Hussmann PCS Bedienungsanleitung

Protocol Control System (PCS) Users Manual

Document No 0709304

Date: 5/17/2005

1. Table of Contents

1. TABLE OF CONTENTS......................................2

2. TABLE OF FIGURES..........................................4

3. DISCLAIMER.......................................................6

4. INTRODUCTION.................................................7

4.1 ORGANIZATION ................................................7

5. PCS HARDWARE................................................8

5.1 PCS CONTROLLER ...........................................8

5.1.1 Input Power.............................................8

5.1.2 Display Contrast Adjust ..........................8

5.1.3 Status LEDs.............................................8

5.1.4 DIP Switches ...........................................8

5.1.5 Mounting .................................................9

5.1.6 Fuse.........................................................9

5.1.7 Controller Wiring....................................9

5.2 PCS EXPANSION BOARD..................................9

5.2.1 Input Power...........................................10

5.2.2 Mounting ...............................................10

5.2.3 Fuse.......................................................10

5.2.4 Expansion Board Wiring.......................10

5.3 PRESSURE TRANSDUCER ................................10

5.4 TEMPERATURE SENSOR..................................11

5.5 FIELD WIRING.................................................11

6. PCS FEATURES.................................................12

6.1 OVERVIEW .....................................................12

6.1.1 Circuit Control ......................................12

6.1.2 Suction Pressure Control.......................12

6.1.3 Lighting Control....................................12

6.1.4 Discharge Pressure Control..................12

6.1.5 Alarms ...................................................12

6.1.6 Maintenance/Diagnostics......................13

7. QUICK START...................................................14

7.1.1 Display and Keypad ..............................14

7.1.2 Login......................................................14

7.1.3 Main Status Screen................................15

7.1.4 Configuration Screens...........................15

7.1.5 Viewing/Changing Suction Pressure

Setpoint 15

7.1.6 Viewing Circuit Temperatures...............16

7.1.7 Viewing/Changing Circuit Temperature

Setpoint 16

7.1.8 Determining if a Circuit is in Defrost....16

7.1.9 Forcing a Defrost..................................17

7.1.10 Alarms ...................................................17

8. CONTROLLER OPERATION......................... 19

8.1 CIRCUIT CONTROL......................................... 19

8.1.1 Defrost.................................................. 19

8.2 PRESSURE CONTROL...................................... 19

8.2.1 Switchback............................................ 19

8.2.2 Pressure Control Algorithm.................. 19

8.3 CONDENSER CONTROL .................................. 20

8.4 MENU STRUCTURE ........................................ 20

8.4.1 Status Screens....................................... 20

8.4.2 Configuration Screens .......................... 20

8.4.3 Maintenance Screens............................ 20

8.4.4 Alarm Screen ........................................ 21

8.4.5 Screen Navigation................................. 21

8.5 SCREENS........................................................ 21

8.5.1 Status Screens....................................... 21

8.5.2 Configuration Screens .......................... 22

8.5.3 Alarms................................................... 32

8.5.4 Maintenance ......................................... 32

9. PUMP STATION................................................ 33

9.1 OVERVIEW..................................................... 33

9.2 HARDWARE ................................................... 33

9.3 OPERATION ................................................... 33

9.3.1 Pump Motor.......................................... 33

9.3.2 Fluid Cooler.......................................... 33

9.4 SCREENS........................................................ 34

9.4.1 Status Screens....................................... 34

9.4.2 Configuration Screens .......................... 34

9.5 ALARMS ........................................................ 37

9.5.1 Controller Reboot................................. 37

9.5.2 Spray Pump Fail................................... 37

9.5.3 Low Speed Fan ..................................... 37

9.5.4 High Speed Fan .................................... 37

9.5.5 Pump 1.................................................. 37

9.5.6 Pump 2.................................................. 37

9.5.7 High Discharge Pressure...................... 37

9.5.8 Low Discharge Pressure....................... 37

9.5.9 Pressure Sensor Fail............................. 37

9.5.10 Inlet Temp probe Fail........................... 37

9.5.11 Outlet Temp probe Fail......................... 37

9.5.12 Ambient Temp Fail ............................... 38

9.5.13 Alarm Winter Override......................... 38

10. SUPERVISORY SYSTEM ............................ 39

10.1 OVERVIEW..................................................... 39

10.2 SUPERVISORY CONNECTION WIRING............. 39

10.3 REQUIREMENTS............................................. 39

10.4 SOFTWARE INSTALLATION ............................ 39

10.5 HARDWARE INSTALLATION........................... 40

10.5.1 RS485 Adapter...................................... 40

10.5.2 PlantVisor Software Key....................... 40

10.6 REMOTE ACCESS ........................................... 41

10.7 OPERATION ................................................... 41

10.7.1 Running the PCS Supervisor................. 41

10.7.2 Navigation ............................................ 42

Protocol Control System Users Manual 2/12/01

10.7.3 Configuration ........................................42

10.8 RUNNING THE SYSTEM...................................46

10.8.1 Troubleshooting.....................................46

10.9 PCS SUPERVISORY SYSTEM SCREENS............46

10.9.1 General Information..............................46

10.9.2 PlantVisor Engine Screens....................46

10.9.3 Supervisory Main Screen.......................47

10.9.4 Unit Main Screen...................................47

10.9.5 System Setup..........................................48

10.9.6 Suction Group/Compressor Setup.........49

10.9.7 Aux Control and Temperature Monitor.49

10.9.8 Light Ckt................................................49

10.9.9 Info ........................................................50

10.9.10 Circuits..............................................50

10.9.11 Alarms ...............................................51

11. APPENDIX A- SUPERVISORY WIRING...53

12. APPENDIX B- TROUBLESHOOTING.......54

12.1 PCS TROUBLESHOOTING ...............................54

12.2 SUPERVISORY SYSTEM TROUBLESHOOTING...54

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Protocol Control System Users Manual 2/12/01

2. Table of Figures

Figure 1- PCS Controller.................................................8

Figure 2- Controller Wiring ............................................9

Figure 3 - PCS Expansion Board...................................10

Figure 4- Expansion Board Wiring ...............................10

Figure 5- PCS Pressure Probe .......................................11

Figure 6- PCS Temperature Probe ................................11

Figure 7- Controller Display .........................................14

Figure 8- Password Screen............................................15

Figure 9- Main Status Screen........................................15

Figure 10- Suction Group Configuration Screen...........15

Figure 11- Circuit Configuration Screen.......................16

Figure 12- Temp Setpoint Configuration Screen...........16

Figure 13- Circuit Maintenance Screen.........................17

Figure 14- Alarm Log Screen........................................17

Figure 15- Alarm Maintenance Screen..........................17

Figure 16- Alarm Confirmation Screen.........................18

Figure 17-Equal Horsepower Example .........................19

Figure 18 - PCS Menu Tree ..........................................20

Figure 19- Main Status Screen......................................21

Figure 20- Lighting Status Screen.................................22

Figure 21- Lighting Status Fields..................................22

Figure 22- Aux Processing Status Screen......................22

Figure 23- System Status Screen...................................22

Figure 24- System Configuration Screen 1 ...................22

Figure 25- System Configuration Screen 2 ...................23

Figure 26- System Configuration Screen 3 ...................23

Figure 27- System Configuration Screen 4 ...................23

Figure 28- System Configuration Screen 5 ...................23

Figure 29- System Configuration Screen 6 ...................24

Figure 30- System Configuration Screen 7 ...................24

Figure 31- System Configuration Screen 8 ...................24

Figure 32- System Configuration Screen 9 ...................24

Figure 33- System Configuration Screen 10 .................24

Figure 34- System Configuration Screen 11 .................25

Figure 35 - System Configuration Screen 12 ................25

Figure 36- System Configuration Screen 13 .................25

Figure 37- Circuit Configuration Screen 1....................25

Figure 38- Circuit Configuration Screen 2....................25

Figure 39- Circuit Configuration Screen 3....................26

Figure 40- Circuit Configuration Screen 5....................26

Figure 41- Circuit Configuration Screen 6....................26

Figure 42- Circuit Configuration Screen 7....................26

Figure 43- Circuit Configuration Screen 8....................27

Figure 44- Circuit Configuration Screen 9....................27

Figure 45- Circuit Configuration Screen 10..................27

Figure 46- Circuit Configuration Screen 11..................27

Figure 47- Circuit Configuration Screen 12..................27

Figure 48- Circuit Configuration Screen 13..................28

Figure 49- Circuit Configuration Screen 14..................28

Figure 50- Circuit Configuration Screen 15..................28

Figure 51- Copy Circuit Configuration Screen .............28

Figure 52- Suction Configuration Screen 1...................29

Figure 53- Suction Configuration Screen 2.................. 29

Figure 54- Suction Configuration Screen 3.................. 29

Figure 55- Suction Configuration Screen 5.................. 29

Figure 56- Suction Configuration Screen 6.................. 29

Figure 57- Suction Configuration Screen 7.................. 30

Figure 58- Discharge Configuration Screen................. 30

Figure 59- Lighting Configuration Screen 1................. 30

Figure 60- Lighting Configuration Screen 2................. 30

Figure 61- Lighting Configuration Screen 2A.............. 30

Figure 62- Lighting Configuration Screen 3................. 30

Figure 63- Lighting Configuration Screen 4................. 31

Figure 64- Aux Configuration Screen 1 ....................... 31

Figure 65- Aux Configuration Screen 2 ....................... 31

Figure 66- Aux Configuration Screen 3 ....................... 31

Figure 67- Aux Configuration Screen 4 ....................... 32

Figure 68- Release Configuration Screen..................... 32

Figure 69- Suction Group Maintenance Screen 1......... 32

Figure 70- Suction Group Maintenance Screen 2......... 32

Figure 71- PSC Main Status Screen ............................. 34

Figure 72- PSC Pump Status Screen............................. 34

Figure 73- PSC Pump Date/Time Screen ..................... 34

Figure 74- PSC Release Screen.................................... 34

Figure 75- PSC Password Screen................................. 35

Figure 76- PSC Configuration Screen 1....................... 35

Figure 77- PSC Configuration Screen 2....................... 35

Figure 78- PSC Configuration Screen 3....................... 35

Figure 79- PSC Configuration Screen 4....................... 35

Figure 80- PSC Configuration Screen 5....................... 35

Figure 81- PSC Configuration Screen 6....................... 36

Figure 82- PSC Configuration Screen 7....................... 36

Figure 83- PSC Configuration Screen 8....................... 36

Figure 84- PSC Configuration Screen 9....................... 36

Figure 85- PSC Configuration Screen 10..................... 37

Figure 86- PSC Configuration Screen 11..................... 37

Figure 87- PSC Alarm Screen ...................................... 38

Figure 88- Installation Screen....................................... 39

Figure 89- RS485 Adapter............................................ 40

Figure 90- PlantVisor Software Key ............................ 40

Figure 91- PlantVisor Engine Demo Mode.................. 41

Figure 92- Plantvisor Engine Screen............................ 41

Figure 93- Logon Screen.............................................. 41

Figure 94- Main Screen................................................ 42

Figure 95- Navigation Examples.................................. 42

Figure 96- Network Management Screen..................... 42

Figure 97- Site Configuration Screen........................... 43

Figure 98- Serial Line Configuration Screen................ 43

Figure 99- Modem Setup Screen.................................. 43

Figure 100- User Configuration Screen........................ 44

Figure 101- Add New User Screen............................... 45

Figure 102- Scheduler Configuration Screen ............... 45

Figure 103- Alarm Priorities Screen............................. 45

Figure 104- Device Alarm Settings.............................. 46

Figure 105- PlantVisor Engine Screen ......................... 47

Figure 106- PlantVisor Engine Detail Screen............... 47

Figure 107- PlantVisor Engine Close Screen ............... 47

Figure 108- Supervisory Main Screen.......................... 47

Page 4

Protocol Control System Users Manual 2/12/01

Figure 109- Unit Main Screen- No Alarms...................48

Figure 110- Main Screen With Alarms.........................48

Figure 111- System Setup Screen..................................49

Figure 112- Suction Group/Compressor Setup Screen..49

Figure 113- Pressure Graph...........................................49

Figure 114- Supervisory Temperature Monitor and Aux

Control Screen.......................................................49

Figure 115- Lighting Circuit Screen..............................50

Figure 116- Information Screen ....................................50

Figure 117- Circuit Setup Screen..................................50

Figure 118- Defrost Setup Screen .................................51

Figure 119- Circuit Temperature Graph........................51

Figure 120- Case Size Screen........................................51

Figure 121- Case Type Screen ......................................51

Figure 122- Supervisory Alarms Screen .......................52

Figure 123 - Supervisory Wiring...................................53

Page 5

Protocol Control System Users Manual 2/12/01

3. Disclaimer

The information contained in this manual has been

carefully checked and it believed to be accurate.

However, Computer Process Controls, Inc. assumes no

responsibility for any inaccuracies that may be contained

herein. In no event will Computer Process Controls, Inc.

be liable for any direct, indirect, special, incidental or

consequential damages resulting from any defect or

omission in this manual, even if advised of the

possibility of such damages. In the interested of

continued product development, Computer Process

Controls, Inc. Reserves the right to make improvements

to this manual, and the products described herein, at any

time without notice or obligation.

Page 6

Protocol Control System Users Manual 2/12/01

4. Introduction

This document describes the Protocol Control System

(PCS). The PCS is an electronic control system designed

specifically to control all functions of the Protocol

Refrigeration System.

4.1 Organization

This document is organized into a number of sections.

The first section is an overview of the hardware. A

“quick start” section is included next to enable users to

quickly get a minimum amount of information needed to

start using the controller. A detailed section follows.

The last section describes the PCS supervisory system.

It is recommended that the user familiarize himself with

the PCS system by reading all sections of this manual

before operation.

Page 7

Protocol Control System Users Manual 2/12/01

5. PCS Hardware

The following are components of the PCS system.

1) PCS Controller

2) PCS Expansion Board

3) PCS Pressure Transducer

4) PCS Temperature Probes

This document describes the elements of the PCS

components. The schematics included with each

Protocol Refrigeration System detail the connections that

are made to the components. Refer to the schematics for

connection details.

WARNING: The Controller and Expansion board use

low voltage (24 VAC) power. However, both units have

high voltage loads connected to them. Extreme caution

should be used when servicing these units. Failure to

observe caution could lead to injury or death.

5.1 PCS Controller

The PCS Controller is a microprocessor based system

that contains a built in display, keypad and I/O (relays

termperature inputs, pressure inputs and digital inputs).

It serves as the user interface and runs the algorithms that

control the protocol refrigeration system. Additional I/O

(relays, digital inputs and temperature inputs) can be

added using the PCS Expansion Board. The controller

contains all the I/O for all compressors in the Protocol

refrigeration system.

The temperature inputs must use the PCS temperature

sensors (described below) and the pressure inputs must

use the PCS pressure probes (described below).

Figure 1 shows a picture of the PCS Controller and

identifies the different parts of the Controller.

Figure 1- PCS Controller

5.1.1 Input Power

The Controller uses 24 VAC (+/-15%, 50/60

Hz) (Class II) power at 50 VA.

5.1.2 Display Contrast Adjust

The contrast of the display can be adjusted by

pressing and holding the ENTER and ESC keys

together and pressing the UP ARROW key to

increase the contrast or the DOWN ARROW

key to decrease the contrast. Refer to

paragraph 7.1.1 for an explanation of how to

identify the keys.

5.1.3 Status LEDs

There are two LED’s on the Controller that

indicate power status. If the Yellow LED is ON

this indicates that the unit is getting power. If it

is OFF, there is either no power to the unit or

the fuse is blown. The Red LED indicates the

status of the Pressure probe power output

(Connector J2 , terminals GND and +VDC). If

the Red LED is ON, there is a fault in the probe

supply. Most likely, the pressure probe is bad

or there is a short in the cable.

5.1.4 DIP Switches

The DIP Switches on the controller should

always be in the down (OFF) position.

Page 8

Protocol Control System Users Manual 2/12/01

5.1.5 Mounting

The Controller is mounted via Din rail mount.

The Controller can be removed from the

mounting by carefully pulling on the 3 small

tabs on the bottom of the controller and rotating

the Controller up. All connectors should be

removed from the unit before removing the

Controller from the mounting.

5.1.6 Fuse

The Controller has an internal fuse. If the

Controller will not power up and you have

verified that the controller is getting input

power, you should replace the fuse. Always

replace with the same type of fuse.

5.1.7 Controller Wiring

The field wiring for the expansion board is

shown in Figure 2. Field wiring for the

controller consists of temperature probes on

inputs 4 through 8.

Figure 2- Controller Wiring

5.2 PCS Expansion Board

The PCS Expansion board is used to provide additional

I/O (relays, digital termination inputs and temperature

inputs) to the PCS Controller. Typically, the expansion

board will contain the I/O for circuits (refrigeration valve

relays, temperature inputs and defrost termination

inputs). The Expansion board contains 8 relay outputs

(Normally Open/Normally Closed outputs), 8

Temperature inputs and 8 Digital inputs.

The temperature inputs must use the PCS temperature

sensors (described below).

The Expansion board is connected to the PCS Controller

by a communications cable (Beldon 8641 or equivalent).

The PCS system supports up to 4 expansion boards. The

address of the expansion board is determined by the

wiring of inputs AD0 and AD1. Table 1 lists the

expansion board address.

Table 1- Expansion Board Addressing

Expansion

Board AD1 AD0

Board 21OPEN OPEN

Board 3 OPEN 24 VAC2

Board 4 24 VAC OPEN

Board 5 24 VAC 24 VAC

Figure 3 shows a picture of the PCS Expansion board

and identifies the different parts of the board.

1The first expansion board is referred to as board 2. The main

controller is referred to as board 1.

2InTable 1, 24 VAC means tied to “G” terminal.

Page 9

Protocol Control System Users Manual 2/12/01

Figure 3 - PCS Expansion Board

5.2.1 Input Power

The Controller uses 24 VAC (+10%/-15%,

50/60 Hz) (Class II) power at 15 VA. Note that

if using the same transformer to power the

controller and expansion board, care must be

taken to connect the G terminals on both boards

to the same side of the transformer and the G0

terminals on both boards to the same side of the

transformer.

5.2.2 Mounting

The Expansion board is mounted via standoffs.

5.2.3 Fuse

The Expansion board has an internal fuse. If the

Expansion board will not power up and you

have verified that the controller is getting input

power, you should replace the fuse. Always

replace with the same type of fuse.

5.2.4 Expansion Board Wiring

The field wiring for the expansion board

consists of the temperature probes and defrost

termination sensors. Refrigeration valve relays

are factory wired to terminal blocks. Figure 4

shows the connection points for the field wiring.

Figure 4- Expansion Board Wiring

5.3 Pressure Transducer

The PCS system uses a 4/20 milliamp pressure

transducer. Inputs are provided for reading suction

pressure (optionally a second suction group pressure) and

discharge pressure. The same type of pressure

transducer is used for reading suction and discharge

pressure. The transducer is a 2 wire connection and is

polarity sensitive (refer to the Protocol schematics for

details). The system reads 0 to 362 PSI.

The wiring for the pressure transducer should not be

routed near cables carrying high voltage.

Figure 5 shows a picture of the pressure transducer.

Page 10

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