Manual - myChiller.com - Support Home | iii 1 Preface This manual is intended to be used in conjunction with Pro Refrigeration’s CR110 Refrigeration Controller

CR110 MANUALPro Refrigeration, Inc

ii | ProRefrigeration,Inc

TableofContents

1 Preface ill

Disclaimer ... . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . ill

Manufacture.Information .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... ill

Customer.Service... . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . ill

2 QuickStart 1

CR110.Controller.Overview.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

Quick.Start.Guide... .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 2

3 CR110Operation 6

CR110.Basic.Controls. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

Modes.Of.Operation .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 7

Temperature.Control.(PI.Loop) ... . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 9

4 CR110Wiring 10

Basic.System.Wiring.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 10

Sensor.Wiring.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 11

CR110.Communications.Wiring.. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 11

5 Troubleshooting 12

Default.CR110.Parameters... .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 12

CR110.Troubleshooting. ... . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 13

Replacement.Parts. ... . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 15

www.prochiller.com | iii

1 Preface

ThismanualisintendedtobeusedinconjunctionwithProRefrigeration’sCR110RefrigerationController.

Thismanualwillguideyouthroughtheprocessofinstalling,configuringandtroubleshootingyourCR110RefrigerationController.

Manufactured By:ProRefrigeration,Inc.

ProRefrigerationislocatedinAuburnWA.Auburnislocated30milesfromSeattle,WAintheshadowofMt.Rainier.

Physical Address:3268thSTSWAuburn,WA98001

www.prochiller.com

Mailing Address: POBOX1528Auburn,WA98071-1528

Telephone: 253-735-9466Fax: 253-735-2631

Customer ServicePleasefeelfreetocontactcustomerservicewithanyquestionspertainingtothisoranyotherProRefrigera-tion,Incproduct.

Customer Support Hours: Monday-Friday 7am-5pm (Pacific Standard Time)

Telephone: 253-735-9466Fax: 253-735-2631Email:[email protected]

Note: CheckthefollowingURLforthelatestversionofthismanualandotherProRefrigera-tion,Incproductdocumentation.http://www.prochiller.com/support

www.prochiller.com | 1

CR110 OVERVIEW

J1:Connectto24VACorDCPowerSource.

S2 Control Switch: Thisswitchcon-trolsthepowerandfunctionoftheCR110card.

LED’s CR1-CR9:CR110outputlights.SeeCR110OutputStatusLED’sforfurtherinformation

Sensors 1-8:0-5VInputSensors.SeeSensorWiringforfurtherinformation.

{

J13: ThisistheCR110’sprimarycommunicationport.

AUX: TheAUXportcanbeusedasanadditionalcommunicationport.

J7 (Analog Output): I->C=4-20mAV->C=0-10V

J20: PortJ20isusedwhenprogram-mingtheCR110EEPROMchip.

J3:01-04 & J8:05-08: 120Voltanalogoutputs.Seebasicsystemwiringforfurtherinformation

{

C Ports: Outputpowercomingfromexternalprotectioncomponents.

120/240: Outputpowercomingfromneutral.

Fuses K1-K8:2AMP130VACoutputfuses.Seereplacementpartssectionforpartnumber.

EEPROM Chip: ThechipisloadedwithlatestversionofCR110controllersoftwareatfactory.

LED’s CR10-CR13:CR110modelights.SeeModesOfOp-erationforfurtherinformation

8-PIN CR110 Communica-tion Chip

Power Surge Suppressor

Commutation Surge Suppressor

14-PIN J7 Analog Output Control Chip

LED CR14:CR14isacommunica-tionindicatorLED.ThelightwillblinkwhenitrespondstoanRS-485Communicationsrequest.

2 | ProRefrigeration,Inc

CR110 Quick Start

STEP 1VerifythatthemainpowertothesystemisOFF.ThiscanbeaccomplishedbyconfirmingthatthedisconnecthandleisintheOFFposition

STEP 2OpentheelectricalpanelandlocatetheCompressorCircuitBreakers

Basic Operation & Features

Thetypicalchillerapplicationcanconsistofonetofourcompressors,eachcompressorcontrolledbyadedicatedCR110ControlCard.TheTPCtouchscreenInter-faceprovidesalocaldisplayandoperatorinterface.TheTPCisnotneededforsystemoperationitsimplymonitors,recordsandprovidesanoperatorinterface.

AllaspectsoftheCR-110operationisbasedonpro-vidingthemostefficientoperationpossible.TheCR-110,looksatthedifferencebetweenthecoldesttemperaturesensorandtheSet-point.ItusesaPIlooptocalculateanoutputsignalfrom0to100per-cent.ThissignalisthenusedbymultipleCR-110’stostagetheliquidlinesolenoidvalveandunloaders.Theresultisaverysmoothandprecisetemperaturecon-trolwithoutshortcyclingthecompressors.Withtheeliminationofmultiplededicatedsetpointscontrollingmultiplecoolingstages,theCR110deliversaflexiblesetupwithmuchtightertemperaturevariationandcontrol.

Onamultiplecompressorsystem,eachcompres-sorutilizestwotemperaturesensorstodetectboththeChilledWaterSupplyTemperatureandChilledWaterReturnTemperature.Thisprovidesacompletefullredundantsystem.Bydefaultthecontrollerwillalternateleadcompressorsafter24hours(adjustable)ofcompressorruntime.

EachCR-110monitorsthecompressorsuctionpres-sure,suctiontemperature,anddischargepressure.Anyfailureofsensorsorexceedingtemperatureandpressurespecificationswillresultinanalarm.Analarmmodewillresultinanautomaticleadchangetothenextcom-pressorandorbackupcompressor.


STEP 6OntheCR110Card,locatetheOFF-RUN-PDtoggleswitch

STEP 7VerifythatthetoggleswitchisintheOFFposition

STEP 8TurnthemainpowertothesystemONbymovingthedisconnecthandletotheONposition

STEP 9Usingavolt-meterverifythatthemainpowervoltagematchesthatofthesystemvoltage

STEP 3SwitchthecompressorcircuitbreakerstotheOFFposition

STEP 4LocatetheCR110Cards

STEP 5RemovethecoverfromtheCR110Cards


STEP 10TurnthePROCESSPUMPswitchtotheONposi-tion.

STEP 11TurntheSTAGEswitchestotheONposition.

STEP 12TurntheCONTROLLERswitchtotheONposition.

STEP 13TurntheCONTROLLERswitchtotheONposition.

STEP 14Verifythatthetemperaturesandsystempressuresdis-playedonthecontrollerinterfacepanelareaccurate.

STEP 15Adjustthesystemsetpointto5ºFhigherthenthecurrentdisplayedtemperature.Pleasereferenceyourdisplaymanualforinstructionsonchangingsetpoint.

STEP 16Verifythatthegaugepressuresareapproximatelythesame(+-3-5psi)asthoseobservedonthecontrollerinterfacepanel.

STEP 17Performsteps12–15fortheremainingCR110Cards.


STEP 18TurntheCR110CardstoggleswitchtotheOFFposi-tion.

STEP 19Resetthelowoilpressurecontrolsforeachcompressor.

.

STEP 20SwitchthecompressorcircuitbreakerstotheONposi-tion.

STEP 21PlaceeachCR-110cardintheRUNmodebyswitch-ingtheOFF-RUN-PDtoggleswitchtotheRUNposition

STEP 22Torestoreyoursystemtonormal,readjustthesystemsetpointtotheappropriatesettingandverifyeachstageisrespondingaccordingly.

TheCR110CardisnowintheRUNMODEandshouldoperateonitsownfromthispointforwardac-

cordingtocoolingdemandandsystemsetpoint.

� | ProRefrigeration,Inc

CR110 Basic Controls

S2 Control SwitchInkeepingwiththebasicconceptofsimplicity,theactualactivecontrolsontheCR-110islimitedtooneswitch.ThisswitchislabeledS2,andislocatedintheupperrighthandcornerofthecircuitboard,andisshowninthepicturebelow.Thisisamulti-functionswitch,whichhasthreepositions.

•Pump Down: Iftheswitchisintheupposition,itwillcausethecompressortogointopumpdownmode.Itshouldpumpdownandshutoff.Thispositionislabeled‘PD’onthecircuitboard.

•Off: Centerpositionisoff.Thisshutsoffpowertothecircuitboardandeffectivelyshutsdownthesystem.Alsoplacingtheswitchintheoffpositionresetsanyalarmconditionswhichmayexist.

•Run: DownpositionisRUN.Thisenablesthesystemtoruninanormalmode,andcontroltherefrigerationsystemaccordingtotheprofilethemicroprocessorisusing.

•Test Mode: ToenterTestMode,movetheswitchfromOFFtoRUNthenrapidlytoPD.ThiswillcausetheCR-110togointoaspecial‘TestMode’fortrou-bleshootingandinitialsetupoptions.

www.prochiller.com | �

Shutdown ShutdownmodeoccurswhentheS2ControlSwitchontheCR110isplacedinthePumpDownposition,oriftheunitisremotelyswitchedoff.InShutdown,thecompressorwillpumpdownifneeded.AremoteShut-downcanbeover-riddenbyswitchingtheS2switchonthecontrollertoOffthenbacktoRun.

Coil Dry CoilDrymodeisactivatedafterahotgasdefrost.Immediatelyafterthedefrostcycle,theliquidlinesolenoidisopenedforapre-settime,withtheevapo-ratorfansoff.Thiswillcauseanymoistureleftintheevaporatorcoiltodry.ThesettingfortheCoildryisinseconds,andisnormallysetfrom30to60seconds.Ifthisvalueissettozero,thecoildryfeaturewillbedisabled.

High Head HighHeadAlarmisactivatedwhenthedischargepressureexceedsapre-setvalue.Thisistypicallyset25to50psilessthanthemechanicalhighpressureswitch.Thisalarmisactivatedinstantaneously.WhenaHighHeadAlarmoccurs,alloutputswillshutoffandthecontrollerwilllockoutofanyothermode.ThealarmcanberesetbyusingtheS2switchonthecontrollertopowertheunitoffandthenbacktotherunpositionorthroughtherestbuttononyourdisplay.

DP Sensor Fail DPSensorFailmodeisafailureofthedischargepres-suresensor.Thisisacriticalsensor,andwillshutdownalloutputsimmediatelyifafailureisdetected.Thefailurecouldbecausedbyanumberofthings;brokenwire,sensorplugorthesensoritself.

SP Sensor Fail SPSensorFailmodeisafailureofthesuctionpressuresensor.Thisisacriticalsensor,andwillshutdownalloutputsimmediatelyifafailureisdetected.Thefailurecouldbecausedbyanumberofthings;brokenwire,sensorplugorthesensoritself.

Modes Of OperationTheCR110has16differentmodesofoperation.TheyarelistedbelowwithdetailandtheircorrespondingLEDindication.TheLED’sreferencedbelowarefromlefttorightCR10,CR11,CR12,andCR13

Standby: StandbyoccurswhenSet-pointismet.InStandby,thecompressorshouldbepumpeddownandreadytostarttherefrigerationcycle.

Refrigeration: RefrigerationmodeoccurswhentheCoolingDemandreachesthepre-settemperature.ThiswilloccurwhenthePIloopadjuststheoutputabovetheLiquidLineSolenoidOnpercentage.Inthismode,theliquidlinesolenoidisopenedandthecompressorwillstartassoonasthesuctionpressurerisestotheCompressorOnparameter.

Defrost: Defrostmodeoccurswhenadefrostcyclehasbeeninitiated.Thisinitiationcanoccurfromanumberofsources,demanddefrost,timeddefrostormanualinitiateddefrost.Thedefrostmodeappliestohotgas,electric,orairdefrost.

Pump Down: PumpDownmodeoccurswhentheRefrigerationmodehasended,orthesuctionpressurerisesabovetheturnonpointinthestandbymode.Inthepumpdownmode,theliquidlinevalveisclosedandthecompressorpumpsdowntothesuctionshutoffpoint.

Short Cycle: ShortCyclemodeisasafeguardthatpreventsthecompressorfromshuttingdownandthenrestartexces-sively.Typicallytheshortcycletimerissetforamini-mumofoneminute.

� | ProRefrigeration,Inc

Fan / Pump Failure Fan/PumpFailureindicatesafailureorshutdownoftheevaporatorfancircuitorcirculationpump,nofeed-backfromtheprovingcircuit.

Program ErrorIfalltheredLED’Sareon,andthegreenLEDison,thisindicatesaProgramErrorandwillpreventnor-maloperation.Iftheflashmemoryhasbeenrepro-grammed,thisconditionwillexist,andtheoperatingprofilewillhavetobeloaded.

Normal OperationNormalOperationisindicatedbyablinkinggreenLEDonCR2.

RS-485 CommunicationsTheLEDlocatedonCR14willblinkwhenitrespondstoaRS-485communicationsrequesttransmittedoverJ13orAUX.

CR110 Output Status LEDsTheCR110has9120voltanalogoutputs.TheyarelistedbelowwiththeircorrespondingLEDindication.

CR1 CondenserFan1

CR3 CondenserFan2

CR4 CondenserFan3

CR5 LiquidLineSolenoid/CoolingDemand

CR6 CirculationPump(Pump off when light is on)

CR7 Compressor

CR8 Unloader1/EvaporatorFan

CR9 Unloader2/Defrost

Low Suction Alarm LowSuctionAlarmmodeisactiveonlyintheRefrig-erationmode.Ithasbothapsivalueforthesuctionpressureaswellasanalarmtimerassociatedwithit.Ifthetimerissettozero,thealarmwillbedisabled.Thelowsuctionalarmpointshouldbesetsomewhereabovethelowoperatorshutoffpoint.Thisisaveryvaluablealarmandshouldbesetaccordingly.UsePTtablesforfreezepoints.

External Alarm ExternalAlarmmodecanbeactivatedbyanumberofexternaldevices.Oilpressure,highheadpressure,phasemonitorandcompressorprotectionmodulesaresomeoftheexternaldevicesthatcanbeusedtosu-pervisetheCR-110controller.ThesedevicesprovidepowertotheJ8-05terminalonthecontroller.Ifanyoneofthesedevicestrip,alloutputswillshutoffandthe3LED’Swillstarttoblink.After5minutestheLED’Swillcomeonsteadyandlockoutinanalarmcondition.Iftheexternalalarmisresetbeforethe5minutesisup,thennormaloperationwillberesumed.

Super Heat TheSuperHeatwindowhasahighandlowsetting,andatimedelay.TheCR-110calculatesthecompres-sorSuctionSuperHeatcontinuously,andcomparesthissettingtothealarmparameters.Mostcompressormanufacturersrecommendthesuctionsuperheatrunbetween20to40degreesF.TheSuperHeatwindowisactiveanytimethecompressorisrunning.Settingthetimedelaytozerowilldisablethisalarm.

Temperature Sensor TheTemperatureSensorFailureAlarmisactivatedwhenacontrollingtemperaturesensorisfoundoutofrange.ExamplewouldbetheRoomSensorwhenrun-ningintheSet-pointmode.

Note: Output4whenusedinachillerap-plicationisnormallyoff.Thisisforfailsafeconditions.Whenoutput4isoff,thecircula-tionpumpshouldberunning.Whenoutput4ison,thepumpisintheoffconditiontosavepower.

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Temperature Control

TheCR110RefrigerationControllerutilizesaPIloopthatoperatesbycomparingthechilledwaterinletsetpointandthecoldestsensor.

EverytimeaPILoopMathCalculationisperformedtheresultisanewOUTPUT.ThesystemusesthisOUTPUTtocontrolthefollowingitems:

• Liquid Line Solenoid Valve On/Off

Liquid Line Solenoid Valve is ON 1.SuctionPressureIncreases 2.CompressorStarts Liquid Line Solenoid Valve is OFF 1.SuctionPressureDecrease 2.CompressorStops

• Unloader Valve On/Off LLS ON% Reached: 1.CoolingDemandisHigh 2.CylinderLoads LLS OFF% Reached: 1.CoolingDemandisLow 2.CylinderUnloads

EachCR110RefrigerationControllercardissuppliedwithit’sowndedicatedsensorsproviding100%redun-dancy.

PI Loop ExplainedThePILoopformulaisshownbelowwithdefinations,detailsandexamples.

NEWOUTPUT=OLDOUTPUT+P+I

• P (Default is 22):+ Pispositivewhenthecoldestsensorreads abovesetpoint.- Pisnegativewhenthecoldestsensorreadsbelow setpoint.

• I (Default is 5):+ Iispsoitivewhenthecoldestsensortempera- tureisincreasing.- Iisnegativewhenthecoldestsensortempera- tureisdecreasing.

Example 1: Old Output = 5% Set Point = 28 F Inlet = 27 F Oulet = 29 F Inlet Temperature Increasing NewOutput=5+(-22)+5 =22

Example 2: Old Output = 30% Set Point = 28 F Inlet = 29 F Oulet = 30 F Inlet Temperature Decreasing NewOutput=30+22+(-5) =47


External ProtectionTherearethreedevicesthatcanremove120VpowertotheCR110cardshuttingdownthesystemandsendingthecontrollerintoanExternalAlarmtheyareshownbelow.Basic System Wiring

Thissectionshowsanoverviewofthetypicalsystem’sinstallationwiring.ThefollowingassumesanAir-CooledProChilleroperatingCR110V2.84orgrater.Belowaresomewiringexamples.Forexactwiringforyoursystempleaserefertoyoursystemselectricalschematics.

CR110 Power WiringMultiplecardsmaybepoweredfromasingletrans-former.Thecontrolpowermustbecommonforeachofthecards.Eachcardrequiresroughly6VAofpower.

Outputs 1-4CF1:CondenserFan1 CF2:CondenserFan2

CF3:CondenserFan3 CP:CirculationPump

Compressor ControlC1:Coompressor1 LL1:LiquidLineSolenoid1

UL1:Unloader1 UL2:Unloader2

Note: Output’s7&8whenusedforUnloadersoperatewithreverselogicforfailsafeoperation.Whentheoutputsarenotlittheunloadershavethecompressorcylindersloaded.

120VA

Card1 Card2

J124VDCJ124VDC

0102

03

04

CF1CF2

CF3CP

Neutral

0506

07

08

C1LL1

UL1UL2

Neutral

CC

240

120

L1

HighPressureSwitch

CompressorProtectionModule

OilSafetySwitch

Neutral


Sensor WiringAlltemperatureandpressuresensors,andcurrentswitchesuseacommon5VDC.

Input Sensor Description•0-500PSIDischargePressureTransducer.

•0-100PSISuctionPressureTransducer.

•CompressorSuctionTemperatureSensor.

•ProcessTemperatureorOutsideAmbientAirTem-peratureSensor(OPTIONALITEM)

•0-100PSIOilPressureTransducer(OPTIONALITEM)

•CirculationPump/EvaporatorFanProvingCurrentSensor

•EvaporatorGlycolInletTemperatureSensor(Canbelocatedinstoragereservoir)

•EvaporatorGlycolOutletTemperatureSensor(Canbelocatedinstoragereservoir)

CR110 Communications WiringTheinter-cardcommunicationsisdoneona2-wireRS-485busswithshield.Therearesimply3wiresthatrunbetweenallcards,connectingtheminparal-lel.Thecommunicationsbaudrateis9600.Belowaresomewiringexamples.Forexactwiringforyoursystempleaserefertoyoursystemselectricalschematics.

Typical Non-RGX Communication Wiring

Typical Wiring With RGX Communications

Note:•OutsideAmbientAirTemperatureSensormustbeusedforlowambientcontroloption.•OilPressureTransducercanbeusedtomeasurenetoilpressure.

To Controller HMI (Refer To Interface Manual)

To Controller HMI (Refer To Interface Manual)

0-100psi 0-500psi 0.5-4.5 VDC

2250 Ohm Thermistor


CR110 Default ParametersBelowisachartthatcontainsthedefaultCR110parametersforProChillerSystemswithonetofourcompressors.Fordirec-tionsonsettingtheseparameterspleaseseetheprogrammingsectionofyourinterfacemanual.


CR110 Troubleshooting


CR1

CR3

CR4

CR5

CR6

CR7

CR8

CR9


Replacement PartsThefollowingisalistofreplacementpartsfortheCR110RefrigerationController.Callforpricingandavailabil-ity.

Description Part Number

CR110ControlCard CR110-B

SuctionPressureTransducer(0-100psi) P499RCP-101C

DischargePressureTransducer(0-500psi) P499RCP-105C

TransducerCable WHA-P399-400C

TemperatureSensor A4175-21

24VDCPowerSupply PS5R-SC24

CurrentSensorSwitch RIBXKTF

AlarmCable J20-CC-ALARM-36

PowerSurgeProtector(VR2) P6KE51CACT-ND

CommunicationSurgeProtector(VR4) P6KE6.8ACCCT-ND

CommunicationChip(U2) MAX483CPA

OutputFuses(K1-K8) Z909-ND

CR110 AccessoriesThefollowingisalistofaccessoriesfortheCR110.Callforpricingandavailability.

Description Part Number

G55GrayscaleInterface G55-BW

G55ColorInterface G55-CL

TS110TouchscreenInterface TS110

RGXCommunicationGateway(WebAccess) 105-1-755

5Port24VEthernetSwitch MOX-EDS-205

Pro Refrigeration, Inc3268thSTSWAuburn,WA98001Tel:800-845-7781Fax:253-735-2631

Documents

Manual - myChiller.com - Support Home | iii 1 Preface This manual is intended to be used in conjunction with Pro Refrigeration’s CR110 Refrigeration Controller