Carel Ir33 din User manual

ir33 platform

ir33

ir33 power

ir33 DIN

powercompact

powercompact small

mastercella

User manual

ENGLISH

IMPORTANT WARNINGS

CAREL bases the development of its products on decades of experience in HVAC, on the continuous

investments in technological innovations to products, procedures and strict quality processes with

in-circuit and functional testing on 100% of its products, and on the most innovative production

technology available on the market.

CAREL and its subsidiaries nonetheless cannot guarantee that all the aspects of the product and the

software included with the product respond to the requirements of the ﬁnal application, despite the

product being developed according to start-of-the-art techniques. The customer (manufacturer,

developer or installer of the ﬁnal equipment) accepts all liability and risk relating to the conﬁguration

of the product in order to reach the expected results in relation to the speciﬁc ﬁnal installation and/or

equipment. CAREL may, based on speciﬁc agreements, acts as a consultant for the positive

commissioning of the ﬁnal unit/application, however in no case does it accept liability for the correct

operation of the ﬁnal equipment/system.

The CAREL product is a state-of-the-art product, whose operation is speciﬁed in the technical

documentation supplied with the product or can be downloaded, even prior to purchase, from the

website www.carel.com.

Each CAREL product, in relation to its advanced level of technology, requires setup/conﬁguration/

programming/commissioning to be able to operate in the best possible way for the speciﬁc application.

The failure to complete such operations, which are required/indicated in the user manual, may cause the

ﬁnal product to malfunction; CAREL accepts no liability in such cases.

Only qualiﬁed personnel may install or carry out technical service on the product.

The customer must only use the product in the manner described in the documentation relating to the

product.

In addition to observing any further warnings described in this manual, the following warnings must be

heeded for all CAREL products:

• Prevent the electronic circuits from getting wet. Rain, humidity and all types of liquids or condensate

contain corrosive minerals that may damage the electronic circuits. In any case, the product should

be used or stored in environments that comply with the temperature and humidity limits speciﬁed in

the manual.

• Do not install the device in particularly hot environments. Too high temperatures may reduce the

life of electronic devices, damage them and deform or melt the plastic parts. In any case, the product

should be used or stored in environments that comply with the temperature and humidity limits

speciﬁed in the manual.

• Do not attempt to open the device in any way other than described in the manual.

• Do not drop, hit or shake the device, as the internal circuits and mechanisms may be irreparably

damaged.

• Do not use corrosive chemicals, solvents or aggressive detergents to clean the device.

• Do not use the product for applications other than those speciﬁed in the technical manual.

All of the above suggestions likewise apply to the controllers, serial boards, programming keys or any

other accessory in the CAREL product portfolio.

CAREL adopts a policy of continual development. Consequently, CAREL reserves the right to make

changes and improvements to any product described in this document without prior warning.

The technical speciﬁcations shown in the manual may be changed without prior warning.

The liability of CAREL in relation to its products is speciﬁed in the CAREL general contract conditions,

available on the website www.carel.com and/or by speciﬁc agreements with customers; speciﬁcally, to

the extent where allowed by applicable legislation, in no case will CAREL, its employees or subsidiaries

be liable for any lost earnings or sales, losses of data and information, costs of replacement goods or

services, damage to things or people, downtime or any direct, indirect, incidental, actual, punitive,

exemplary, special or consequential damage of any kind whatsoever, whether contractual,

extra-contractual or due to negligence, or any other liabilities deriving from the installation, use or

impossibility to use the product, even if CAREL or its subsidiaries are warned of the possibility of such

damage.

Disposing of the parts of the controller:

The controller is made up of metal and plastic parts and a lithium battery. All these

parts must be disposed of separately in compliance with the local standards in force on

waste disposal.

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ir33 +030220440 - rel. 2.0 - 01.05.2006

Content

1. INTRODUCTION 7

1.1 Main features ..........................................................................................................................................7

2.1 Display .....................................................................................................................................................9

2. USER INTERFACE 9

2.2 ir33,ir33 power and ir33DIN keypad................................................................................................10

2.3 powercompact, powercompact small and MasterCella keypad ................................................11

3. INSTALLATION 12

4. PROGRAMMING THE INSTRUMENTS 13

4.1 Modifying the parameters ...................................................................................................................13

4.2 Storing the new values assigned to the parameters .....................................................................13

4.3 Classiﬁcation of the parameters.........................................................................................................13

4.5 Setting the set point..............................................................................................................................14

4.6 Alarms with manual reset....................................................................................................................14

4.7 Procedure for setting the default parameter values......................................................................14

4.8 Semi-automatic serial address assignment procedure.................................................................14

5.1 Parameter copying key.........................................................................................................................15

5. ACCESSORIES 15

5.2 Remote control......................................................................................................................................16

5.3 RS485 serial interface...........................................................................................................................17

5.4 Programming kit ...................................................................................................................................17

5.5 Transformers (ir33, power, DIN).......................................................................................................17

5.6 RS485 serial board (DIN)....................................................................................................................17

5.7 RS485 serial board (MasterCella)......................................................................................................17

5.8 Door interlock (MasterCella)..............................................................................................................17

5.9 Terminals (MasterCella).......................................................................................................................18

5.10 Repeater display interface option ....................................................................................................18

5.11 IR00R*0000 display terminal ............................................................................................................18

5.12 PST00VR100 display terminal (powercompact) ...........................................................................18

5.13 Optional interface-repeater display connection cable ................................................................18

6. DESCRIPTION OF THE FUNCTIONS 19

6.1 Models .....................................................................................................................................................19

6.2 Testing the display and keypad on start-up ....................................................................................19

6.3 Switching the controller ON and OFF..............................................................................................20

6.5 Light management................................................................................................................................21

6.6 Defrost.....................................................................................................................................................21

6.7 New defrost activation modes ...........................................................................................................24

6.8 Pump down and low pressure...........................................................................................................26

6.9 Continuous cycle...................................................................................................................................26

6.10 High condensing temperature alarm..............................................................................................28

6.11 Control with dead band.....................................................................................................................29

6.12 Control with second step...................................................................................................................30

6.13 Anti-sweat heater function.................................................................................................................31

6.14 Antifreeze alarm...................................................................................................................................31

6.15 Special functions for the management of multiplexed cabinets (mpx)..................................32

6.16 HACCP (Hazard Analysis and Critical Control Point)...................................................................33

ENGLISH

7. DESCRIPTION OF THE OPERATING PARAMETERS 34

7.1 Temperature probe management parameters................................................................................34

7.2 Temperature control parameters........................................................................................................36

7.3 Compressor management parameters.............................................................................................38

7.4 Defrost management parameters......................................................................................................40

7.5 Alarm management parameters ........................................................................................................43

7.6 Fan management parameters.............................................................................................................50

7.7 General conﬁguration parameters.....................................................................................................51

7.8 HACCP alarm management parameters ..........................................................................................54

7.9 RTC and timed defrost management parameters..........................................................................55

7.10 Summary table of operating parameters........................................................................................56

8. ALARMS AND SIGNALS 58

8.1 Summary table of alarms and signals: display, buzzer and relay...............................................58

8.2 Table of alarms and signals: functions enabled/disabled ............................................................59

Fig. 1.b - ir33DIN

Fig. 1.c - powercompact - powercompact small

Fig. 1.a - ir33, ir33 power

Fig. 1.d - MasterCella

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ir33 +030220441 - rel. 2.0 - 01.05.2006

1. INTRODUCTION

The ir33 platform for refrigeration is a complete range of products made up of integrated electronic

microprocessor controllers with LED display, designed especially for the control of stand-alone refrigeration

units: These controllers are especially suitable in applications that require high load switching power, a

considerable number of outputs, functions and control with direct access from the keypad, high front

panel IP and, at the same time, a compact shape that signiﬁcantly reduces the overall dimensions.

The irr33 range is easy to install and ensures optimisation of production times for the manufacturer in

mass production.

Numerous models are available, providing the best solution for each application at the most competitive

price.

1.1 Main features

Power supply

Models are available with power supply in the following versions: 12Vac, 12 to 24 Vac/dc (switching),

230Vac or 115 to 230 Vac (switching).

All the models, furthermore, feature a low power mode to increase immunity to voltage drops.

When the voltage inside the instrument falls below a certain threshold, the unit switches off the display

so as to reduce power consumption, while still continuing to operate normally: the main relays remain

energised and, as soon as the voltage returns to the normal level, the display comes on again.

LED display

The controller is fitted with a very powerful and aesthetically pleasant display, with 3 digits and decimal

point, minus sign and icons to simplify the reading of the values and the operating status.

Alarm buzzer

All models are fitted with a buzzer to signal the alarms

Keypad

Keypad with 4 or 8 buttons, depending on the product, with clear indications and direct functions.

Remote control

To simplify the setting and display of the parameters, depending on the model, the instrument can be ﬁtted

with an infrared receiver to allow the use of the new compact remote control: this device can be used on

a series of ir33 controllers in the same room, without problems of interference. In fact, each controller is

identiﬁed by a different access code.

Duty setting

This function ensures the operation of the compressor even when the control probe (room probe) is

faulty. If the probe is disconnected or short-circuited, the compressor is activated at set intervals, with a

running time (in minutes) equal to the value assigned to the duty setting parameter (parameter C4), and

a ﬁxed OFF time of 15 minutes.

Smart defrost

All ir33 series controllers can, as standard, manage the defrost functions in new modes with much more

efﬁcient algorithms for optimising the times (see the paragraph on smart defrosts).

Multifunction input

All the instruments have two digital inputs that can be used in different modes, depending on the

value set for the “digital input conﬁguration” parameters (parameters A4 and A5 for ir33, ir33power,

powercompact small, + parameter A9 for ir33DIN, powercompact, MasterCella). These inputs can be

used to enable/disable the defrost, to manage serious alarms that require the immediate shut-down of

the unit (e.g. high pressure) or delayed shut-down of the unit (e.g. low pressure), or alternatively can be

conﬁgured to read NTC probes, with parameters /3 and /4 for ir33, ir33power, powercompact small,

+ parameter /A5 for ir33DIN, powercompact, MasterCella.

Multifunction output

According to the model, the ir33 family can be provided with an additional multi-function output for

remote control of the alarm signal for controlling additional units with ON/OFF activation.

Real time clock

The wide range also includes models ﬁtted with built-in real time clock.

Pump down

This function ensures the compressor is stopped only when the evaporator is discharged (see the

paragraph “Pump down and low pressure”).

Condenser

One of the new characteristics offered by these controllers is the possibility to manage, via an NTC probe

input, the condensing temperature for both the alarms and control functions, using the auxiliary output

conﬁgured by parameters H1 and H5.

Double evaporator

Two independent evaporators can be managed, connected to the same circuit. The end of defrost

temperatures are independent and can be set by parameters dt1/dt2.

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ir33 +030220441 - rel. 2.0 - 01.05.2006

HACCP

This function, increasingly required in the refrigeration market, is included as standard on all models with clock.

This allows the monitoring of critical points by measuring and recording the temperatures in the event of high

temperature alarms or power failures.

Up to 3 high temperature alarms and 3 alarms corresponding to power failures can be saved.

Light management

The ir33 platform has been enhanced by the introduction of the function for managing the light when

the door opens, set by parameter.

Keypad protection

The keypad and the remote control can be disabled to avoid tampering by unauthorised persons, above

all in the event when the controller is installed in an area open to the public.

Continuous cycle

The “continuous cycle” function ensures the operation of the compressor for the time set by the

corresponding parameter. This function is useful when a rapid reduction in the temperature is required.

Serial connection

The entire range has an RS485 serial port for network connection to supervisor or telemaintenance

systems using a shielded twisted pair cable.

Index of protection

The gasket inside the front panel and the material used to make the keypad guarantee IP65 protection

for the controller on the front panel.

Installation

The controllers are mounted using the screws at the front, or alternatively using two quick-ﬁt side brac-

kets, with compact dimensions, made from plastic.

In-circuit testing

The ir33 platform controllers are made using the most advanced SMD technology. All the controllers

undergo “IN-CIRCUIT TESTING” to check electrical operation of all components.

NTC probe

The controllers can manage two types of NTC probes (see parameter “/P”): standard version –50T90°C

(NTC0*HP*) or alternatively the model for high temperatures, up to 150°C (enhanced NTC –40T150°C).

Watch dog

This feature prevents the microprocessor from losing control over the unit even in the presence of

considerable electromagnetic disturbance. In the event of abnormal operation, the watchdog function

re-establishes the initial operating status.

Not all the competitors ﬁt their products with this safety feature.

Electromagnetic compatibility

The ir33 platform is compliant with EU standards on electromagnetic compatibility. The quality and the

safety of the ir33 controllers are ensured by the CAREL ISO 9001 certiﬁed design and production system

and by the CE mark on the product.

Network functions

The controllers feature management of multiplexed defrosts, remote alarm signals and the downloading

of the parameters via the local network.

Parameter selection

Selection of the parameters on the display simpliﬁed by the use of icons or with the standard Carel

procedure.

Conﬁguration of the digital inputs

The digital inputs can be conﬁgured and used as NTC probe inputs, by simply setting a parameter.

Connectors

Models ﬁtted with spade connectors or ﬁxed screw terminals.

Options

• programming key;

• RS485 serial interface can be added at any time;

• optional repeater display for models with switching power supply.

For further information, see the chapter on “Accessories”.

Number of relays

Number of relays Compressor Light

ir33 from 1 to 4 8A and 16 A

ir33power from 1 to 4 2Hp

ir33DIN from 1 to 5 16 A and 2Hp

powercompact from 2 to 5 8A, 16 A and 2Hp

powercompact small from 2 to 4 2Hp

masterCella from 3 to 5 30 A 70A (2Hp)

MasterCella

ir33, ir33 DIN, ir33 power,

powercompact, powercompact small

Fig. 2.a

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ir33 +030220441 - rel. 2.0 - 01.05.2006

2.1 Display

ICON FUNCTION DESCRIPTION Normal operation Start up

ON OFF BLINK

COMPRESSOR ON when the compressor starts. Flashes when the activation

of the compressor is delayed by safety times.

Compressor on Compressor off awaiting activation

FAN ON when the fan starts.Flashes when the activation of the

fan is prevented due to external disabling or procedures in

progress.

Fan on Fan off awaiting activation

DEFROST ON when the defrost is activated. Flashes when the activa-

tion of the defrost is prevented due to external disabling or

procedures in progress.

Defrost in progress Defrost not in progress awaiting activation

AUX Flashes if the anti-sweat heater function is active, ON when

the auxiliary output (1 and/or 2) selected as AUX (or LIGHT

in ﬁrmware version 3.6) is activated.

AUX auxiliary output

active(version 3.6 light auxiliary

output active)

AUX auxiliary output

not active

Anti-sweat heater function active

ALARM ON following pre-activation of the delayed external digital

input alarm. Flashes in the event of alarms during normal

operation (e.g. high/low temperature) or in the event of

alarms from an immediate or delayed external digital input.

Delayed external alarm (before

the time ‘A7’ elapses)

No alarm present Alarms in norm. operation

(e.g. High/low temperature) or

immediate or delayed alarm

from external digital input

CLOCK ON if at least one timed defrost has been set.At start-up,

comes ON for a few seconds to indicate that the Real Time

Clock is ﬁtted.

If at least 1 timed defrost event

has been set

No timed defrost

event set

Alarm clock ON if real-

time clock

present

LIGHT Flashes if the anti-sweat heater function is active, ON

when the auxiliary output (1 and/or 2) selected as LIGHT

is activated (in ﬁrmware version 3.6 it does not ﬂash in

anti-sweat heater mode and comes on when the dead band

output is active).

Light auxiliary output

on(version 3.6 dead band

auxiliary output active)

Light auxiliary output

off

Anti-sweat heater function

active(version 3.6 does not ﬂash

in anti-sweat heater mode)

SERVICE Flashes in the event of malfunctions, for example E2PROM

errors or probe faults.

No malfunction Malfunction (e.g. E2PROM error

or probe fault). Contact service

DISPLAY Shows temperature in range -50 to +150°C.The temperature

is displayed with resolution to the tenths between –19.9 and

+ 19.9 °C (59.9 in ﬁrmware revision 3.4). The display of the

tenths can be disabled by setting a parameter.

HACCP ON if the HACCP function is enabled.Flashes when there are

new HACCP alarms stored (HA and/or HF alarm shown on

the display).

HACCP function enabled HACCP function not

enabled

HACCP alarm saved (HA and/or

HF)

CONTINUOUS

CYCLE

ON when the CONTINUOUS CYCLE function is activated.

Flashes if the activation of the function is prevented due to

external disabling or procedures in progress (E.g.: minimum

compressor OFF time).

CONTINUOUS CYCLE opera-

tion activated

CONTINUOUS CYCLE

function not activated

CONTINUOUS CYCLE operation

requested

Tab. 2.a

2. USER INTERFACE

ir33, ir33 power ir33 DIN

Fig. 2.b

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ir33 +030220441 - rel. 2.0 - 01.05.2006

Icon Normal operation Start up Automatic address

assignment request

pressing the button alone pressing together with other buttons

PRG/MUTE

If pressed for more than 5 seconds, accesses

the menu for setting the type “F” parameters

(frequent).Mutes the audible alarm (buzzer)

and deactivates the alarm relay

PRG+SET: if pressed together for more than 5 seconds,

accesses the menu for setting the type “C” parameters

(conﬁguration) or downloading the parameters.PRG+UP/

AUX: if pressed for more than 5s, resets any alarms with

manual reset

If pressed for more than 5

seconds at start-up, activates

the RESET default parame-

ters procedure

If pressed for more than 1

second, starts the automatic

address assignment pro-

cedure

aux

UP/AUX

If pressed for more than 1 s, activates deacti-

vates the auxiliary output.

UP/AUX+DOWN/DEF: if pressed together for more than 5

seconds, activates/deactivates continuous cycle operation.

UP/AUX +SET: if pressed together for more than 5 secon-

ds, starts the report printing procedure (if the controller is

connected to the printer interface).UP/AUX +PRG/MUTE:

if pressed together for more than 5 seconds, resets any

active alarms with manual reset.

def

DOWN/DEF

If pressed for more than 5 seconds activates a

manual defrost

DOWN/DEF +UP/AUX: if pressed together for more than 5

seconds activates/deactivates continuous cycle operation.

DOWN/DEF +SET: if pressed together for more than 5 se-

conds, displays a sub-menu used to access the parameters

relating to the HACCP alarms (‘HA’, ’HAn’, ’HF’, ’HFn’).

SET

If pressed for more than 1 second, displays

and/or sets the set point.

SET+PRG/MUTE: if pressed together for more than 5

seconds accesses the menu for setting the type “C”

parameters (conﬁguration) or downloading the para-

meters.SET+DOWN/DEF: if pressed together for more

than 5 seconds, displays a sub-menu used to access the

parameters relating to the HACCP alarms (‘HA’, ’HAn’,

’HF’, ’HFn’).SET+UP/AUX: if pressed together for more

than 5 seconds, starts the report printing procedure (if the

controller is connected to the printer interface).

Tab. 2.b

Procedure for displaying and deleting the HACCP alarms

1. Press T+SET for more than one second;

2. the display will show the name of the ﬁrst of the parameters of the HA and HF alarms;

3. use the S+Tbuttons to display the codes relating to the HA and HF alarms;

4. when having reached the desired parameter press SET to display the value;

5. if the selected parameter is HA or HF, us S+T, to scroll the year, month, day, hour, minutes and duration of the last HA or HF alarm activated.

e.g.: y03 M07 d22 h23 m57 t99 start again…

The sequence indicates that the last HA or HF alarm was activated on 22 July 2003 at 23:57 and lasted 99 hours.

Press SET again to return to the list of the parameters relating to the HA and HF alarms.

The following operations are possible from inside the menu:

a. delete the HACCP alarm by pressing T+SET for more than 5 seconds (the message rES indicates that the alarm has been deleted, the HACCP LED stops ﬂashing, the HA

and/or HF signal is also reset, and the monitoring of HA is reinitialised);

b. delete the HACCP alarms and the alarms saved (HAn, HA, HA1, HA2, HFn, HF, HF1, HF2) by pressing T, SET and Sfor more than 5 seconds (the message rES indicates

that the alarms have been deleted, the HACCP LED stops ﬂashing, the HA and/or HF signal is reset, the HAn, HA, HA1, HA2, HFn, HF, HF1, HF2 alarms saved are reset and

the monitoring of HA is reinitialised)

c. Normal operation can be resumed at any time by pressing the button for 3 seconds or waiting for the expiry of the session due to timeout (60 seconds) without pressing any

button.

2.2 ir33, ir33 power and ir33DIN keypad