Guardian Controls International RCC20 Series User manual

Guardian Controls International 1
RCC20X (C5L2)
Controller for Reciprocating Compressors.
Operation and Set-up Manual
General
Guardian Rcc20X (C5L2) Controller is a self-contained unit requiring a single electrical
supply to control and monitor up to 5 reciprocating compressors, each with motor and 2
loading valves. It provides inputs for pressures, temperatures and plant faults, and mains
outputs for compressor motor and capacity control. Local digital temperature and alarm
display is provided by the Guardian SKD9 key-switch display unit, which also gives access to
all control and configuration parameters. Full RS-485 communications enables the controller
to be integrated into a Guardian Consultant network to provide data logging and alarming.
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 2
CONTENTS
General ................................................................................................................................1
Termination and Layout.....................................................................................................3
RCC-20X ‘C5L2’ Input/Output Signals..............................................................................3
RCC-20X C5L2 Termination Wiring..................................................................................5
Compressor control...........................................................................................................6
Condenser control.............................................................................................................7
Getting Started....................................................................................................................8
Hardware configuration checks.........................................................................................8
SKD.9 Display unit operation...........................................................................................9
Configure unit address....................................................................................................10
Enter Passcode PP05 for normal changes.....................................................................10
Select Address................................................................................................................10
RS485 Communications .................................................................................................10
OPERATION ......................................................................................................................11
SD9 DISPLAY INDICATIONS............................................................................................11
Compressor Displays......................................................................................................11
TRIPS AND ALARMS........................................................................................................13
PACK AND COMPRESSOR SAFETY TRIPS ................................................................13
ALARMS .........................................................................................................................14
MODE CHANGE Compressors.......................................................................................15
GLOBAL RS485 COMMANDS........................................................................................15
CONDENSER FAN DISPLAY............................................................................................16
HIGH DISCHARGE PRESSURE....................................................................................16
FAN OVERLOAD TRIPS ................................................................................................16
MODE CHANGE CONDENSERS...................................................................................17
FAN CAPACITY MANUAL..............................................................................................17
USEFUL BUTTON SEQUENCES......................................................................................18
Reset ALARM or TRIP....................................................................................................18
Change suction control setpoint and differential.............................................................18
Check Unit Model............................................................................................................18
Select Stub, Case No and Address.................................................................................18
SETUP OPERATION.............................................................................19
Setup Functions (Normal) passcode 05 .........................................................................20
PP05 Menu.........................................................................................................................20
Compressors...................................................................................................................20
Condenser Fans..............................................................................................................20
CONTROL PARAMETER DEFINITIONS...........................................................................21
Configure the controller?.................................................................................................21
Compressor Control?......................................................................................................22
Test control outputs?.......................................................................................................27
Condenser Control?........................................................................................................27
Pressure transducer scaling?..........................................................................................30
COMMUNICATIONS..............................................................................31
SETUP / COMMISSIONING PARAMETERS.........................................32
PP05 Normal Menu Compressor Settings......................................................................32
PP05 Normal Menu Condenser Settings........................................................................34
PP11 Menu - Settings Level 2.........................................................................................35
INDEX ....................................................................................................36
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 3
Termination and Layout
RCC-20X ‘C5L2’ Input/Output Signals
C5L2 Main Unit
Analogue Inputs Terminal
P1 LP 23-/24+ Suction Pressure -1 to 24 bar
P2 HP 25-/26+ Discharge Pressure -1 to 24 bar
P3 SATP 27-/28+ Satellite Pressure -1 to 24 bar
P4 KWH 31/32 Kilo-Watt Hour Pulse
Analogue Inputs Terminal
Not used 4/5
Not used 4/6
Not used 4/7
Not used 4/8
Pack Suction 4/9 Suction temperature Degrees C.0 to 150
Pack Discharge 4/10 Discharge temperature Degrees C.0 to 150
Mains Input 230vac / 24vac
Phase fail 18 230vac / 24vac
Relay Outputs 230VAC 3 amp. Maximum Accumulative Current 10 amp.
RLY1 11 Compressor 1 Motor (50%) 230vac
RLY2 12 Compressor 1 Capacity (75%) 230vac
RLY3 13 Compressor 1 Capacity (100%) 230vac
RLY4 14 Compressor 2 Motor (50%) 230vac
RLY5 15 Compressor 2 Capacity (75%) 230vac
RLY6 16 Compressor 2 Capacity (100%) 230vac
SSR7 17 System Healthy 230vac
AC Supply 19 Neutral 230vac
20 Line 230vac
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 4
C5L2 Extention Unit 1
Digital Inputs Terminal
Common Neutral 1
C1 Running /Trip 2 Compressor 1 input 230vac
C2 Running /Trip 3 Compressor 2 input 230vac
C3 Running/ Trip 4 Compressor 3 input 230vac
Not Used 5 230vac
Oil Level 6 Pack oil level alarm/trip 230vac
HP safety trip 7 High pressure safety trip 230vac
LL level alarm 8 Liquid level low alarm 230vac
CFAN OVERLOAD 9 Condenser fan overload alarm 230vac
Not used 18 230vac
Relay Outputs 230 V AC 3 amp. Maximum Accumulative Current 10 amp.
RLY1 11 Compressor 3 Motor (50%) 230vac
RLY2 12 Compressor 3 Capacity (75%) 230vac
RLY3 13 Compressor 3 Capacity (100%) 230vac
RLY4 14 Condenser Fan 1 230vac
RLY5 15 Condenser Fan 2 230vac
RLY6 16 Condenser Fan 3 230vac
SSR7 17 Condenser Fan 4 230vac
AC Supply 19 Neutral 230vac
20 Line 230vac
C5L2 Extention Unit 2
Digital Inputs Terminal
Common Neutral 1
C4 Running 2 Compressor 4 running 230vac
C5 Running 3 Compressor 5 running 230vac
Not Used 4
Not Used 5
Not Used 6
Not Used 7
Not Used 8
Not Used 9
Not Used 18
Relay Outputs 230 AC 3 amp. Maximum Accumulative Current 10 amp.
RLY1 11 Compressor 4 Motor (50%) 230vac
RLY2 12 Compressor 4 Capacity (75%) 230vac
RLY3 13 Compressor 4 Capacity (100%) 230vac
RLY4 14 Compressor 5 Motor (50%) 230vac
RLY5 15 Compressor 5 Capacity (75%) 230vac
RLY6 16 Compressor 5 Capacity (100%) 230vac
SSR7 17 Not Used 230vac
AC Supply 19 Neutral 230vac
20 Line 230vac
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Guardian Controls International 5Guardian Controls International 5
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06
RCC-20X C5L2 Termination Wiring.
RS485 HIGHWAY
CABLE TO EXTENSION UNIT
16-X Extension
NOT AVAILABLE
10
9
8
7
6
NOT USED
C3 RUNNING / TRIP
C2 RUNNING /TRIP
C1 RUNNING /TRIP
NEUTRAL
5
4
3
2
1
DISCHARGE TEMP
SUCTION TEMP
NOT USED
NOT USED
NOT USED
NOT USED
5
27
10
9
KWH
DIG 4-20mA
SWP4
SWP3
KWH
AMP
LEV
8
7
6
32
31
30
29
28
+
A
OV DC
B
SUCT
FAN
DISC
4
3
E
2
26
-
+
25
24
-
+
0V
22
23
-
+
21
1
B
A
E
FAN 3
FAN 4
NOT USED
20
SSR7
19
18
17
16
230VAC Line
230VAC Neutral
FAN 2
FAN 1
RLY5
RLY6
RLY4
RLY3
15
14
13
RLY2
RLY1
12
11
15
PHASE FAIL
SYSTEM HEALTHY
20
19
TRIPS
SAFETY
SSR7
RLY6
18
17
16
C1 CAPACITY 75%
C1 MOTOR 50%
RLY5
RLY4
RLY3
14
13
12
RLY2
RLY1
11
SERIAL KEYSWITCH DISPLAY
MG0411
G
-
-
+4-20mA
+
+
-
4-20mA
4-20mA
C5L2
C1 CAPACITY 100%
C2 MOTOR 50%
C2 CAPACITY 75%
C2 CAPACITY 100%
C3 CAPACITY 75%
C3 MOTOR 50%
C3 CAPACITY 100%
OIL LEVEL TRIP
HP SAFETY TRIP
LL LEVEL TRIP
CFAN OVERLOAD
SELECT SOFF FOR CAPACITY OFF DURING START UP
SELECT SON FOR CAPACITY ON DURING START UP
SELECT CPOS FOR LOADING
SELECT CNEG FOR UNLOADING
WITH OPTO-ISOLATED INPUT
OPTIONAL
0-10V DC OUTPUT
FAN SPEED INVERTER
+
_
RCC-20
-1 to 24 bar
-1 to 24 bar
SUCTION PRESSURE
DISCHARGE PRESSURE
P1 LP
SATELITE PRESSURE
-1 to 24 bar
P2 H.P
P3 SATP
P4 KWH PULSE
16-X Extension
NOT AVAILABLE
10
9
8
7
6
NOT USED
NOT USED
C5 RUNNING / TRIP
C4 RUNNING / TRIP
NEUTRAL
5
4
3
2
1
C5 CAPACITY 100%
NOT USED
NOT USED
20
SSR7
19
18
17
16
C5 CAPACITY 75%
C5 MOTOR 50%
RLY5
RLY6
RLY4
RLY3
15
14
13
RLY2
RLY1
12
11
C4 CAPACITY 75%
C4 MOTOR 50%
C4 CAPACITY 100%
NOT USED
NOT USED
NOT USED
NOT USED
MODIFIED
230VAC Neutral
230VAC Line
SELECT dtF0 FOR COMPRESSOR RUNNING SIGNALS
SELECT dtF1 FOR COMPRESSOR TRIP SIGNALS
1
2
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GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06
Controller function.
This description is for the C5L2, which controls compressors and condenser fans.
Compressor control.
Compressors are staged on and off in response to changes in the measured suction
pressure. Which compressor is started or stopped depends on the following :-
Compressor Start.
1. Suction pressure is above the control set-point plus dead band. (See Page 22).
2. Stage up delay has elapsed. (See Page 24).
3. Compressor not at tripped status. (See Page 14)
4. Starts per hour timer, (anti-recycle timer), has elapsed.(See Page 24)
5. Delay after stop has elapsed. (See Page 24).
6. Compressor with the lowest run hours is then selected to start.
7. Stage up delay is reset.
Compressor increase capacity.
1. Suction pressure is above the control set-point plus dead band. (See Page 22).
2. Capacity loading delay has elapsed. (See page 24).
3. Next capacity loading output is used according to polarity selected.(See Page 22)
4. Capacity loading delay is reset.
Compressor decrease capacity.
1. Suction pressure is below the control set-point minus dead band. (See Page 22).
2. Capacity loading delay has elapsed. (See page 24).
3. Next capacity output is used according to polarity selected.(See Page 22)
4. Capacity loading delay is reset.
Compressor Stop.
1. Suction pressure is below the control set-point minus dead band. (See Page 22).
2. Maximum number of unloaded compressors has been reached(See Page 22)
3. Stage down delay has elapsed.(See Page 24)
4. Compressor with the longest run hours and shortest re-cycle delay is stopped.
5. Stage down delay is reset.
Compressor Standby
Any compressor .in the pack may be designated as the standby compressor 'Sb'.
The standby compressor only runs if one of the other compressors in the pack has tripped.
Compressor Enabled, Disabled, Not fitted
Any compressor .in the pack may be designated as disabled or not fitted.
Only 'Enabled' compressors run.

Guardian Controls International 7
Condenser control.
ans Start. sure is above control set-point plus dead band. (See Page 28).
s elapsed. (See Page 28).
This is description is for ‘Linear’ fan control.
F 1. Discharge pres
2. Stage delay ha
3. Fan is started in numerical order.
4. Stage delay is reset.
Fans Stop.
1. Discharge pressure is below control set-point minus dead band. (See Page 22).
2. Stage delay has elapsed. (See Page 28).
3. Fan is stopped in last on first off order.
4. Stage delay is reset.
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 8
Getting Started
uardi with
•ULTIMATE FLEXIBILITY
This m n designers, installers, service mechanics and supermarket
with the necessary information to achieve the above objectives.
All use
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
settings for setpoints, timers and addresses. All these settings need to be done using the
SKD.9 Keyswitch Display, so the understanding of the button operation of this unit is
essential.
) 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.
) Mains power input voltage and hardware switch and link option selections (if any are
required) must correspond to the selected unit model configuration.
d) 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.
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 SKD.9 Keypad/display unit is fitted correctly in its 6-way telephone socket.
f) The RS485 highway connections (if required) are wired to the correct terminals and the
screen drain wire is continuous to earth.
G an Controllers provide refrigeration engineers
•ASSURED MONITORING
•RELIABLE ALARMS
anual provides refrigeratio
personnel
rs require to know a few basic facts about this controller before successfully starting to
b
c
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 9
SKD.9 Display unit operation. splay unit to be plugged into the
lephone jack socket in the controller before any settings can be changed.
The SKD.9 is connected to the GUARDIAN controller via a 6-core telephone cable.
The SKD.9 Keyswitch/Display comprises a plastic enclosure housing a PCB with four
membrane pushbuttons, four LED displays and a 2-position Keyswitch.
GUARDIAN controllers require a SKD.9 Keyswitch Di
te
@in sequence.
?
se
Button operation shorthand.
subsequent displays will be shown in this handbook as
EX
Pre which then displays AUTO
Th ode to OFF and displays -OFF
Press ‘next’ Auto ‘enter’.
rEt= =-17
means the display alternates between the value identifier tag and the latest value.
rEt= =oc= FAIL
means the display alternately flashes between the value identifier tag (return air
temperature), the measured value ( open circuit ) and the alarm or trip message.
SKD.9 buttons have the following functions when pressed:-
’next’ button displays next value or menu selection
/’raise’ button raises a menu settings value or menu item selection.
<’lower’ button decreases a menu settings value or item selection.
’accept’ or ‘enter’ button accepts any alarm and is used for entering a menu
lection or settings value data entry .
The two position keyswitch is not used
To assist in easy set-up of control setpoints, delays, timers and other configuration settings,
the sequence of button presses and
below:
ii) A button symbol means press that button
iii) A display box shows the result of the last button press on the SKD.9 display.
AMPLES
@ Auto @ -OFF ? -OFF is shorthand for
ss ‘next’ button
Press ‘next’ button which then displays OFF
en press ‘enter’ button which changes the control m
@:@ Auto ?
repeatedly until is displayed then press
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06

Guardian Controls International 10
Configure unit address.
Enter Passcode PP05 for normal changes
Before any permanent change of controller settings are made then the correct entry of the
appropriate passcode is necessary.
Most normal system settings require entry of passcode PP05
@:@ SEt= ? PP00 /:/ PP05 ?
Press ‘next’ repeatedly until SEt is displayed then press ‘enter’. PP00 is displayed.
Press ‘raise’ repeatedly until PP05 is displayed and then press ‘enter’.
Select Address
.g. set-up unit for address 180.5
005
TANT PC for central alarm monitoring and
n be sent to
rther details
e
Enter Passcode as button sequence as above
@:@ Unit ?
@:@ A001 /:/ A180 ? A180
@ d005 ? d
@:@ End= ? =-26
RS485 Communications
When the correct highway address has been entered as above then the controller can
communicate with the Guardian CONSUL
temperature display. Control setpoints, defrost times and alarm limits may the
he controller from the PC rather than using the SKD9 Keyswitch display. For fut
see page 31
GUARDIAN Rcc20X ( C5L2) issue v1.0b 14/08/06