Guardian Controls International RCC-50 User guide

Guardian Controls International Ltd 1
GUARDIAN RCC-50
Reciprocating Compressor Controller
•Single-stage or Dual-stage Reciprocating compressor controller
•Pressure, temperature, capacity% and load% displays
•Suction pressure setpoint control of up to 4 capacity loading valves
•Alarm and trip monitoring
•Multiple pack/compressor system control
•Local panel operation and set-up of pack configuration & control modes
•Communications for remote monitoring and set-up
Operation and Setup Manual
The GUARDIAN RCC-50 Compressor Pack Controller provides suction pressure setpoint
control and alarm monitoring for either a single-stage or a dual-stage large industrial
reciprocating compressor with up to 4 loading valves.
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Contents
GUARDIAN RCC-50................................................................................1
GETTING STARTED................................................................................4
BUTTON OPERATION SHORTHAND.................................................................................5
HARDWARE CONFIGURATION CHECKS.........................................................................5
CONFIGURE UNIT MODEL, SYSTEM No & ADDRESS ....................................................6
Enter Passcode.................................................................................................................6
Select Unit Model..............................................................................................................6
Select System No and Address ........................................................................................7
RS485 Communications ...................................................................................................7
UNIT MODELS.........................................................................................8
OVERVIEW ..........................................................................................................................8
Functions...........................................................................................................................8
Displays.............................................................................................................................9
Pushbuttons......................................................................................................................9
GENERAL SPECIFICATION..............................................................................................10
AVAILABLE UNIT MODELS (RCC-50).............................................................................10
RCC-50 Input/Output Signals........................................................................................11
RCC50 Fuse Ratings......................................................................................................12
RCC50 FUSES and LED LAYOUT.................................................................................13
RCC-50 Termination Wiring - SSrL model selection.......................................................14
RCC-50 Termination Wiring - dSrL model selection.......................................................15
OPERATION..........................................................................................16
RCC-50 PANEL LAYOUT..................................................................................................16
CONTROL STATUS LED LAMPS ..................................................................................16
LED LAMPS. ...............................................................................................................17
ALARM INPUTS..............................................................................................................17
SYSTEM STATUS DISPLAYS........................................................................................17
Enter System Setup Mode...........................................................................................17
Control status displays. ...............................................................................................18
Relay ouput status.......................................................................................................18
Inputs...........................................................................................................................18
Trip inputs....................................................................................................................19
SAFETY TRIP INDICATIONS.........................................................................................19
DISPLAY PUSHBUTTON OPERATION............................................................................20
‘view’ ...............................................................................................................................20
‘type’................................................................................................................................20
CONTROL PUSHBUTTON OPERATION..........................................................................22
“mode”.............................................................................................................................22
“Mode-MANUAL”.............................................................................................................22
“Mode-AUTOMATIC” ......................................................................................................22
“RESET”..........................................................................................................................23
“stop”...............................................................................................................................23
“start”...............................................................................................................................23
“Lower”............................................................................................................................23
“Raise”.............................................................................................................................23
SETTINGS CHANGE PUSHBUTTON OPERATION.........................................................24
“next”...............................................................................................................................24
“Accept”...........................................................................................................................24
“raise”..............................................................................................................................24
“Lower”............................................................................................................................24
ALARM ACCEPT AND RESET PUSHBUTTON OPERATION.........................................25
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SETPOINTS .......................................................................................................................26
CONTROL MODES............................................................................................................27
CONTROL..............................................................................................28
COMPRESSOR CONTROL OPERATION.........................................................................28
POWER UP.....................................................................................................................28
RUNNING .......................................................................................................................28
STOPPING......................................................................................................................30
MODES CHANGES ........................................................................................................30
TIMER SETPOINTS ...........................................................................................................30
SETUP ...................................................................................................31
Compressor Settings .......................................................................................................31
Unit Settings:...................................................................................................................31
Clock Settings.................................................................................................................31
System Settings..............................................................................................................32
Port Settings....................................................................................................................33
Hours run ........................................................................................................................33
Analog.............................................................................................................................33
PT....................................................................................................................................33
Test.................................................................................................................................34
Done................................................................................................................................34
TRANSDUCER SETUP & CALIBRATION.....................................................................35
TRANSDUCER SETUP...............................................................................................35
PRESSURE TRANSDUCER SETUP..........................................................................36
CAPACITY % SETUP .................................................................................................37
MOTOR LOAD % SETUP ...........................................................................................37
COMMUNICATIONS..............................................................................38
MONITOR HIGHWAY MODBUS COMMUNICATIONS (COM1).......................................38
CONTROL HIGHWAY COMMUNICATIONS (COM2) .......................................................39
Suction Group Control Communications........................................................................40
Setup / Commissioning Parameters ...............................................................................41
Settings display and change facilities............................................................................43
RCC-50 Enclosure wiring: for trips negative .................................................................45
RCC-50 Enclosure wiring: for trips positive. .................................................................46
FITTING NEW EPROM..........................................................................47
CORRECT POSITIONING OF EPROM ALIGN INDICATED INDENTS.............................47
Index ..................................................................................................................................48
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GETTING STARTED
Guardian Controllers provide refrigeration engineers with
•ULTIMATE FLEXIBILITY
•ASSURED MONITORING
•RELIABLE ALARMS
This manual provides refrigeration designers, installers, service mechanics and supermarket
personnel with the necessary information to achieve the above objectives.
All users require to know a few basic facts about this controller before successfully starting to
perform their design, commissioning, maintenance or operating functions.
a) All GUARDIAN controllers need to be set up with a unit model selection and other basic
b) settings for setpoints, timers and addresses.
c) The shorthand used in the following chapters for concisely expressing button pressing
and selection sequences to do all this set-up needs to be understood.
d) Mains power input voltage and hardware switch and link option selections
(if any are required) must correspond to the selected unit model configuration.
e) Since each controller can be configured in a number of different ways to perform flexible
refrigeration control then an understanding of how to find out what unit model is currently
selected, what it does and how it is connected, is also necessary.
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BUTTON OPERATION SHORTHAND
To assist in easy set-up of control setpoints, delays, timers and other configuration settings,
the sequence of button presses and subsequent displays will be shown in this handbook as
below:
ii) A button symbol, followed by text means press that button. “@accept”
iii) A double button, followed by text means press that button repeatedly. “@:@raise”
iv) A display box with the window above it shows the result of the last button press on
the display.
DISCHARGE OIL2
==== 2.0b
“@:@raise”
DISCHARGE OIL2
==== 2.5b
v) DISCHARGE OIL2 DISCHARGE OIL2
H.P. ==== trip ====
Means the display alternately flashes between identifier and trip message
HARDWARE CONFIGURATION CHECKS
Prior to switching on the GUARDIAN controller check that the hardware unit is the correct
type for the incoming mains voltage.
When satisfied that the correct type of controller is available then the following checks should
be made prior to controller installation or replacement
a) Ensure mains supply is wired correctly to the appropriate TERMINAL WIRING drawing for
the model selected.
b) Ensure that any transducer selector switches specified on the TERMINAL WIRING
diagram are in the correct state.
c) Ensure any shorting link selector pins specified on the TERMINAL WIRING diagram are
correctly fitted.
d) Ensure that probes are wired to the terminal WIRING DIAGRAM and the correct type of
thermistor or pressure transducer probes are fitted.
e) The RS485 highway connections (if required) are wired to the correct terminals and the
screen drain wire is continuous to earth.
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CONFIGURE UNIT MODEL, SYSTEM No & ADDRESS
Enter Passcode
Before any permanent change of controller settings are made then the correct entry of the
appropriate passcode is necessary.
The settings available for change on each passcode are as follows; Passcode
Passcode level 1 setpoints, low & high alarm settings 07
Passcode level 2 low & high trip settings and all level 1 09
Passcode level 3 system settings and levels 1 & 2 15
Enter passcode 15
DISCHARGE OIL2 “@view”= “SETPOINT” “@next” “@next”
pASS codE
DISCHARGE OIL2 DISCHARGE OIL2
==-= ==12
“@:@raise” ==-= ==15
“@accept”
Press “view” to select “SETPOINT”, then press the “next” button twice to enter
the passcode settings.
Press “raise” repeatedly until passcode 15 is selected and then press “accept”
Select Unit Model
Enter Passcode as button sequence above.
“@:@view”= “SYSTEM”
SUCTION OIL1 “@:@type”= “SAFETY TRIPS”
==sE tUP=
DISCHARGE OIL2
==== =yEs
“@accept”
DISCHARGE OIL2 DISCHARGE OIL2
==== Unit
“@accept” ==== SSrL
“@:@raise”
DISCHARGE OIL2
==== dSrL
“@accept”
Press ‘view’ repeatedly until ‘SYSTEM’ is selected.
Press ‘type’ repeatedly until ‘SAFETY TRIPS’ is selected. Press ‘accept’
‘Unit’ is displayed press ‘accept’
Display shows unit model currently selected which may be wrong.
Press ‘raise’ repeatedly until correct model is displayed (e.g.SSrL) and then press ‘accept’
which causes the display to wink briefly and display the new unit model selection (e.g dSrL)
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Select System No and Address
e.g. setup unit for system 65 compressor number 1 at address 195
Enter setup as button sequence as above
SUCTION OIL1
==sE tUP=
DISCHARGE OIL2
==== =yEs
“@accept”
DISCHARGE OIL2
DISCHARGE OIL2
==== Unit
“@accept” ==== dSrL “@next”
DISCHARGE OIL2
DISCHARGE OIL2
==== Sn01
“@:@raise” ==== Sn65 “@accept”
DISCHARGE OIL2 “@next”
==== Cn01
“@accept”
DISCHARGE OIL2
“@next”
==== A=01
“@:@raise”
DISCHARGE OIL2
==== A195
“@accept”“@:@next”
DISCHARGE OIL2
==== donE
“@accept”
RS485 Communications
When the correct system number, case/compressor number and highway address have
been entered as above then the controller can communicate with the GUARDIAN Consultant
Terminal PC for central alarm monitoring and temperature display. Control setpoints, timers
and alarm limits may then be sent to the controller from the PC.
For further details see page 38
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UNIT MODELS
Guardian controllers may be configured in a number of different ways dependent on unit
model selection. Each unit model fulfils a different refrigeration temperature monitoring and
control requirement. In order to perform the required refrigeration control then each model
has different uses for the controller’s input output signals. This section gives details of all the
model variations available for the controller and the way to connect the wiring to the plant
devices and measuring transducers.
OVERVIEW
Functions
The GUARDIAN RCC-50 controller provides facilities for:-
MONITORING
Measurement of 5 pressures and 5 temperatures and pack load for control, alarm and trip
display.
Calculation of differential pressures and superheat temperatures for control, alarm and trip
display.
Detection of digital input states on up to 8 safety trip inputs.
ALARMS
Detection after a preset guardtime of pressure and temperature High/Low alarms when the
compressor is in operation. Alarms are indicated by alternating a =Hi= or =Lo=
message on the appropriate temperature or pressure display.
TRIPS
Detection of pressure and temperature High/Low trips which stop the compressor. Trips are
indicated by the flashing red TRIPPED lamp and an alternating 'TRIP' message on the
appropriate temperature/pressure display.
Automatic trips include:-
high discharge temperature
low suction pressure
high discharge pressure
MCB overload
high/low suction superheat
low oil flow
Low oil level
Detection of safety trips which stop the compressor.
Trips are indicated by the flashing red TRIPPED lamp and an appropriate message.
Trips vary dependent on pack model configuration.
ie :- nncb ,H.P. ,diff,syst alternating with a trIP message on the
appropriate display.
CONTROLS
Control of compressor motors, and different combinations of loading valves dependent on
suction pressure setpoint.
Startup and run sequences use preset timers and limits plus compressor runhours to
determine control sequence actions.
Compressor stage is indicated by LED lamps on the control panel.
Suction pressure initiation of other compressors in the system via a RS485 link when in
REMOTE mode.
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Displays
i). SUCTION, DISCHARGE, OIL1 & OIL 2 .
SUCTION OIL1
2.1b 11.7b
4-digit 7-segment LED displays for display of
measurements setpoints/limits for temperatures and
pressures
DISCHARGE OIL2
The contents change dependent on ‘view’ and
10.2b 11.5b ‘type’ selections
ii). CAPACITY%.
CAPACITY%
100
3-digit 7-segment LED displays for display of loading timers
and capacity.
iii). MOTOR LOADING%.
MOTOR LOAD%
105
3-digit 7-segment LED displays for display of timers and
motor load.
iv). COMPRESSOR No.
No
1
1-digit 7-segment LED display
Pushbuttons.
All pushbuttons are embossed, tactile membrane switches.
start, stop, raise & lower used to control compressors when in manual mode.
RESET used after a trip to reset the compressor.
Mode, view & type used in conjunction with appropriate LED displays to select
control, display or settings change facilities.
accept, next used in conjunction with raise, lower and appropriate LED
displays during setpoint and limit settings changes.
Unaccepted alarms and trips are acknowledged by pressing accept.
Pushbuttons on the local control panel permit operator display of setpoints, pressures,
temperatures, alarm and trip settings and compressor runhours and status.
Setpoints, alarm and trip settings may be changed from the panel after entry of the
appropriate passcode.
The compressor may be selected to operate in one of three control modes:-
MANUAL, LOCAL or REMOTE MODES.
Safety interlocks, alarm, trip, startup and shutdown sequence controls are automatic in
all three modes.
In MANUAL mode, the each compressor may be individually started and stopped and the
pack capacity raised and lowered by operator pushbutton control from the local panel.
In LOCAL automatic mode, the compressor is started and stopped under control of the
suction pressure setpoint.
REMOTE automatic mode allows up to six RCC-50 units to be connected via a two-wire
communication link (RS485) to provide 6-unit system control.
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GENERAL SPECIFICATION
Power 110 or 230 Vac 50 hz 30VA (dependent on model type)
Operation 0 to 50ºC
Approx. Dimensions:
Control panel: 300 x 220mm
Control unit: 300 x 230 x 90mm
The GUARDIAN RCC-50 control unit comprises a printed circuit board in an IP65 ABS
enclosure for mounting at the rear of the compressor pack control panel with the display
unit mounted on the door and has overall dimensions:- 300 x 230 x 90mm.
The unit is fitted with two-part screw-clamp terminals for the connection of the
appropriate input/output signals. (See input/output section)
The GUARDIAN RCC-50 control panel comprises a membrane, pushbutton and display
panel mounted on the front of the control unit.
The membrane front panel has a Black background with white lettering and blue buttons with
dimensions 300x220mm.
AVAILABLE UNIT MODELS (RCC-50)
C1LF 1 compressors with 4x25% loading selection
4 condenser fans
8 trips
2 alarms Low Liquid Level
Condenser Fan Fail
1 input External Max demand unload i/p
C1L4 1 two-stage compressor with 0,30,60,80,100%
loading selection with intermediate pressure
4 condenser fans
8 trips
3 start signals
2 alarms Low Liquid Level
Condenser Fan Fail
1 input External Max demand unload i/p
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