J&E Hall Fridgewatch 4000

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Publication 3-71

Issue 3.3 : 01/23

Installation, Operating and Maintenance Manual

Fridgewatch

4000 Controller Mk2

Software Version FW40Mk2P3.105 Onwards

This publication is applicable to the following

J & E Hall International Compressors:

HallScrew HSO 2000, HS 3100, HS 3200,

HS 4200, HS 5200 and HS 6200

Series Compressors

Main Page

Table of Contents5
About this Publication14
Safety Warnings and Symbols14
Units of Measurement14
Terminology14
Additional Copies14
Care and Protection of Fridgewatch15
Anti-Static Precautions15
Electrical Interference15
Prolonged Storage15
Abbreviations16
Table 1 Abbreviations16
General Description17
Standalone Versions17
Table 2 Fridgewatch 4000 Controller (Standalone Versions) - Technical Data17
Human-Machine Interfaces (HMI) Displays18
Fig 1 Fridgewatch 4000 Controller (Standalone Versions) - Front Panel and HMI Displays18
Fig 2 Fridgewatch 4000 Controller (Standalone Standard Version) - Panel Internal Layout19
Fig 3 Fridgewatch 4000 Controller (Standalone Standard and Harsh Environment Versions) - Enclosure21
Fridgewatch 4000 Controller (Standalone Arrangement) - Mounting22
Fig 4 Fridgewatch 4000 Controller (Standalone Arrangement) - Mounting22
Fridgewatch 4000 Controller (Standalone Arrangement) - HMI Interface23
Integrated Version23
Application23
Plant Control and Monitoring23
Table 3 Analogues, Settings and Delay Times23
Safety Monitoring24
Options for Set Point Control24
Set Point, Start and Stop Values, Second Set Point and Set Point Override24
Operating Modes24
Table 4 Options for Set Point Control24
Limiting25
Oil Management Systems25
Auxiliary Control25
Table 5 Set Point, Start and Stop Values, Second Set Point Value and Set Point Override25
Principles of Control26
Compressor Capacity Control26
Hallscrew HSO 2000 Series Capacity Modulation by Slide Valves26
Hallscrew HS 3100 to HSO 6200 Series Capacity Modulation by Slide Valves26
Slide Valve Position Signal27
Intermediate Load Outputs27
Fig 5 Proportional and Integral (P + I) Control28
Proportional and Integral (P + I) Control29
Proportional Band29
Integral Action Time30
Fig 6 Integral Control Action30
Set Point Temperature/Pressure31
Evaporator Superheat Set Point/Liquid Level Set Point Value31
Economiser Superheat Set Point32
Starting and Stopping the Compressor32
Fig 7 Possible Compressor Start/Stop and Capacity Control Modes33
Control Philosophy for Compressor Operation after a Transmitter Failure34
Capacity Control by Fridgewatch 400034
Auto Capacity Control34
Remote Capacity Control34
Manual Capacity Control35
Limiting Inputs35
Current Limiting35
Suction Pressure Limiting35
Discharge Pressure Limiting35
Evaporator Cooled Medium Outlet Temperature Limiting35
Table 6 Summary of Limiting Inputs and Associated Settings35
Other Limiting Conditions36
Levels of Limiting36
Discharge High Pressure Trip Switch Function36
Oil Management Systems37
Table 7 Summary of Differential Pressure Sensing37
Summary of Differential Pressure Sensing38
Table 8 All Hallscrew Compressors - Oil Pressure Trips by Differential Pressure Switches38
Table 9 HSO 2000 Series Compressors - Oil Pressure Trips by Transmitters39
Demand Oil Pump40
Table 10 HS 3100, HS 3200, HS 4200, HS 5200 and HS 6200 Series Compressors - Oil Pressure Trips by Transmitters40
Oil Filling Pump41
Fridgewatch System Controller and SCADA42
Fridgewatch System Controller42
SCADA System42
Fig 8 Fridgewatch 4000 Controller Interface with Fridgewatch System Controller43
Fig 9 Fridgewatch 4000 Controller Interface with SCADA44
Installation45
Digital Inputs and Outputs45
Analogue Inputs - Installing Transmitters45
Fig 10 Digital Inputs with Inputs Connected (Page 1 Illustrated)45
Transmitter Wiring46
Transmitter Enabling and Calibration46
Using Fridgewatch 4000 to Drive Relays46
Fig 11 Connecting Diodes46
Fig 12 Transmitter Installation47
Status Indicators48
User Interface48
Hard' and 'Soft' Display Function Buttons48
Interface Common to Every Page48
Time and Date48
Access Level48
Table 11 'Hard' and 'Soft' Display Function Buttons48
Reset Required Indicator, Acknowledge and Reset Buttons49
Current Alarms and Alarm History49
Menu Page49
Home Page and Digins50
Back/Next, Analogue Inputs and P + I Diagnostics50
Home Page51
Fig 13 Home Page Example: Compressor in 'Off' Mode and SC1 and SC2 Not Configured51
Fig 14 Home Page Example: Compressor 'Available52
Fig 15 Home Page Example: Compressor 'Tripped52
Start (Manual Start/Stop Only)53
Load and Unload (Manual Capacity Control Only)53
Controlled Stop/Stop Button RESET53
System Diagnostics54
Fig 16 System Diagnostics Page54
Menu Page55
Fig 17 Menu Page55
Read-Only Pages56
Digital Inputs56
Fig 18 Digital Inputs Pages 1 to 356
Digital Outputs58
Fig 19 Digital Outputs Pages 1 to 358
Analogue Inputs60
Fig 20 Analogue Inputs Pages 1 to 460
Analogue Outputs62
Fig 21 Analogue Outputs Pages 1 and 262
P + I Diagnostics63
Fig 22 P + I Diagnostics Page63
Primary/Secondary64
Fig 23 Primary Compressor Page64
Fig 24 Secondary Compressor Page64
Trending and Logging Data65
Fig 25 Trending and Logging Data Page65
Fig 26 Trending Data - Evaporator Inlet and Outlet Temperature65
Fig 27 Trending Data - Condenser Inlet and Outlet Temperature66
Fig 28 Trending Data - Compressor Discharge, Suction and Oil Temperature66
Fig 29 Trending Data - Compressor Discharge, Suction and Oil Injection Pressure67
Fig 30 Trending Data - Compressor Capacity67
Fig 31 Trending Data - Compressor Motor Current68
Fig 32 Trending Data - Compressor Lub Oil and Net Oil Pressure, Oil Filter Differential Pressure68
Fig 33 Trending Data - Compressor Discharge and Suction Superheat69
Fig 34 Trending Example 170
Fig 35 Trending Example 170
Fig 36 Connecting to the CPU Via Ethernet Cable72
Fig 37 Trending and Logging Data - Data Logging73
Fig 38 Uploading Data Log Files74
Clean Screen76
Fig 39 Clean Screen76
Operator Settings Pages77
System Control Settings77
Fig 40 System Control Settings Pages 1 to 377
Economiser Control Settings79
Fig 41 Economiser Control Settings Pages 1 and 279
Liquid Injection Control Settings80
Fig 42 Liquid Injection Control Settings Page80
Evaporator and Oil Cooler Control Settings81
Fig 43 Evaporator and Oil Cooler Control Settings Pages 1 and 281
Condenser Control Settings82
Fig 44 Condenser Control Settings Page82
Hot Gas Valve Control Settings83
Fig 45 Hot Gas Valve Control Settings Page83
Suction Pressure Limiting Control Settings84
Fig 46 Suction Pressure Limiting Control Settings Page84
Primary/Secondary Control Settings85
Fig 47 Primary/Secondary Control Settings Page85
Alarm, Limiting and Trip Settings, Delay Times86
Fig 48 Alarm, Limit & Trip Settings Pages 1 to 1186
Operating Mode92
Fig 49 Operating Mode Page92
Set Time and Date93
Fig 50 Set Time and Date Page93
Configuration Settings94
ANIN Configuration94
Fig 51 ANIN Configuration Pages 1 to 494
System Configuration Settings97
Fig 52 System Configuration Pages 1 to 697
Hours Run and Number of Starts101
Simulate Outputs101
Fig 53 Hours Run and Number of Starts Page101
Passwords102
Password Security102
Fig 54 Screen Page Categories and Colour Coding102
Entering a Password103
Fig 55 Password Logon103
Commissioning104
Supplying Power for the First Time104
Commissioning - Sequence of Operations104
Authority to Use Passwords105
Inputting System Configuration Settings105
Changing System Configuration Settings after Commissioning106
Inputting Operator Settings106
Changing Operator Settings after Commissioning106
Operating Mode for the First Start106
Fig 56 Viewing or Changing System Configuration Settings107
Fig 57 Viewing or Changing Control Settings108
Fig 58 Viewing or Changing Operator Settings109
Display Messages111
Information Only Messages111
Alarm Messages111
Trip Messages111
Alarm, Trip and Information Only Messages112
Suction Pressure: Alarm, Limiting and Trip112
Suction Temperature High: Trip112
Suction Superheat: Alarm112
Table 12 Suction Pressure: Alarm, Limiting and Trip112
Table 13 Suction Temperature High: Trip112
Table 14 Suction Superheat: Alarm112
Discharge Pressure High: Alarm, Limiting and Trip113
Discharge Temperature High: Alarm and Trip113
Discharge Superheat: Alarm113
Table 15 Discharge Pressure High: Alarm, Limiting and Trip113
Table 16 Discharge Temperature High: Alarm and Trip113
Table 17 Discharge Superheat: Alarm113
Oil Differential Pressure at Start-Up (ODP2) Low: Trip114
Oil Differential Pressure During Running (ODP1) Low: Alarm and Trip114
Table 18 Oil Differential Pressure at Start-Up (ODP2) Low: Trip114
Table 19 Oil Differential Pressure During Running (ODP1) Low: Alarm and Trip114
Oil Filter Differential Pressure High: Alarm and Trip115
Oil Injection Temperature High: Alarm and Trip115
Lube Oil Temperature High: Alarm and Trip115
Table 20 Oil Filter Differential Pressure High: Alarm and Trip115
Table 21 Oil Injection Temperature High: Alarm and Trip115
Table 22 Lube Oil Temperature High: Alarm and Trip115
Oil Separator/Reservoir Level Low: Trip116
Oil Drain Not Clear: Information and Trip116
Compressor Slide Valve Position (Motor Speed) Error: Alarm116
Compressor Failed to Unload: Trip116
Table 23 Oil Separator/Reservoir Level Low: Trip116
Table 24 Oil Drain Not Clear: Information and Trip116
Table 25 Compressor Slide Valve Position (Motor Speed) Error: Alarm116
Table 26 Compressor Failed to Unload: Trip116
Condenser Cooling Medium Inlet Temperature: Alarm117
Condenser Cooling Medium Outlet Temperature: Alarm117
Condenser Cooling Medium Differential Pressure Low: Alarm and Trip117
Evaporator Cooled Medium Inlet Temperature: Alarm117
Table 27 Condenser Cooling Medium Inlet Temperature: Alarm117
Table 28 Condenser Cooling Medium Outlet Temperature: Alarm117
Table 29 Condenser Cooling Medium Differential Pressure Low: Alarm and Trip117
Table 30 Evaporator Cooled Medium Inlet Temperature: Alarm117
Evaporator Cooled Medium Outlet Temperature: Alarm, Limiting and Trip118
Evaporator Cooled Medium Differential Pressure: Alarm and Trip118
Table 31 Evaporator Cooled Medium Outlet Temperature: Alarm, Limiting and Trip118
Table 32 Evaporator Cooled Medium Differential Pressure: Alarm and Trip118
Evaporator Liquid Level: Alarm and Trip119
Compressor Motor Current: Limiting119
Compressor Motor Temperature High: Trip119
Table 33 Evaporator Liquid Level: Alarm and Trip119
Table 34 Compressor Motor Current: Limiting119
Table 35 Compressor Motor Temperature High: Trip119
Compressor Motor or Starter Failure120
Table 36 Compressor Motor or Starter Failure120
Oil Pump Motor or Starter Failure121
Table 37 Oil Pump Motor or Starter Failure121
Condenser Pump/Fan Motor or Starter Failure122
Table 38 Condenser Pump/Fan Motor or Starter Failure122
Evaporator Cooled Medium Pump Motor or Starter Failure123
User Trip123
Emergency Stop Pressed123
Table 39 Evaporator Cooled Medium Pump Motor or Starter Failure123
Table 40 User Trip123
Table 41 Emergency Stop Pressed123
Starting or Loading Inhibited124
Force Unload124
Table 42 Starting or Loading Inhibited124
Table 43 Force Unload124
External Controller Fault: Evaporator, Economiser, Oil Rectifier or Liquid Injection125
User Input Faults 1 and 2 (Digins I301.4 and I301.5)125
Table 44 External Controller Fault: Evaporator, Economiser, Oil Rectifier or Liquid Injection125
Table 45 User Input Faults 1 and 2125
Refrigerant Leak Detector126
Transmitter out of Range126
Table 46 Refrigerant Leak Detector126
External Reset and Alarms, Clearing Alarms and Trips127
External Alarm/Trip Acknowledge/Reset127
External Audible and Visual Alarms127
Compressor Healthy Signal127
Identifying and Clearing Alarms and Trips127
Normal Healthy Condition127
Table 47 External Alarms Digouts Q201.5 and Q201.6 Behaviour127
Alarm Condition128
Acknowledge Alarm128
Trip Event128
Fig 59 Identifying and Clearing Alarms and Trips129
Fig 60 Limiting, Alarm and Alarm History Screens131
Operator Settings132
System Control Settings132
Set Point, Start and Stop Values133
Stop-To-Start Time Differential133
Proportional and Integral (P + I) Control133
Compressor Unload Limit134
Load and Unload Pulse Duration134
Intermediate Load Outputs135
Fig 61 Example of Using Intermediate Load Output 1136
Variable Volume Ratio (VV ) Configuration for Hallscrew 5200 and 6200 Series Compressors137
Table 48 Variable Volume Ratio (VV R ) Applications, Values for S20 and SC48137
Economiser Control Settings138
Fig 62 Cycle Time139
Economiser Control Enable and Disable140
Liquid Injection Control Settings141
Evaporator and Oil Cooler Control Settings143
Evaporator Control Settings143
Oil Cooler Control Settings145
Condenser Control Settings146
Hot Gas Bypass Valve Control Settings148
Primary/Secondary Control Settings150
Suction Pressure Limiting Control Valve Settings151
Alarm, Limiting and Trip Settings, Delay Times153
Motor Current High153
Discharge Pressure High153
Suction Pressure Low154
Fig 63 Discharge Pressure High: Settings ALT9, ALT10, ALT11, ALT12 and ALTT3154
Suction Pressure High155
Oil Differential Pressure Low at Start-Up155
Fig 64 Suction Pressure Low: Settings ALT2, ALT3, ALT7, ALT8 and ALTT2155
Oil Differential Pressure Low During Running156
Oil Filter Differential Pressure High157
Oil Injection Temperature High157
Fig 65 Oil Differential Pressure Low During Running: Settings ALT14, ALT15, ALTT5, ALTT6 and ALTT27157
Lube Oil Temperature High158
Discharge Temperature High158
Suction Temperature High158
Condenser Cooling Medium Inlet Temperature High or Low158
Condenser Cooling Medium Outlet Temperature High or Low158
Condenser Cooling Medium Differential Pressure Low159
Evaporator Cooled Medium Inlet Temperature High or Low159
Evaporator Liquid Level160
Fig 66 Condenser Cooling Medium Differential Pressure Low: Settings160
ALT43, ALT44, ALTT23, ALTT31 and ALTT33160
Evaporator Cooled Medium Outlet Temperature Low161
Fig 67 Evaporator Liquid Level: Settings ALT51, ALT52, ALT53, ALTT34 and ALTT35161
Evaporator Cooled Medium Outlet Temperature High162
Evaporator Cooled Medium Differential Pressure High162
Fig 68 Evaporator Cooled Medium Outlet Temperature Low: Settings162
ALT24, ALT25, ALT26, ALT27 and ALTT11162
Evaporator Cooled Medium Differential Pressure Low163
Suction Superheat High163
Suction Superheat Low164
Discharge Superheat High164
Fig 69 Evaporator Cooled Medium Differential Pressure Low: Settings164
ALT33, ALT34, ALTT14, ALTT16 and ALTT32164
Discharge Superheat Low165
Unload Pulses Per Sample Time165
Oil Drain Delay Time165
User Trip Nuisance Trip Delay Time165
Oil Separator/Reservoir Nuisance Trip Delay Time165
Configuration Settings166
ANIN Configuration, Calibration and Scaling166
Transmitter Calibration Overview166
Fig 70 Transmitter Calibration166
Pressure Transmitter Calibration167
Fig 71 Transmitter Calibration - Examples167
Temperature Transmitter Calibration168
Motor Current Transmitter Calibration169
Compressor Slide Valve Position LVDT Calibration169
System Configuration170
Compressor Number170
System Refrigerant170
Table 49 System Refrigerant Type - Values for SC2170
Compressor Drive171
Compressor Number of Starts171
Oil Management System171
Oil Differential Pressure at Start-Up171
Oil Differential Pressure During Running172
Table 50 Oil Differential Pressure (ODP2) Sensing Defined - Values for SC7172
Table 51 Oil Differential Pressure (Running) ODP1 Sensing Defined - Values for SC8172
Oil Filter Differential Pressure173
Table 52 Oil Filter Differential Sensing Defined - Values for SC9173
Compressor Capacity Control Valve Type174
Table 53 Capacity Control Valve Application and Operation - Values for SC10174
Compressor Slide Valve Position/Motor Speed Correction175
Fig 72 Slide Valve Position (Svp)/Motor Speed: Error Tolerance - Values for SC11176
Slide Valve Position/Motor Speed Value for Minimum Load177
Compressor Fails to Unload at Start177
Control, Start and Stop Variables, Second Set Point177
Run Enable Signal178
Table 54 Run Enable Required in Different Operating Modes - Values for SC18178
Compressor Start Time179
Oil Pump Start Time and Minimum Run Time179
Demand Oil Pump Start and Stop179
Evaporator Pump Selection, Start and Run Times180
Condenser Start Time and Run-On Time180
Pump-Down180
Oil Rectifier Enable181
Economiser Superheat Control Enable181
Evaporator Superheat or Liquid Level Control Enable182
Liquid Injection Control Enable182
Condensing Pressure Control Enable182
Compressor Slide Valve Position/Motor Speed Definition183
Operating Mode Indication183
Communications183
Table 55 Operating Mode Indication - Values for SC42183
Hot Gas Bypass Valve or Suction Pressure Limiting Control Enable184
Primary/Secondary185
Variable Speed Drive185
Measurement Units185
Fig 73 Example of FW4000 Display Page in Metric and Imperial Units186
Table 56 Metric Pressure Transmitter and Temperature Sensor Ranges Used with FW4000186
Maintenance187
Maintenance Check List187
Spares187
Table 57 Maintenance Check List187
Fig 74 FW4000 Stand-Alone Version Internal Equipment Layout and Terminal Arrangement188
Table 58 Fuses and Relays, Electronic Modules and HMI189
Table 59 Residual Risk Register190
Appendix 1 Residual Risk Register190
Fig 75 Panel Isolator IQ1 for Incoming 24 V DC 10 Amp Supply191
Fig 76 Terminal Nomenclature and Identification191
Appendix 2 Wiring Connections191
Fig 77 Slot 1 CPU on Board DIGINS, Addresses I100.0 to I101.5, ANIN 24 and ANOUT 6192
Fig 78 Slot 2 CPU on Board DIGINS, Addresses I200.0 to I201.7194
Fig 79 Slot 3 CPU on Board DIGINS, Addresses I300.0 to I301.7196
Fig 80 Slot 1 CPU on Board DIGOUTS, Addresses Q100.0 to Q101.1198
Fig 81 Slot 2 CPU on Board DIGOUTS, Addresses Q200.0 to Q201.7200
Fig 82 Slot 3 CPU on Board DIGOUTS, Addresses Q300.0 to Q301.7202
Fig 83 Slot 4 ANINS 0 to 3, ANOUTS 0 and 1204
Fig 84 Slot 5 ANINS 4 to 7, ANOUTS 2 and 3205
Fig 85 Slot 6 ANINS 8 to 11, ANOUTS 4 and 5205
Fig 86 Slot 7 ANINS 12 to 15207
Fig 87 Slot 8 ANINS 16 to 19207
Fig 88 Slot 9 ANINS 20 to 23207
Fig 89 RS 485 Communication Board210
Table 60 RS 485 Termination and Bias210
Table 61 Analogue Input ANIN 00/ANIN 25 Quick-Reference and Calculated Values212
Appendix 3 Analogue Inputs and Outputs212
Table 62 Analogue Inputs ANIN 00/ANIN 25 Transmitters213
Table 63 Analogue Outputs ANOUT 00/ANOUT 07213
Table 64 Digital Inputs I100.0/I301.7214
Appendix 4 Digital Inputs and Outputs214
Table 65 Digital Outputs Q100.0/Q301.7216
Table 66 HMI Trip Display Messages217
Appendix 5 HMI Display Messages217
Table 67 HMI Alarm Display Messages218
Table 68 HMI Limiting Display Messages219
Table 69 HMI out of Range Display Messages219
Table 70 HMI out of Range Display Messages220
Table 71 SCADA Information: ANINS, Calculated Values, ANOUTS Etc221
Appendix 6 SCADA Information221
Table 72 SCADA Information: ANIN out of Range Flags223
Table 73 SCADA Information: ALT Trip Flags225
Table 74 SCADA Information: ALT Alarm Flags226
Table 75 SCADA Information: Limiting Flags227
Table 76 SCADA Information: Alarm Inhibit Flags228
Table 77 SCADA Information: DIGINS229
Table 78 SCADA Information: DIGOUTS230
Table 79 SCADA Information: Communications231
Table 80 SCADA Information: Data Received231
Table 81 SCADA Information: Data Block 33 @ 4 Ma and Data Block 34 @ 20 Ma232
Table 82 SCADA Information: Array 'Elapsed Time Array for HMI Data Block 53233
Table 83 SCADA Information: Array 'Control Diagnostic Data234
Table 84 System Control Setting Addresses S1/S23235
Appendix 7 Control Setting Addresses235
Table 85 Economiser Control Setting Addresses EC1/EC14236
Table 86 Evaporator Control Setting Addresses E1/E12236
Table 87 Condenser Control Setting Addresses C1/C10237
Table 88 Liquid Injection Control Setting Addresses LI1/LI9237
Table 89 Hot Gas Bypass Valve Control Setting Addresses HG1/HG8237
Table 90 Primary/Secondary Control Setting Addresses PS1/PS5238
Table 91 Oil Cooler Control Setting Addresses OC1/OC2238
Table 92 Suction Pressure Limiting Control Valve Setting Addresses SPL1/SPL8238
Table 93 Alarm, Limiting and Trip Setting Addresses ALT0/ALT53239
Table 94 Alarm, Limiting and Trip Delay Time Setting Addresses ALTT0/ALTT35241
Table 95 Analogue Input Configuration Setting Addresses ANIN 00/ANIN 25242
Table 96 System Configuration Setting Addresses SC1/SC53244
Table 97 Compressor Number/Compressor Serial Number Record246
Appendix 8 Settings Record246

Power Supply	24 VAC/DC
Operating Temperature	-20 to +60°C
Mounting	DIN Rail
Display	LCD
Input Voltage	24 VAC/DC
Enclosure Rating	IP20
Communication Protocol	Modbus RTU
Weight	200g

J&E Hall Fridgewatch 4000 - User Manual

Table of Contents

J&E Hall Fridgewatch 4000 Specifications

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