probe range (lower value +1 if the probe detects relative

pressure).

6. Push the

SET

key to confirm the value. The PA20: adjustment of read out

corresponding to 20mA parameter will be displayed.

7. Set the higher value of the range (higher value +1 if the probe detects relative pressure).

8. Push the SET key to confirm the value. Next parameter will be displayed.

Do the same things for the Probe 2, FA04, FA20 parameters.

3.3 How to set the kind of display: relative or absolute pressure

After setting the probe range by means of the PA04, PA20 parameters, it’s possible to select if

the absolute or relative pressure has to be displayed.

The controller is pre-set for RELATIVE PRESSURE displaying.

If the absolute pressure has to be displayed, act as in the following:

9. Enter the Programming mode by pressing the Set and DOWN key for 3s.

10. Select the “Pr2” parameter. Then enter the password 3 –2 - 1.

1. Select by pushing the UP key the rELP parameter.

2. Push the SET to modify the value.

3. Set the AbS value and push the SET key to confirm it.

To exit: Press SET + UP or wait 30s without pressing a key.

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4. User interface

4.1 Displaying

UPPER DISPLAY LOWER DISPLAY ICONS

Temperature Pressure -Working loads

-Measurement unit

-Alarm or status Icons

4.2 Keyboard

SET To see or modify the set point. in programming mode it selects a parameter or confirm

an operation.

Alarm menu: By holding it pressed for 3s, the current alarm is erased.

(UP) To enter the Alarm menu.

In programming mode: it browses the parameter codes or increases the displayed

value.

With Hot key inserted: it starts the Hot key programming procedure.

(DOWN)In programming mode: it browses the parameter codes or decreases the

displayed value.

Manual restart of loads: By holding it pressed for 3s, it switches on again loads

previous locked by a safety digital input alarm.

/CLOCK To display the loads running hours.

By holding it pressed for 3s the Maintaining menu is entered.

KEY COMBINATIONS

To lock and unlock the keyboard.

SET +

To enter the programming mode.

SET +

To exit the programming mode.

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4.3 THE ICONS

LED FUNCTION MEANING

ON Celsius degrees

ON Fahrenheit degrees

bar ON bar displaying

PSI ON PSI displaying

ON Load 1 on

Flashing Load 1 is waiting to start (1HZ). or digital input alarm for Load 1 (2Hz).

o Load 1 in maintenance status (2Hz).

ON Load 2 on

Flashing Load 2 is waiting to start (1HZ). or digital input alarm for Load 2 (2Hz).

o Load 2 in maintenance status (2Hz).

ON Load 3 on

Flashing Load 3 is waiting to start (1HZ). or digital input alarm for Load 3 (2Hz).

o Load 3 in maintenance status (2Hz).

ON Load 4 on

Flashing Load 4 is waiting to start (1HZ). or digital input alarm for Load 4 (2Hz).

o Load 4 in maintenance status (2Hz).

ON The Maintenance menu has been entered

Flashing One or more loads have been placed in maintenance status

ON Alarm is happening

ON All the stored alarms have been seen

Flashing A new alarm has happened.

5. How to see and modify the set point

5.1 How to see the set point of compressors or fans

If the controller can manage compressors or fans, the set point are displayed in sequence,

otherwise only the set point of the enabled section will be displayed.

1) Push and release the SET key;

2) The Lower display will show the “SEtC” label for compressor/ “SEtF” label

for fans, will the Upper display will show its value.

To exit: push the SET key or wait for 30 without pressing any keys.

5.2 How to modify the set point of compressors or fans

WARNING: before setting the target set points for the first time, check and, if necessary,

modify the type of freon (par. FtyP) and the default unit of measurement (par. dEU) for

compressors and fans

PROCEDURE

1. Set the kind of freon by means of the FtyP parameter (see 3.1 How to set the kind of

gas)

2. Set the measurement unit (dEU par.).

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3. Check and if necessary modify the set point limits (LSE and HSE par.).

1. Push the SET key for more than 2 seconds;

2. The Lower display will show the “SEtC” label for compressor/“SEtF” label

for fans, will the Upper display will show its value flashing.

3. To change the Set value push the

within 30s.

4. To memorise the new value and pass to the normal display push the SET

key.

To exit: push the SET key or wait for 30 without pressing any keys.

6. Parameters programming

6.1 How to enter the “Pr1” parameter list

To enter the “Pr1” parameter list, user accessible, operate as follows:

1. Hold pressed the SET and DOWN key for 3s.

2. The controller displays the name of the parameter in the Lower display, its

value on the Upper display.

3. Press the “SET” key: the value of the parameter will start blinking.

4. Use “UP” or “DOWN” to change the value.

5. Press “SET” to store the new value and move to the following parameter.

To exit: Press SET + UP or wait 30s without pressing a key.

NOTE: the set value is stored even when the procedure is exited by waiting the time-out to

expire.

6.2 How to enter in parameters list “Pr2”

The “Pr2” parameter list is protected by a security code (Password).

SECURITY CODE is 321

To access parameters in “Pr2”:

1. Enter the “Pr1” level.

2. Select “Pr2” parameter and press the “SET” key.

3. The flashing value “0 --” is displayed.

4. Use

to input the security code and confirm the figure by pressing “SET” key.

5. Repeat operations 2 and 3 for the other digits.

NOTE: each parameter in “Pr2” can be removed or put into “Pr1” (user level) by pressing

“SET” +

. When a parameter is present also in “Pr1” decimal point of the lower display is on.

6.3 How to change parameter values

1. Enter the Programming mode.

2. Select the required parameter with

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3. Press the “SET” key the value start blinking.

4. Use

to change its value.

5. Press “SET” to store the new value and move to the following parameter.

To exit: Press SET + UP or wait 15s without pressing a key.

NOTE: the new programming is stored even when the procedure is exited by waiting the time-

out.

7. How to disabled an output

To disabled an output during a maintenance session means to exclude the output from the

regulation.

7.1 How to disabled an output during a maintenance session.

1. Push the CLOCK key for 3s.

2. The LED’s of the first output is switched on, the Lower displa

shows the “StA” label, while the Upper display shows the “On” label

if the first output is enabled, or the “oFF” label if the output is disabled for a maintenance

section.

With compressor with more steps all the LED’s linked to the compressor and the valves

are switched on..

3. Select the output by pressing the UP or DOWN key.

4. To modify the status of the output: push the SET key, the status of the output starts

flashing, then push the UP or DOWN to pass from “On” to “OFF” and viceversa.

5. Push the SET key to confirm the status and pass to the next output..

To exit: push the CLOCK key or wait 30 sec

7.2 Output disabled signalling.

If an output is disabled its led blinks (2 Hz)

7.3 Regulation with some outputs disabled.

If some outputs are disabled they don’t take part to the regulation, so the regulation goes on

with the other outputs.

8. Running hours of loads

8.1 How to display the running hours of a load.

The controller memorises the running hours of each load.

To see how long a load has been working follow this procedure:

1. Press and release the “CLOCK” key.

2. The led of the first output is switched on, the Upper Display shows

the “HUr” label, while the Lower Display shows the shows the

running hours of the first output.

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