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ECKELMANN VS 3000 - User Manual

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eckelmann.de
VORSTAND: DR.-ING. GERD ECKELMANN, VORSITZENDER - DR.-ING. PETER CORDES, DR.-ING. FRANK-THOMAS MELLERT
VORSITZENDER DES AUFSICHTSRATES: HUBERTUS G. KROSSA AMTSGERICHT WIESBADEN HRB 12636
VS 3000 Pack Controller
Firmware V3.00

Table of Contents

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ECKELMANN VS 3000 Specifications

General IconGeneral
BrandECKELMANN
ModelVS 3000
CategoryController
LanguageEnglish

Summary

System Design of VS 3000

Digital inputs;outputs

Details on digital inputs and outputs for the basic VS 3000 configuration.

Analog inputs;outputs

Details on analog inputs and outputs for the VS 3000 controller.

SIOX Supply - Power supply for SIOX extension module

Information on power supply for SIOX extension modules.

New features compared to earlier versions

Overview of new features introduced in firmware versions 3.00 and 2.98.

Application of VS 3000

Compressor control (step controller)

Details on compressor control using step controller for single-circuit systems.

Low-pressure control;compressor control:

Explanation of low-pressure and compressor control methods.

Base load rotation

Description of base load rotation functionality for compressors.

Compressor monitoring

Details on compressor monitoring functions.

Load shedding

Explanation of load shedding functionality.

High-pressure control;fan control

Description of high-pressure and fan control methods.

Base load rotation;Fan overload protection

Information on base load rotation and fan overload protection.

Data archiving:

Overview of data archiving functions including messages, starts, and run times.

Liquid level monitoring

Details on monitoring functions such as motor overload, bursting disk, and pressure.

Discharge gas defrosting:

Information on discharge gas defrosting, specifically the D2D two-pipe system.

Function of VS 3000

3.1 System configuration

Description of the VS 3000's system configuration with LP and HP control loops.

Compressor control

Overview of compressor control functions including load shedding, base load rotation, and safety loop.

Low-pressure control (LP, compressor control) for single-circuit systems

Details on LP control for single-circuit systems using step or combined control.

High-pressure control (HP, condenser control) for single-circuit systems

Details on HP control for single-circuit systems using step or speed control.

3.2 Low-pressure control; Compressor control

Explanation of LP and compressor control methods.

Step controller

Explanation of step control for loading/unloading compressor stages.

Combined controller

Explanation of combined control for variable-speed compressors.

3.2.1 Setting parameters for LP transducer characteristic

Guide to setting LP transducer parameters for matching controller to transducer.

3.2.2 Neutral zone

Explanation of the neutral zone's function in low-pressure control.

3.2.3 Control algorithm

Description of the controller's cycle time and control algorithm.

3.2.4 Control algorithm with step controller

Detailed explanation of the control algorithm for step controllers, including setpoint comparison and step switching.

3.2.5 Control algorithm with combined controller

Explanation of the control algorithm for combined controllers, including P and I actions.

3.3 Loading and unloading fixed-speed compressors

Details on how fixed-speed compressors are loaded and unloaded based on capacity demands.

Compressor without capacity control

Graph illustrating controller action for single-stage compressors without capacity control.

Compressor with capacity control

Graph illustrating controller action for two-stage capacity control compressors.

3.4 COP optimization

Explanation of how the system optimizes Coefficient of Performance for energy efficiency.

3.5 Compressor control times

Details on compressor actuation timing for step and combined control, including basic and variable times.

3.6 Calculating setpoint

Methods for calculating setpoints.

3.6.1 Calculating setpoint by outdoor temperature

Method for calculating the setpoint based on current room temperature.

3.6.2 Demand-dependent calculation of setpoint

How setpoints are adjusted based on refrigeration load from case/coldroom controllers.

3.7 Processing load-level information

How the system processes load-level data from case/coldroom controllers for setpoint adjustment.

3.8 Response to fault conditions

How the system responds to CAN bus faults on individual stations and global bus faults.

3.9 Demand-dependent setpoint shift parameters

Parameters defining the range, increment, and interval for demand-dependent setpoint shifts.

3.10 Humidity shift

How humidity affects the setpoint, using the Humidity Shift parameter.

3.11 Ambient data

How ambient data like room temperature, outdoor temperature, and humidity are used for setpoint shifts.

3.12 Second setpoint - Setpoint increase;decrease

Using a second setpoint for better matching to night/weekend operation.

3.13 Refrigeration compressor packs with oil equalizer

Explanation of the oil equalization process in compressor packs.

3.14 Capacity-controlled compressors

Details on controlling compressors with capacity stages and their sequence.

Compressor loading

Illustrates compressor loading sequence for a specific system configuration.

Compressor unloading

Illustrates compressor unloading sequence for a specific system configuration.

3.15 Load shedding

How forced shutdown of compressors is used for load shedding to prevent energy consumption.

3.16 Emergency power mode

How emergency power mode reduces load during power supply faults.

3.17 Compressor base load rotation

Explanation of compressor base load rotation for uniform runtime.

3.17.1 Base load rotation with variable-speed compressors

Details on base load rotation for variable-speed compressors and fixed-speed compressors.

3.18 Compressor monitoring

Functions for monitoring compressor status, including overload, oil pressure, and temperature.

3.19 Safety loop

How safety contacts (e.g., HP cutout) disable compressors in critical situations.

3.20 Monitoring of motor overload cutout

How the motor overload cutout monitors compressor motors and its enabling modes.

3.21 Monitoring low oil pressure cutout

How the low oil pressure cutout monitors compressor oil pressure and its activation.

3.22 Monitoring cylinder head temperature

How cylinder head temperature is monitored to prevent compressor damage.

Compressor fault with combined control

Conditions leading to compressor faults with combined control.

Compressor fault with single-stage compressors

How faults on single-stage compressors affect capacity stages.

Compressor fault with capacity-controlled compressors

How faults on multi-stage compressors affect capacity stages.

3.23 Monitoring high pressure

How high pressure is measured and monitored using transmitters and cutouts.

3.24 CO2 cascade

Handling HP fault conditions in CO2 LT packs with NT systems in a cascade.

3.25 Monitoring low pressure

How low pressure is monitored and compressor shutdown occurs if limits are exceeded.

3.26 Monitoring compressor starts

Limiting compressor starts per hour to prevent short cycling.

3.27 High-pressure control; Condenser control

Controlling high pressure or condensing temperature using condenser fans.

S Step controller

Control via enabling or disabling condenser capacity stages.

S Speed controller

Control via speed adjuster using an analog signal.

S Parallel combined controller

Control via speed adjuster with fans in parallel.

S Staged combined controller

Combination of step control and continuous control with variable-speed fan.

3.27.1 Setting parameter for HP transducer characteristic

Guide to setting HP transducer parameters for matching controller to transducer.

3.27.2 Neutral zone

Neutral zone's effect on fan stage actuation in step control.

3.27.3 Control algorithm

Description of controller cycle time and control algorithm for HP control.

3.27.4 Control algorithm with step controller

Detailed explanation of the control algorithm for HP step controllers.

3.27.5 Calculating setpoint with step controller

Method for calculating the condensing temperature setpoint based on outdoor temperature.

3.27.6 Condenser fan control times with step controller

Explanation of time delays for loading/unloading condenser fan stages.

3.27.7 Control algorithm with continuous control

Explanation of the PI control algorithm for continuous fan speed control.

3.27.8 Calculating setpoint with continuous control

Calculation of condensing temperature setpoint and speed setpoint using PI control.

3.27.8.1 Control algorithm with parallel combined controller

Detailed explanation of control algorithm for parallel combined fan control.

Enabling fan stages

Parameters and rules for enabling fan stages, including disabling Fan Stage 1.

3.27.8.2 Control algorithm for staged combined controller

Explanation of control algorithm for staged combined fan control.

3.27.9 Heat recovery mode

Implementation of heat recovery mode using HR max. and HR dif. parameters.

3.28 HP setpoint increase

Option to enter a temperature offset for HP setpoint when setpoint toggle is active.

3.29 Fan protection; HP base load rotation

Functions for protecting fan motors and base load rotation for fans.

3.30 Monitoring condenser fan motors

Monitoring condenser fan motors using digital inputs and overload cutouts.

Step control

Monitoring condenser fans in step control systems.

Speed control

Monitoring condenser fans in speed control systems.

Combined controller

Monitoring condenser fans with combined controllers.

3.31 Starting characteristics

Difference between first start and restart conditions.

3.31.1 First start

Ways to initiate the first start of the VS 3000 Pack Controller.

3.31.2 Restart

Restart procedure after power return, preserving parameter settings.

3.32 Monitoring refrigerant level

How the controller monitors refrigerant level via a liquid level switch.

3.33 Monitoring burst disk

How the controller monitors a burst disk via a digital input.

3.34 Monitoring external alarm; speed adjuster

Forwarding external alarms or using an input for compressor control frequency changer faults.

3.35 Disabling refrigeration points

How refrigeration points are disabled due to compressor pack faults.

3.36 Discharge gas defrosting

Method of passing compressed vapor through evaporators for defrosting.

3.36.1 Setpoints for discharge gas defrosting

How to check and adjust setpoints for discharge gas defrosting.

3.36.2 Actual values for discharge gas defrosting

Checking digital inputs and outputs for discharge gas defrosting.

3.36.3 Manual control of D2 D

Manually initiating defrosting for Z2 cases and coldrooms.

3.36.4 Discharge gas defrosting in fault conditions

How defrosting behaves during power failures and other fault conditions.

3.36.5 Sequence of joint Z2 discharge gas defrosting

Step-by-step sequence for joint discharge gas defrosting of Z2 cases and coldrooms.

3.36.6 Sequence of Z2 display case discharge gas defrosting

Sequence for defrosting Z2 display cases separately.

3.36.7 Sequence of Z2 discharge gas defrosting with coldroom defrost mode set to El. With UA 300

Sequence for Z2 discharge gas defrosting with coldroom defrost mode set to Electric Defrost.

3.36.8 Sequence of Z2 coldroom discharge gas defrosting

Defrost sequence for Z2 coldrooms when defrosted separately or with auxiliary defrost.

3.37 Archiving of operating data

Archiving of operating data.

3.37.1 Compressor;fan operating hours

Measurement and storage of total running time for compressors and fans.

3.37.2 Daily run times and compressor starts

Recording of daily run times, compressor starts, and activity.

3.37.3 Compressor pack activity;utilization

Formula and explanation for calculating compressor pack activity/utilization.

Installation and Startup of VS 3000

4.1 Connection and safety notes

Essential safety regulations and notes for connecting the VS 3000 Pack Controller.

4.2 Installation

Instructions for installing the VS 3000 Pack Controller, including mounting and power.

4.3 Basic parameter settings on hardware

Configuring basic parameters using DIP Switch S1 and Decade Switch S2.

4.3.1 Basic settings with S1

Setting compressor pack type, number of extension modules, and discharge gas defrosting via DIP Switch S1.

Setting service mode

How to set the controller to service mode for maintenance purposes.

Setting firmware update mode

How to set the controller for firmware updates.

4.3.2 Basic settings with S2

Setting the Node Number or deactivating CAN bus communication using Decade Switch S2.

4.4 Basic parameter settings in software

Setting system configuration parameters like refrigerant, sensor match, and compressor stages in software.

4.5 Replacing the battery

Procedure for replacing the backup battery of the pack controller.

4.6 Installing update software

Procedure for installing the LDS Download Software on a PC.

4.6.1 Installing update software on the PC

Step-by-step guide to install the LDS Download Software on a PC.

4.6.2 Updating current firmware in VS 3000

Procedure for updating the VS 3000 firmware using a PC.

Pin and Terminal Assignments of VS 3000

5.1 Pin assignments

Detailed pin assignments for the VS 3000 Pack Controller's basic module.

Pin assignments of VS 3000 basic module - side connections

Visual layout of pin assignments for the VS 3000 basic module's side connections.

Pin assignments of first SIOX extension module

Pin assignments for the first SIOX extension module.

Pin assignments of second SIOX extension module

Pin assignments for the second SIOX extension module.

Pin assignments of SIOX D2 D extension module for discharge gas defrosting

Pin assignments for the SIOX D2D extension module used for discharge gas defrosting.

Pin assignments of SIOX extension module - side connections

Side connection pin assignments for SIOX extension modules.

5.2 Inputs;outputs for 4 compressor capacity stages; 4 fan stages

List of digital inputs and outputs for 4 compressor and 4 fan stages.

Analog Intputs

Details of analog inputs for temperature, pressure, and humidity sensors.

Analog Outputs

Details of analog outputs for fan and compressor control.

Interfaces

Interface connections including CAN bus, RS232, TTY, and SIOX.

Power Supply

Power supply connections including 230V AC, grounding, and SIOX power.

5.3 Inputs;outputs for 8 compressor capacity stages; 8 fan stages

List of digital inputs and outputs for 8 compressor and 8 fan stages, including SIOX module.

Digital Outputs

Digital outputs for compressor and fan control, including SIOX modules.

Analog Intputs

Analog inputs for temperature, pressure, and humidity sensors with SIOX modules.

Analog Outputs

Analog outputs for fan and compressor control, including SIOX modules.

Interfaces

Interface connections (CAN, RS232, TTY, SIOX) for SIOX modules.

Power Supply

Power supply connections (230V AC, SIOX) for SIOX modules.

5.4 Inputs;outputs for 12 compressor capacity;12 fan stages

List of digital inputs and outputs for 12 compressor and 12 fan stages, including SIOX modules.

Digital Intputs

Digital inputs for compressor and fan monitoring, including SIOX modules.

Digital Outputs

Digital outputs for compressor and fan control, including SIOX modules.

Analog Intputs

Analog inputs for temperature, pressure, and humidity, with SIOX modules.

Analog Outputs

Analog outputs for fan and compressor control, with SIOX modules.

Interfaces

Interface connections (CAN, RS232, TTY, SIOX) for SIOX modules.

Power Supply

Power supply connections (230V AC, SIOX) for SIOX modules.

5.5 Inputs;outputs of SIOX D2 D extension module for discharge gas defrosting

Inputs and outputs for the SIOX D2D module for discharge gas defrosting.

Operating Modes of VS 3000

6.1 Emergency manual-automatic mode selection

Selecting manual or automatic mode for emergency operation of the refrigeration pack.

6.2 Service mode

How to enter and use Service Mode for manual actuation of outputs.

6.3 Displaying operating status

Interpreting indications for suction pressure, condensing pressure, and setpoint characteristics.

Operation of VS 3000

7.1 Operation with CI 3000 Store Computer or AL 300 Operator Terminal

How to operate the VS 3000 using the CI 3000 Store Computer or AL 300 Operator Terminal.

7.2 Menus and screens

Understanding the menu structure, numbering, and navigation of the VS 3000 controller.

Selecting menu items

How to select menu items using numeric keys and cursor keys.

Operating screens

How operating screens display values and allow scrolling or paging.

Scrolling

Using cursor keys to scroll through lines or blocks of data.

Paging

Using cursor keys to page through screens with multiple pages.

Cancelling entry block

How to deactivate the entry block to allow parameter changes.

Superuser mode (granting Superuser rights)

Procedure for granting Superuser rights for service personnel.

Activating service mode

How service technicians can suppress remote alarms for maintenance.

Entering text

How to enter text using the alphanumeric keypad and ENTER key.

Alphanumeric key assignments

Using the MODE key to shift between upper and lower case letters.

Deleting text entry

How to delete text entries using MODE and MINUS/DECIMAL keys.

Cancelling an entry

Using the ESC key to cancel an entry without applying it.

Exiting menus and screens

How to exit menus and screens using the ESC key or automatic timeout.

7.3 Operation; Parameter setting of VS 3000 Pack Controller

How to operate and set parameters for the VS 3000 Pack Controller.

Menu Structure of VS 3000

Working with menus and screens

See Section 7 for details on working with menus and screens.

8.1 Menu tree

Hierarchical overview of all menus and screens in the VS 3000 system.

8.1.1 Menu 0 Main Menu

The main menu interface for navigating through system functions.

8.1.2 Menu 1 Summery

Summary screen showing actual values for LP and HP temperatures and pressures.

8.1.3 Menu 2 Actual Values

Menu for viewing actual values for Analog, Compressor, Condenser fan, System, and D2D.

S Menu 2-1 Analog values

Detailed display of analog values including pressures, temperatures, and humidity.

S Menu 2-1-a Analog Values Cylinder Head Temperatures

Specific display of cylinder head temperatures for compressors.

S Menu 2-2 Compressor

Menu for viewing compressor status: motor overload, oil pressure, manual switch, capacity stage.

S Menu 2-3 Condenser fan

Menu for viewing condenser fan status: motor overload, output, and speed settings.

S Menu 2-4 System

Menu showing system status for HP cutout, LP cutout, burst disk, alarms, and load shedding.

S Menu 2-5 D2 D Discharge Gas Defrosting

Menu for viewing D2D discharge gas defrosting status and parameters.

8.1.4 Menu 3 Setpoints

Menu for setting system configuration, control parameters, and monitoring.

S Menu 3-1 System config.

Configuration settings for refrigerant, sensors, compressor/fan stages, and safety parameters.

S Masque 3-1-d Enable comp.stages

Enabling/disabling of compressor stages based on module configuration.

S Masque 3-1-e Enable cond.stages

Enabling/disabling of condenser stages based on module configuration.

S Masque 3-1-b Transducer;Sensor Matching

Matching LP and HP pressure transducers to the controller's signal interface.

S Masque 3-1-b-a LP-Transducer

Selecting the signal interface for the LP pressure transducer (4-20mA or 0-10V).

S Masque 3-1-b-b HP-Transducer

Selecting the signal interface for the HP pressure transducer (4-20mA or 0-10V).

S Masque 3-1-c Select Text For Oil;HP Fault

Selecting predefined messages for oil or HP faults.

S Masque 3-1-a Select Refrigerant

Selecting the refrigerant type for the system.

S Menu 3-2 Control

Menu for setting LP and HP control parameters.

S Menu 3-2-1 LP-Control

Settings for LP control, including general control, adjustment, and day/night modes.

S Menu 3-2-1-1 Compressor Control

Settings for compressor control type, minimum speed, and adjusting difference.

S Masque 3-2-1-1-a Control type

Selecting the control type for LP control: Step, Speed, or Combined.

S Menu 3-2-1-2 t0-adjustment

Settings for adjusting t0 shift based on room temperature or consumer.

S Masque 3-2-1-2-a t0-adjustment

Selecting the method for t0 shift: by room temperature or consumer.

S Menu 3-2-1-3 LP-Control day

LP control settings for daytime operation, including setpoints and load/unload times.

S Masque 3-2-1-3-a Basic load time

Setting basic load times for compressor stages during daytime operation.

S Masque 3-2-1-3-b Vari. load time F ON

Setting variable load times for compressor stages during daytime operation.

S Masque 3-2-1-3-c Basic unload time F OFF

Setting basic unload times for compressor stages during daytime operation.

S Masque 3-2-1-3-d Vari. unload time F OFF

Setting variable unload times for compressor stages during daytime operation.

S Menu 3-2-1-4 LP-control night

LP control settings for nighttime operation, including setpoints and load/unload times.

S Masque 3-2-1-4-a Basic load time F ON

Setting basic load times for condenser stages during nighttime operation.

S Masque 3-2-1-4-b Vari. load time F ON

Setting variable load times for condenser stages during nighttime operation.

S Masque 3-2-1-4-c Basic unload time F OFF

Setting basic unload times for condenser stages during nighttime operation.

S Masque 3-2-1-4-d Vari. unload time F OFF

Setting variable unload times for condenser stages during nighttime operation.

S Menu 3-2-2 HD-Control

Menu for HP control settings, including control type and parameters.

S Menu 3-2-2-1 HD-Control

Detailed settings for HP control: control type, fan speed, and factors.

S Masque 3-2-2-1-a Control type

Selecting the HP control type: Step, Speed, or Combined.

S Masque 3-2-2-1-b HP Actuation Type - Star;Delta Operating Mode

Setting HP actuation type for fan control: Direct, SSFF, or SSSF.

S Menu 3-2-2-2 Setpoints

Settings for HP control setpoints, including temperature limits, HR mode, and times.

S Masque 3-2-2-2-a Bas. load time F ON

Setting basic load times for condenser stages in HR mode.

S Masque 3-2-2-2-b Var. load time F ON

Setting variable load times for condenser stages in HR mode.

S Masque 3-2-2-2-c Bas.unload time F OFF

Setting basic unload times for condenser stages in HR mode.

S Masque 3-2-2-2-d Var.unload time F OFF

Setting variable unload times for condenser stages in HR mode.

S Menu 3-3 Comp. monitor

Settings for compressor monitoring: OFF/ON temperatures, delays, and limits.

S Menu 3-4 Liq.level monitor

Monitoring low refrigerant level and associated delay time.

S Menu 3-5 Ext. alarms

Setting time delay and message text for external alarms.

S Menu 3-6 Base load

Parameters for compressor and fan base load rotation, including cycle times.

S Menu 3-7 Messages

Configuration of messages for motor cutout, oil pressure, temperature, and pressure faults.

Alarms and Messages of VS 3000

9.1 Reporting system

How the system recognizes, logs, and transmits messages and alarms.

9.2 Structure of alarms;messages

Format of displayed alarms/messages: ID, message text, date, time, priority.

9.3 Types of alarm

Categorization of alarms into process and system faults.

9.3.1 Process fault alarms

List and description of various process fault alarms recorded by the controller.

9.3.2 System fault alarms

List and description of system fault alarms, including measuring loop errors and battery faults.

Specifications of VS 3000

10.1 Electrical Data of VS 3000

Electrical specifications including power supply, inputs, outputs, and ports.

10.2 Mechanical data of VS 3000

Physical dimensions and mounting information for the VS 3000 controller.

10.3 Mechanical data of SIOX extension module

Physical dimensions and mounting information for the SIOX extension module.

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