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Fridgewatch 2000
J&E Hall Fridgewatch 2000 User Manual
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Public
atio
n:
3-
59
Fridgewatc
h 2000
Control
ler Mk5
Issue
3.
2
: 0
5
.2
3
Public
atio
n 3
-
59
Section 3
Page
1
of 2
22
Issue
3.
2
: 0
5
.2
3
In
sta
ll
ati
on,
Op
erat
in
g an
d M
ain
ten
an
ce M
anu
al
Fri
dgew
atc
h
®
2000 Con
trolle
r Mk5
This publ
ication is appl
icable to th
e following
J & E
Hall Int
erna
t
iona
l
Compressors a
nd Packages:
HallScrew 2000,
2
100
,
3100, 3200
and 4200
Ser
ies
Compres
sors
2
Table of Contents
Table of Contents
5
About this Publication
11
Safety Warnings and Symbols
11
Units of Measurement
11
Terminology
11
Additional Copies
11
Care and Protection of Fridgewatch
12
Anti-Static Precautions
12
Electrical Interference
12
Prolonged Storage
12
Personnel Permitted to Install, Commission and Maintain Fridgewatch
13
Abbreviations
13
Table 1 Abbreviations
13
General Description
14
System Settings
15
Construction
15
Technical Data
15
Table 2 Technical Data
15
Fig 1 Control Internal Layout (Upper)
16
Fig 2 Control Door Internal Layout (Upper)
17
Fig 3 230 V Internal Layout (Lower)
17
Fig 4 Internal Layout
18
Enclosure Dimensions and Details of Cable Entries
19
Fig 5 Enclosure Dimensions and Details of Cable Entries
19
Security
20
Table 3 Overview of Access Levels and Passwords
20
Password Access Levels
21
Access Level User
21
Access Level Indication Buttons
21
Read Only
21
Operator Setting
21
Configuration Setting
21
Access Levels Operator and Configuration
21
Fig 6 Password Logon
22
Mk5 Fridgewatch 2000 HMI
23
User Interface
23
Menu System
23
Fig 7 Setting Pages
23
Configuration Settings
24
Configuration Settings List or Table
24
Settings Numbers and Timer
24
Fig 8 Fridgewatch Configuration Settings List or Table
24
Fig 9 Fridgewatch Configuration Settings Numbers and Timer
24
Settings Number Setting
25
Configuration Settings ANIN (Configuration Setting)
25
Fig 10 Fridgewatch Configuration Settings Number
25
Fig 11 Fridgewatch Configuration Settings ANIN
25
Push Buttons Functions on the Fridgewatch HMI
26
Fig 12 Mk5 Fridgewatch 2000 HMI
26
SIMATIC HMI Outdoor Panel
27
Fig 13 SIMATIC HMI Outdoor Panel
27
Menu Page
28
Software Version
28
IP Address
28
Home Page
28
Fig 14 Menu Page
28
Analogue Points Pages 1 to 3
29
Fig 15 Analogue Ports
29
Digital I/O (DIGIN/DIGOUT)
30
Digital Inputs Page 1 and 2 (DIGIN)
30
Fig 16 Digital Inputs
30
Fig 17 Digins Operation
30
Digital Outputs Pages 1 and 2 (DIGOUT)
31
Fig 18 Digouts
31
Fig 19 Digouts Operation
31
Diagnostics: Page 1 and 2
32
Fig 20 Diagnostics
32
Fig 21 Diagnostics
32
P + I Trends
33
Fig 22 P + I (Measured Temperature)
33
Fig 23 P + I (Measured Pressure)
33
Current Alarms
34
Alarm History
34
Fig 24 Current Alarms
34
Fig 25 Alarm History
34
System Limits and Information Displays
35
10.10.1. Limiting
35
Fig 26 Limiting
35
10.10.2. Information Only
36
Fig 27 Information Only
36
Modbus Registers Pages 1 to 5
37
Fig 28 Modbus Register
37
Requires Operator Password (Yellow)
38
Control Settings
38
Fig 29 Control Settings
38
Primary / Secondary Settings
39
Fig 30 Primary / Secondary Control Settings
39
Fig 31 Secondary Control Settings
39
Double Set Point and Days
40
Fig 32 Double Set Point & Set Day of the Week
40
Liquid Injection Settings
41
Fig 33 Liquid Injection & Oil Cooler Control Settings
41
Operating Mode
42
Clean Screen
42
Fig 34 Operating Mode Selection
42
Fig 35 Clean Screen
42
Requires Configuration Password (Orange)
43
Hours Run and Number of Starts
43
Fig 36 Hours Run & Number of Starts
43
Set Time and Date
44
Fig 37 Set Date & Time
44
Anins Configuration Pages 1 to 3
45
Fig 38 Anins Configuration
45
System Configuration Pages 1 to 7
46
Fig 39 System Configuration
46
Settings S1 to S287 Pages 1 to 38
47
Fig 40 System Setting
47
ALT Settings (Alarm, Limit & Trip) Pages 1 to 7
48
Fig 41 ALT Timer Settings
48
ALT (Alarm, Limit & Trip) Timer Settings Pages 1 to 7
49
Fig 42 ALT Timer Settings
49
Home Page
50
Time and Date
50
Fig 43 Home Page
50
Menu/Back Button
51
Compressor and Refrigerant Numbers
51
New Alarm and Acknowledged Alarm Exists
51
Compressor Status
52
Start (Manual Start)
52
Oil Fill Button
52
Load and Unload (Manual Capacity Control Only)
53
Controlled Stop/Stop Button RESET
53
Communications
54
Fig 44 RS 485 Communication Board
54
Fig 45 RS 485 Termination and Bias
54
RS 485 Port Parameters
55
Communication (Comms)
55
Fig 46 Configure Comms Port
55
Communications Example
56
Principles of Control
57
Compressor Capacity Control
57
Compressor Slide Valve Position (SVP)
57
Slide Valve Position Signal
58
Compressor Variable Speed Drive (VSD)
58
Intermediate Load Outputs
58
Hallscrew 2100 Series and 3100 Old Series Compressors
59
Hallscrew 3100 New Series, 3200 and 4200 Series Compressors
59
Proportional and Integral (P + I) Control
59
Proportional Band
60
Fig 47 Proportional and Integral (P + I) Control
61
Integral Action Time
62
Set Point Temperature/Pressure
62
Fig 48 Integral Control Action
62
Primary / Secondary Operation
63
Fig 49 Primary Control Settings
63
Starting the Primary Compressor
64
Fig 50 Secondary Control Settings
64
Starting and Stopping the Secondary Compressor
65
Starting and Stopping the Compressor
66
Fig 51 Control Settings
66
Fig 52 Possible Compressor Start/Stop and Capacity Control Modes
67
Control Philosophy for Compressor Operation after a Transmitter Failure
68
Capacity Control by Fridgewatch Controller
69
Auto Capacity Control
69
Manual Capacity Control
69
Remote Capacity Control
69
Limiting Inputs
70
Control Strategy for Limiting Inputs
70
Current Limiting
71
Pump-Down
71
High Pressure Cut-Out Function by Transmitter
72
Table 4 Under-Range Trip Pressures for Different Transmitter Types
72
Oil Management Systems
73
Table 5 Summary of Differential Pressure Sensing
73
Summary of Differential Pressure Sensing
74
Table 6 All Hallscrew Compressors - Oil Pressure Trips by Differential Pressure Switches
74
Table 7 HS 2000 Series Compressors - Oil Pressure Trips by Transmitters
75
Table 8 HS 2100 and HS 3100 Series Compressors - Oil Pressure Trips by Transmitters
76
Demand Oil Pump
77
Table 9 HS 3100 (New Series), HS 3200 and HS 4200 Series Compressors
77
Oil Pressure Trips by Transmitters
77
Oil Filling Pump
78
Installation
79
Analogue Inputs for Sensing Start, Stop and Set Point Values
79
Using Two Start, Stop and Set Point Values
79
Table 10 Transmitter Inputs
79
Table 11 Rule for Selecting Controlling Parameters for Two Start Value/Set Point/Stop Value Sets
79
Digital Outputs
80
System Monitoring
80
Installing Transmitters
80
Using Fridgewatch to Drive (Switch) Relays
80
RS 485 Modbus RTU Station Address
80
Fig 53 Transmitter Installation
81
Summary of Primary / Secondary Connections
82
Power Supply Connections (Lower Half of Enclosure)
82
Panel Heater
83
Wiring Connections to DC Circuits (Upper Half of Enclosure)
83
Opto-Electronic Liquid Sensor Interface Units
83
Connections to Economiser Solenoid Valves
83
Fig 54 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves
84
Terminal Block Wiring Upper
85
Fig 55 DIGIN Wiring Connections to Slot 1
85
Fig 56 DIGIN Wiring Connections to Slot 1
86
Fig 57 DIGIN Wiring Connections to Slot 2
87
Fig 58 DIGIN Wiring Connections to Slot 2
88
Fig 59 DIGIN Wiring Connections to Slot 2
89
Fig 60 DIGOUT Wiring Connections to Slot 1
90
Fig 61 DIGOUT Wiring Connections to Slot 1
91
Fig 62 DIGOUT Wiring Connections to Slot 2
92
Fig 63 DIGOUT Wiring Connections to Slot 2
93
Fig 64 ANIN and ANOUT Wiring Connections to Slot 5
94
Fig 65 ANIN and ANOUT Wiring Connections
95
Fig 66 Wiring Connections to External Devices
96
Fig 67 Wiring Connections to External Devices
97
Fig 68 Wiring Connections Pt 100 and Motor Current
98
Fig 69 Wiring Connections Input / Output
99
Fig 70 Wiring Connections Input / Output
100
Fig 71 Wiring Connections Input / Output
101
Terminal Block Wiring Lower
102
Fig 72 Wiring Connections Relay Outputs Lower Half of Panel
102
Fig 73 Wiring Connections Relay Outputs Lower Half of Panel Continued
103
Fig 74 Wiring Connections for Primary / Secondary Without External Run Request or Run Enable Signal
104
Fig 75 Wiring Connections for Primary / Secondary with External Run Request or Run Enable Signal
104
Commissioning
105
Supplying Power for the First Time
105
Commissioning - Sequence of Operations
105
Authority to Use Passwords
106
Analogue Input Transmitter Calibration and Setup
106
Fig 76 Transmitter Calibration - Examples
106
Transmitter Calibration
107
Pressure Transmitter Calibration
107
Fig 77 Transmitter Calibration
107
Temperature Transmitter Calibration
108
Motor Current Transmitter Calibration
108
Compressor Slide Valve Position LVDT Calibration
109
Inputting Control Settings
109
Changing System Configuration Settings after Commissioning
110
Changing Control Settings after Commissioning
110
Operating Mode for the First Start
110
Changing the Operating Mode
110
Fig 78 Changing the Operating Mode
111
Event Codes
112
Information Only Events
112
Alarm Messages
112
Trip Events
112
Transmitter out of Range
113
External Audible and Visual Alarms
113
Compressor Healthy off
113
Event Codes Description
113
Control Settings
137
Compressor Settings
138
Fig 79 Control Settings
138
Table 12 Run Enable Required in Different Operating Modes - Values for S14
140
Table 13 Evaporator Pump Running Status When Compressor Is Stopped
142
Table 14 Operating Mode Indication Using Setting S19
143
Fig 80 Flowchart to Assist in Adjusting Start Value/Set Point/Stop Value Times
146
Table 15 Reason for Last Normal Compressor Stop - Values for S38
148
Table 16 Reason for Current Trip (Event) - Values for S39
149
Table 17 Reason for Compressor Not Starting - Values 0 to 10 for S40
150
Table 18 Reason for Compressor Not Starting - Values 11 to 20 for S40
151
Fig 81 Starts Per Hour
152
Fig 82 Example of Using Intermediate Load Output 1
156
Fig 83 Set Date and Time
158
Table 19 Values for S75 to S80 Current Date and Time
158
Table 20 Values for P28 Oil Filter Pressure Drop
161
Table 21 Values for S147 Oil Feed Differential Pressure (ODP2) Sensing Defined
163
Table 22 Values for S149 Oil Injection Differential Pressure (ODP1) Sensing Defined
164
Table 23 Automatic Scaling of P34 Energy Consumption Counter
167
Table 24 Refrigerant Type - Values for S184
170
Fig 84 Slide Valve Position (Svp)/Motor Speed: Error Tolerance - Values for S18
172
Fig 85 Possible Compressor Start/Stop and Capacity Control Modes
174
Fig 86 Liquid Injection Settings
176
Fig 87 Cycle Time
177
System Settings
185
Alarm, Limit and Trip Settings and Delay Times
185
Oil Feed Differential Pressure (ODP)
185
Evaporator Cooled Medium Outlet Temperature Low P19
186
Fig 88 Evaporator Cooled Medium Outlet Temperature Low: Settings S165, S166, S237, S167 and S266
186
Oil Differential Pressure (ODP 1) Low During Running
187
Fig 89 Oil Differential Pressure Low During Running: Settings S153, S154, S155, S273, S150 and S52
187
Discharge Pressure P12 or Temperature P16
188
Discharge Pressure High P12
188
Fig 90 Discharge Pressure High: Settings S235, S161, S162, S170 and S259
188
Suction Pressure P11
189
Suction Pressure Low
189
Fig 91 Suction Pressure Low: Settings S157, S158, S230, S159 and S258
189
User Analogue Pressure or Temperature P6
190
User Analogue (P6) Low
190
Fig 92 User Analogue Low: Settings S250, S252, S251, S249 and S277
190
Measured Pressure P2
191
Measured Pressure Low
191
Fig 93 Measured Pressure Low: Settings S241, S94, S95, S96 and S262
191
Measured Temperature P1
192
Measured Temperature Low
192
Fig 94 Measured Temperature Low: Settings S245, S90, S91, S92 and S264
192
Maintenance
193
Maintenance Check List
193
Table 25 Maintenance Check List
193
Spares
194
Fuses
194
Table 26 Fuses
194
Appendix 1 Residual Risk Register
195
Appendix 2 Measured Points P1/P34 Quick-Reference
197
Table 27 Event Codes E1 to E25 Quick-Reference
201
Appendix 3 Event Codes E1/E107 Quick-Reference
201
Table 28 Event Codes E26 to E57 Quick-Reference
202
Table 29 Event Codes E58 to E89 Quick-Reference
203
Table 30 Event Codes E90 to E107 Quick-Reference
204
Table 31 MODBUS Addresses and SCADA Information Pakmod a to P32
205
Appendix 4 MODBUS Addresses and SCADA Information
205
Table 32 MODBUS Addresses and SCADA Information P33 to S23
206
Table 33 MODBUS Addresses and SCADA Information S24 to Opakmod [35]
207
Table 34 MODBUS Addresses and SCADA Information P5 [34] to Required SVP
208
Table 35 Compressor Number/Compressor Serial Number Record
209
Appendix 5 Settings Record
209
4
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J&E Hall Fridgewatch 2000 Specifications
General
Brand
J&E Hall
Model
Fridgewatch 2000
Category
Controller
Language
English
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