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30GK Series
PRO-DIALOG Control
Air-Cooled Liquid Chillers
50 Hz
Installation, operation and maintenance instructions
1
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TABLE OF CONTENTS 1 - SAFETY CONSIDERATIONS..................................................................................................................................................4 1.1 - General .................................................................................................................................................................................4 1.2 - Avoiding electrocution........................................................................................
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5 - PRO-DIALOG PLUS CONTROL OPERATION ................................................................................................................. 27 5.1 - Start/stop control ................................................................................................................................................................ 27 5.2 - Heating/cooling selection ............................................................................................................................
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1 - SAFETY CONSIDERATIONS IMPORTANT: Risk of electrocution: Even when the main power isolator or 1.1 - General circuit breaker is off, it is still possible for certain compo- nents such as crankcase heaters and trace heaters to be Installation, start-up and servicing of equipment can be hazard- energised, since they are connected to a separate power source. ous if factors particular to the installation are not considered: operating pressures, electrical components, voltages and the Even when
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2 - GENERAL DESCRIPTION 2.2 - Abbreviations used 2.1 - General In this manual the circuits are called circuit A and circuit B. The compressors in circuit A are labelled A1, A2, A3 and A4. PRO-DIALOG Plus is a system for controlling units which use Those in circuit B are labelled B1, B2, B3 and B4. A1 and B1 reciprocating compressors*: are the lead compressors. Single or dual circuit Air or water-cooled condensers The following abbreviations are frequently used: Non-reversible heat pumps AI
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3 - HARDWARE DESCRIPTION The various control components are arranged in modules within the control cabinet: 3.1 - General Control module: This comprises the basic board, the user interface, the EXV control board and option boards, Control board as well as the customer’s terminal block. 2 Start-up module: This consists of the start-up boards, 9 1 compressor protection boards, as well as the compressor 3 circuit breakers and contactors. Fan module (air-cooled unit): Consists of one or two
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3.2.7 - Light emitting diodes on boards 3.2.3 - The user interface All boards continuously check and indicate the proper The user interface is in two parts: operation of their electronic circuits. A light emitting diode The main interface: This gives access to all of the (LED) lights on each board when it is operating properly. control parameters for the unit. It consists of a 2-digit primary display block and a secondary 4-digit display Red LED block with 10 LEDs and 5 buttons. The summary
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3.3.3 - The evaporator pumps 3.3.6 - Thermistors The controller can regulate one or two evaporator pumps, with These all have similar characteristics. automatic changeover between the two pumps. Evaporator entering water temperature sensor 3.3.4 - The condenser pump The evaporator entering water temperature sensor is installed in In appropriate cases the controller can regulate a condenser the evaporator wall in the free space at the side of the tube pump (for water-cooled units or air-cooled un
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3.4 - User connections The connections below are available at the customer’s terminal block. Some of them can only be used in special operating modes. For further details see the sections that describe the functions (section 5) and the configurations (section 4.2.1). NOTE: The bridge between terminals 32, 63 and 65 on the customer’s terminal block must not be removed. CONNECTION BLOCK DESCRIPTION CONNECTOR/CHANNEL TERMINAL DESCRIPTION REMARKS Alarm relay output, circuit A J3 / CH24 30A - 31A Ind
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4 - SETTING UP PRO-DIALOG PLUS CONTROL 4.1 - Local interface general features MAIN INTERFACE SUMMARY INTERFACE MAIN INTERFACE SUMMARY INTERFACE DUAL-CIRCUIT AIR-COOLED DUAL-CIRCUIT WATER-COOLED CHILLER INTERFACE CHILLER INTERFACE MENU BLOCK MENU BLOCK The local interface enables a number of operating parameters to Main interface be displayed and modified. It gives access to all PRO-DIALOG PLUS data and operating functions. It consists of: The interface consists of two distinct parts: the main in
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The summary interface (right hand section) includes a mimic The following operating types can be selected using the diagram of the unit, together with push-buttons and LEDs. It Start/Stop button: gives quick access to the main operating parameters of the unit. OPERATING TYPES SUMMARY INTERFACE LEDS 4-DIGIT DISPLAY DESCRIPTION LED INDICATION WHEN LIT LOFF Local Off. The unit is halted in local mode. Green LED: L-On Local On. The unit is in local control mode and is authorised The unit is authori
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4.3 - Menus NOTE: The access to a sub-menu may require entering a password. This is automatically requested. See section 4.5.7.2. 4.3.1 - Selecting a menu The MENU button authorises you to select a menu from the 10 The example below shows how to modify the value of item 1 main menus that are available. Each time you press this button in the Setpoint menu. one of the 10 LEDs lights up in turn alongside each of the MODIFYING THE VALUE OF A PARAMETER icons representing a main menu. The active menu
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4.4 - General menu structure 13 MAIN MENUS STATUS TEMPERATURES PRESSURES SETPOINTS INPUTS OUTPUTS CONFIGURATION ALARMS ALARMS HISTORY RUNTIME SUB-MENUS RUNTIME 2 RUNTIME 1 USER SERVICE FACTORY MAINTENANCE [RuntiME 2] [RuntiME 1] [USEr] [SErviCE] [FACtorY] [MAintEnAnCE] SUB-SUB-MENUS USER 1 USER 2 SCHEDULE 1 SCHEDULE 2 HOLIDAYS HOUR + DATE BROADCAST SERVICE 1 SERVICE 2 SERVICE 3 MASTER/SLAVE [USEr 1] [USEr 2] [SCHEduLE 1] [SCHEduLE 2] [HoLidAy] [dAtE] [brodCASt] [SErviCE 1] [SErviCE 2] [SErviCE 3
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4.5 - Menu tree structure MENU 14 ITEM STATUS TEMP PRESSURES SETPOINTS INPUTS OUTPUTS CONFIG ALARMS ALARMS HIST RUNTIMES 0 Default display Evaporator water Discharge pressure, Cooling setpoint 1 Contact 1: remote on/off Compressor status, SUB-MENU: Number of active alarms/ Historic alarm code 1 SUB-MENU: entering temp. circuit A circuit A User Configuration [USEr] resets Runtimes 1 1 Active modes Evaporator water Suction pressure, circuit Cooling setpoint 2 Contact 2: remote Compressor status, S
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4.5.1 - Description of the Information menu INFORMATION MENU [3] ITEM FORMAT UNITS DESCRIPTION 0 Automatic display mode. It cycles through the following displays: ±nn.n °C 1: Controlled water temperature: temperature of the water that the unit tries to maintain at the control point. 2: Unit operating type LOFF - Local Off L-On - Local On Local On - based on unit clock. L-Sc - CCn - CCN Control. rEM - Remote Control MASt - Master unit 3: Unit status Off: Unit is stopped and not authorised to sta
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DESCRIPTION OF OPERATING MODES (ITEM 1 OF THE INFORMATION MENU) MODE # MODE NAME DESCRIPTION 7 Delay at start-up active The delay at start-up operates after the unit has been switched on. If the delay has not expired, the mode is active. The delay is configured in the User1 configuration menu. 8 2nd cooling setpoint active The second cooling setpoint is active. See section 5.7.1 9 Setpoint reset active In this mode, the unit uses the reset function to adjust the leaving or entering water temper
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4.5.4 - Description of the Setpoints menu SETPOINTS MENU [2] ITEM FORMAT UNITS RANGE COMMENTS 0 ±nn.n °C See table below This item lets you display and modify Cooling setpoint 1* 1 ±nn.n °C See table below This item lets you display and modify Cooling setpoint 2* 2 nnn °C See table below This item lets you display and modify Heating setpoint*, only displayed for heat pumps. 3 [1] nnn °C See table below This item lets you display and modify the condensing setpoint*. It is used by the control to r
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4.5.5 - Description of the Inputs menu INPUTS MENU [2] ITEM FORMAT UNITS COMMENTS 0 OPEn/CLoS - Remote contact 1 status This contact is used to start (contact closed) and stop (contact open) the chiller. It is only valid, if the unit is in the remote operating control (rEM) mode. 1 OPEn/CLoS - Remote contact 2 status This contact is used to select a cooling only setpoint, if the unit is in cooling mode and in the remote operating control (rEM) type. Contact open = csp1 Contact closed = csp2 2[1]
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OUTPUTS STATUS 2 AND TESTS MENU [2] [3] - cont. ITEM FORMAT UNITS DESCRIPTION 4 [1] tESt - Fan contactor status/test, circuit B - b1 = fan contactor assembly 1 - b2 = fan contactor assembly 2 b3 = fan contactor assembly 3 b4 = fan contactor assembly 4 This item permits display of the fan stages. It also permits independent testing. In test mode the direction arrows permit successive display of 0001, 0010, 0100 and 1000, so as to in turn force authorisation of each output. 5 tESt Alarm command st
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4.5.6.3 - Manual tests The menus User 1 [USEr 1] and User 2 [USEr 2] are pass- This function allows the user to test the outputs individually, if word-protected. The other menus are directly accessible, except the machine is completely shut down (LOFF). To carry out a if item 12 of the User 1 menu (password for all configurations) manual test use the arrow keys to access the output to be tested has been validated. and press the Enter key (longer than 2 seconds) to activate the modification mode.
