J&E Hall Fridgewatch 2000

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Publication: 3-59

Fridgewatch 2000 Controller Mk5

Issue 3.2 : 05.23

Publication 3-59 Section 3

Page 1 of 222 Issue 3.2 : 05.23

Installation, Operating and Maintenance Manual

Fridgewatch

2000 Controller Mk5

This publication is applicable to the following

J & E Hall International Compressors and Packages:

HallScrew 2000, 2100, 3100, 3200 and 4200 Series Compressors

Main Page

Table of Contents5
About this Publication11
Safety Warnings and Symbols11
Units of Measurement11
Terminology11
Additional Copies11
Care and Protection of Fridgewatch12
Anti-Static Precautions12
Electrical Interference12
Prolonged Storage12
Personnel Permitted to Install, Commission and Maintain Fridgewatch13
Abbreviations13
Table 1 Abbreviations13
General Description14
System Settings15
Construction15
Technical Data15
Table 2 Technical Data15
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 Layout18
Enclosure Dimensions and Details of Cable Entries19
Fig 5 Enclosure Dimensions and Details of Cable Entries19
Security20
Table 3 Overview of Access Levels and Passwords20
Password Access Levels21
Access Level User21
Access Level Indication Buttons21
Read Only21
Operator Setting21
Configuration Setting21
Access Levels Operator and Configuration21
Fig 6 Password Logon22
Mk5 Fridgewatch 2000 HMI23
User Interface23
Menu System23
Fig 7 Setting Pages23
Configuration Settings24
Configuration Settings List or Table24
Settings Numbers and Timer24
Fig 8 Fridgewatch Configuration Settings List or Table24
Fig 9 Fridgewatch Configuration Settings Numbers and Timer24
Settings Number Setting25
Configuration Settings ANIN (Configuration Setting)25
Fig 10 Fridgewatch Configuration Settings Number25
Fig 11 Fridgewatch Configuration Settings ANIN25
Push Buttons Functions on the Fridgewatch HMI26
Fig 12 Mk5 Fridgewatch 2000 HMI26
SIMATIC HMI Outdoor Panel27
Fig 13 SIMATIC HMI Outdoor Panel27
Menu Page28
Software Version28
IP Address28
Home Page28
Fig 14 Menu Page28
Analogue Points Pages 1 to 329
Fig 15 Analogue Ports29
Digital I/O (DIGIN/DIGOUT)30
Digital Inputs Page 1 and 2 (DIGIN)30
Fig 16 Digital Inputs30
Fig 17 Digins Operation30
Digital Outputs Pages 1 and 2 (DIGOUT)31
Fig 18 Digouts31
Fig 19 Digouts Operation31
Diagnostics: Page 1 and 232
Fig 20 Diagnostics32
Fig 21 Diagnostics32
P + I Trends33
Fig 22 P + I (Measured Temperature)33
Fig 23 P + I (Measured Pressure)33
Current Alarms34
Alarm History34
Fig 24 Current Alarms34
Fig 25 Alarm History34
System Limits and Information Displays35
10.10.1. Limiting35
Fig 26 Limiting35
10.10.2. Information Only36
Fig 27 Information Only36
Modbus Registers Pages 1 to 537
Fig 28 Modbus Register37
Requires Operator Password (Yellow)38
Control Settings38
Fig 29 Control Settings38
Primary / Secondary Settings39
Fig 30 Primary / Secondary Control Settings39
Fig 31 Secondary Control Settings39
Double Set Point and Days40
Fig 32 Double Set Point & Set Day of the Week40
Liquid Injection Settings41
Fig 33 Liquid Injection & Oil Cooler Control Settings41
Operating Mode42
Clean Screen42
Fig 34 Operating Mode Selection42
Fig 35 Clean Screen42
Requires Configuration Password (Orange)43
Hours Run and Number of Starts43
Fig 36 Hours Run & Number of Starts43
Set Time and Date44
Fig 37 Set Date & Time44
Anins Configuration Pages 1 to 345
Fig 38 Anins Configuration45
System Configuration Pages 1 to 746
Fig 39 System Configuration46
Settings S1 to S287 Pages 1 to 3847
Fig 40 System Setting47
ALT Settings (Alarm, Limit & Trip) Pages 1 to 748
Fig 41 ALT Timer Settings48
ALT (Alarm, Limit & Trip) Timer Settings Pages 1 to 749
Fig 42 ALT Timer Settings49
Home Page50
Time and Date50
Fig 43 Home Page50
Menu/Back Button51
Compressor and Refrigerant Numbers51
New Alarm and Acknowledged Alarm Exists51
Compressor Status52
Start (Manual Start)52
Oil Fill Button52
Load and Unload (Manual Capacity Control Only)53
Controlled Stop/Stop Button RESET53
Communications54
Fig 44 RS 485 Communication Board54
Fig 45 RS 485 Termination and Bias54
RS 485 Port Parameters55
Communication (Comms)55
Fig 46 Configure Comms Port55
Communications Example56
Principles of Control57
Compressor Capacity Control57
Compressor Slide Valve Position (SVP)57
Slide Valve Position Signal58
Compressor Variable Speed Drive (VSD)58
Intermediate Load Outputs58
Hallscrew 2100 Series and 3100 Old Series Compressors59
Hallscrew 3100 New Series, 3200 and 4200 Series Compressors59
Proportional and Integral (P + I) Control59
Proportional Band60
Fig 47 Proportional and Integral (P + I) Control61
Integral Action Time62
Set Point Temperature/Pressure62
Fig 48 Integral Control Action62
Primary / Secondary Operation63
Fig 49 Primary Control Settings63
Starting the Primary Compressor64
Fig 50 Secondary Control Settings64
Starting and Stopping the Secondary Compressor65
Starting and Stopping the Compressor66
Fig 51 Control Settings66
Fig 52 Possible Compressor Start/Stop and Capacity Control Modes67
Control Philosophy for Compressor Operation after a Transmitter Failure68
Capacity Control by Fridgewatch Controller69
Auto Capacity Control69
Manual Capacity Control69
Remote Capacity Control69
Limiting Inputs70
Control Strategy for Limiting Inputs70
Current Limiting71
Pump-Down71
High Pressure Cut-Out Function by Transmitter72
Table 4 Under-Range Trip Pressures for Different Transmitter Types72
Oil Management Systems73
Table 5 Summary of Differential Pressure Sensing73
Summary of Differential Pressure Sensing74
Table 6 All Hallscrew Compressors - Oil Pressure Trips by Differential Pressure Switches74
Table 7 HS 2000 Series Compressors - Oil Pressure Trips by Transmitters75
Table 8 HS 2100 and HS 3100 Series Compressors - Oil Pressure Trips by Transmitters76
Demand Oil Pump77
Table 9 HS 3100 (New Series), HS 3200 and HS 4200 Series Compressors77
Oil Pressure Trips by Transmitters77
Oil Filling Pump78
Installation79
Analogue Inputs for Sensing Start, Stop and Set Point Values79
Using Two Start, Stop and Set Point Values79
Table 10 Transmitter Inputs79
Table 11 Rule for Selecting Controlling Parameters for Two Start Value/Set Point/Stop Value Sets79
Digital Outputs80
System Monitoring80
Installing Transmitters80
Using Fridgewatch to Drive (Switch) Relays80
RS 485 Modbus RTU Station Address80
Fig 53 Transmitter Installation81
Summary of Primary / Secondary Connections82
Power Supply Connections (Lower Half of Enclosure)82
Panel Heater83
Wiring Connections to DC Circuits (Upper Half of Enclosure)83
Opto-Electronic Liquid Sensor Interface Units83
Connections to Economiser Solenoid Valves83
Fig 54 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves84
Terminal Block Wiring Upper85
Fig 55 DIGIN Wiring Connections to Slot 185
Fig 56 DIGIN Wiring Connections to Slot 186
Fig 57 DIGIN Wiring Connections to Slot 287
Fig 58 DIGIN Wiring Connections to Slot 288
Fig 59 DIGIN Wiring Connections to Slot 289
Fig 60 DIGOUT Wiring Connections to Slot 190
Fig 61 DIGOUT Wiring Connections to Slot 191
Fig 62 DIGOUT Wiring Connections to Slot 292
Fig 63 DIGOUT Wiring Connections to Slot 293
Fig 64 ANIN and ANOUT Wiring Connections to Slot 594
Fig 65 ANIN and ANOUT Wiring Connections95
Fig 66 Wiring Connections to External Devices96
Fig 67 Wiring Connections to External Devices97
Fig 68 Wiring Connections Pt 100 and Motor Current98
Fig 69 Wiring Connections Input / Output99
Fig 70 Wiring Connections Input / Output100
Fig 71 Wiring Connections Input / Output101
Terminal Block Wiring Lower102
Fig 72 Wiring Connections Relay Outputs Lower Half of Panel102
Fig 73 Wiring Connections Relay Outputs Lower Half of Panel Continued103
Fig 74 Wiring Connections for Primary / Secondary Without External Run Request or Run Enable Signal104
Fig 75 Wiring Connections for Primary / Secondary with External Run Request or Run Enable Signal104
Commissioning105
Supplying Power for the First Time105
Commissioning - Sequence of Operations105
Authority to Use Passwords106
Analogue Input Transmitter Calibration and Setup106
Fig 76 Transmitter Calibration - Examples106
Transmitter Calibration107
Pressure Transmitter Calibration107
Fig 77 Transmitter Calibration107
Temperature Transmitter Calibration108
Motor Current Transmitter Calibration108
Compressor Slide Valve Position LVDT Calibration109
Inputting Control Settings109
Changing System Configuration Settings after Commissioning110
Changing Control Settings after Commissioning110
Operating Mode for the First Start110
Changing the Operating Mode110
Fig 78 Changing the Operating Mode111
Event Codes112
Information Only Events112
Alarm Messages112
Trip Events112
Transmitter out of Range113
External Audible and Visual Alarms113
Compressor Healthy off113
Event Codes Description113
Control Settings137
Compressor Settings138
Fig 79 Control Settings138
Table 12 Run Enable Required in Different Operating Modes - Values for S14140
Table 13 Evaporator Pump Running Status When Compressor Is Stopped142
Table 14 Operating Mode Indication Using Setting S19143
Fig 80 Flowchart to Assist in Adjusting Start Value/Set Point/Stop Value Times146
Table 15 Reason for Last Normal Compressor Stop - Values for S38148
Table 16 Reason for Current Trip (Event) - Values for S39149
Table 17 Reason for Compressor Not Starting - Values 0 to 10 for S40150
Table 18 Reason for Compressor Not Starting - Values 11 to 20 for S40151
Fig 81 Starts Per Hour152
Fig 82 Example of Using Intermediate Load Output 1156
Fig 83 Set Date and Time158
Table 19 Values for S75 to S80 Current Date and Time158
Table 20 Values for P28 Oil Filter Pressure Drop161
Table 21 Values for S147 Oil Feed Differential Pressure (ODP2) Sensing Defined163
Table 22 Values for S149 Oil Injection Differential Pressure (ODP1) Sensing Defined164
Table 23 Automatic Scaling of P34 Energy Consumption Counter167
Table 24 Refrigerant Type - Values for S184170
Fig 84 Slide Valve Position (Svp)/Motor Speed: Error Tolerance - Values for S18172
Fig 85 Possible Compressor Start/Stop and Capacity Control Modes174
Fig 86 Liquid Injection Settings176
Fig 87 Cycle Time177
System Settings185
Alarm, Limit and Trip Settings and Delay Times185
Oil Feed Differential Pressure (ODP)185
Evaporator Cooled Medium Outlet Temperature Low P19186
Fig 88 Evaporator Cooled Medium Outlet Temperature Low: Settings S165, S166, S237, S167 and S266186
Oil Differential Pressure (ODP 1) Low During Running187
Fig 89 Oil Differential Pressure Low During Running: Settings S153, S154, S155, S273, S150 and S52187
Discharge Pressure P12 or Temperature P16188
Discharge Pressure High P12188
Fig 90 Discharge Pressure High: Settings S235, S161, S162, S170 and S259188
Suction Pressure P11189
Suction Pressure Low189
Fig 91 Suction Pressure Low: Settings S157, S158, S230, S159 and S258189
User Analogue Pressure or Temperature P6190
User Analogue (P6) Low190
Fig 92 User Analogue Low: Settings S250, S252, S251, S249 and S277190
Measured Pressure P2191
Measured Pressure Low191
Fig 93 Measured Pressure Low: Settings S241, S94, S95, S96 and S262191
Measured Temperature P1192
Measured Temperature Low192
Fig 94 Measured Temperature Low: Settings S245, S90, S91, S92 and S264192
Maintenance193
Maintenance Check List193
Table 25 Maintenance Check List193
Spares194
Fuses194
Table 26 Fuses194
Appendix 1 Residual Risk Register195
Appendix 2 Measured Points P1/P34 Quick-Reference197
Table 27 Event Codes E1 to E25 Quick-Reference201
Appendix 3 Event Codes E1/E107 Quick-Reference201
Table 28 Event Codes E26 to E57 Quick-Reference202
Table 29 Event Codes E58 to E89 Quick-Reference203
Table 30 Event Codes E90 to E107 Quick-Reference204
Table 31 MODBUS Addresses and SCADA Information Pakmod a to P32205
Appendix 4 MODBUS Addresses and SCADA Information205
Table 32 MODBUS Addresses and SCADA Information P33 to S23206
Table 33 MODBUS Addresses and SCADA Information S24 to Opakmod [35]207
Table 34 MODBUS Addresses and SCADA Information P5 [34] to Required SVP208
Table 35 Compressor Number/Compressor Serial Number Record209
Appendix 5 Settings Record209

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J&E Hall Fridgewatch 2000 Specifications

General

Power Supply	24 VAC/DC
Enclosure Rating	IP65
Communication Protocol	Modbus RTU
Number of Inputs	8
Number of Outputs	4
Power Consumption	5W
Weight	0.5 kg
Communication	RS485
Humidity Range	non-condensing
Inputs	Digital and Analog

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