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INSTRUCTION MANUAL FOR SCREW COMPRESSOR UNIT CONTROLLER MYPRO-CPIV MYPRO-CPIV (standard version) Read this manual carefully before you can use and service MYPRO-CPIV safely and properly. F1 START STOP CLEAR ALARM F2 F3 F4 F5 F6 F7 1 2 3 4 5 6 7 8 9 0 . - ALT ESC SAVE ENTER SH IFT DELETE TAB MYPRO-CPⅣ QT108300 - 1 - • This manual has been prepared as a guide to allow you to use the Screw Compressor Unit Controller MYPRO-CPIV properly and safely. Follow all the instructions in this manual. Failure to do so could result in unforeseen accidents. • Keep this manual handy for ready and regular reference by all persons working on your MYPRO-CPIV. • If the manual is lost or damaged, contact any of the Mayekawa offices or sales/service centers in your area to order a new copy. • This manual must remain with the product when you resell it to another user. • Mayekawa reserves the right to make changes to the specifications of the product the contents of this manual for improvements without prior notice. • If you have any query due to inconsistency between the product and the information in this manual that can result from such changes, please ask questions to any of the Mayekawa offices or sales/service centers in your area. • Be sure to start operation, inspection, and servicing of the equipment only after having thoroughly read and understood all the hazard preventive instructions and precautions in this manual. Almost all the past accidents occurred due to failure to follow the basic safety rules. All safety instructions and precautions in this manual are highlighted by appropriate one of the following symbol-letter combinations: Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, will or could result in minor or moderate injury. This also indicates an instruction that should be followed to obtain full performance from the product. • The safety instructions and precautions in this manual are not exhaustive. There may be other safety precautions to be observed that vary from user to user. It is your responsibility to establish a safety management system most appropriate for your particular use of the product. • Never disassemble or otherwise interfere with the Screw Compressor Unit Controller MYPRO-CPIV, as it contains many electronic components that can be adversely affected by disassembly or other interference. Mayekawa Mfg. Co., Ltd. assumes no responsibility for any undesirable consequences that would result from disassembly of or interference with the controller. • Use this controller solely for control and management of the screw compressor units produced by Mayekawa Mfg. Co., Ltd. Important Notice DANGER WARNING CAUTION QT108300 - 2 - Preface Thank you for your purchase of Mayekawa Screw Unit Controller MYPRO-CPIV (hereafter called ‘CP4’ in this manual). Before installing and putting your CP4 into service, check the following points: a. Is your CP4 exactly of the factory-option variation you specified? CP4 is available from the following 12 factory-option variations: CPIV-110 (standard version): 16 digital inputs/outputs; 16 analog inputs; 2 communication ports CPIV-111: 16 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports CPIV-110C: 16 digital inputs/outputs; 16 analog inputs; 2 communication ports; 2 extension communication ports CPIV-111C: 16 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports; 2 extension communication ports CPIV-210: 32 digital inputs/outputs; 16 analog inputs; 2 communication ports CPIV-211: 32 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports CPIV-210C: 32 digital inputs/outputs; 16 analog inputs; 2 communication ports; 2 extension communication ports CPIV-211C: 32 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports; 2 extension communication ports CPIV-220: 32 digital inputs/outputs; 32 analog inputs; 2 communication ports CPIV-221: 32 digital inputs/outputs; 32 analog inputs; 4 analog outputs; 2 communication ports CPIV-220C: 32 digital inputs/outputs; 32 analog inputs; 2 communication ports; 2 extension communication ports CPIV-221C: 32 digital inputs/outputs; 32 analog inputs; 4 analog outputs; 2 communication ports; 2 extension communication ports b. Are all necessary items supplied? Check the items in the package against the packaging list. The standard version CP4 should be provided with a set of the following items: Control panel enclosure, analog input boards (AI10, AI11); connection cable (1-meter long C1200); digital input/output board (OIA0); connection cable (1-meter long C1300); power cables (1.2-meter long C0312 x 2, 1.2-meter long C0322 x 1); noise filter (rating: 250 VAC, 6 A); instruction manual (one copy of this manual) c. Are the settings in the following windows correct? Be sure to confirm the following settings in the corresponding windows before putting CP4 into service. ‘SETUP’ menu windows (F6): Are the settings for the ‘OPTION SETUP’ items appropriate for the compressor unit under control? (see Chapter 4) ‘ADJUSTMENT’ menu windows (F5): Is the scaling setting for each sensor correct? (see Chapter 5) ‘LIMITS’ menu windows (F3): Are the settings for each alarm appropriate? (see Chapter 7) ‘SETPOINT’ menu window (F1): Are the start/stop (‘CUT IN / CUT OUT’) settings appropriate? (see Chapter 6) Mayekawa Mfg. Co., Ltd. QT108300 - 3 - Table of Contents Preface .........................................................................................................................................................................................2 Table of Contents..........................................................................................................................................................................3 Chapter 0 Information on This Manual..........................................................................................................................................6 0.1 This Manual and Other Related Manuals .......................................................................................................................6 0.2 Organization of This Manual...........................................................................................................................................6 0.3 Glossary of Special Terms..............................................................................................................................................7 0.4 Units ...............................................................................................................................................................................8 0.5 Words Displayed on Screen ...........................................................................................................................................8 0.6 Acronyms and Abbreviations..........................................................................................................................................8 Chapter 1 General Description .....................................................................................................................................................9 1.1 Functions and Features..................................................................................................................................................9 1.2 Menu-Window Organization (Menu Tree).......................................................................................................................91.3 Usable Control Functions Depending on Selected Factory Options.............................................................................11 Chapter 2 Components and Their Functions ..............................................................................................................................13 2.1 Front Panel...................................................................................................................................................................13 2.2 Parts on CPU Board (REF-CX100-PR01) ....................................................................................................................15 2.2.1 Reset Switch on CPU Board................................................................................................................................17 2.2.2 Replacement of Memory Backup Battery on CPU Board .....................................................................................18 2.3 EPROM Board (REF-CX100-RM01) ............................................................................................................................19 2.3.1 Replacement of EPROM on CPU Board ..............................................................................................................20 2.4 Analog Input Boards (REF-CX100-AI01, REF-CX100-AI11) ........................................................................................21 2.4.1 Current / Voltage Selection and Terminal Block Connections for Analog Input Boards .........................................22 2.4.2 Input Type Selection for Channels 15 and 16 of Analog Input Boards ..................................................................23 2.5 Optional Analog Output Board (REF-CX100-DA01) .....................................................................................................24 2.6 Optional Digital Input/Output Drive Base (DB) Board (REF-CX100-DB01) ..................................................................25 2.7 Digital Input/Output Board (REF-MCS200-OIA0, REF-MCS200-OIE0 (Optional)) .......................................................26 2.8 Optional Communication Board (REF-CX100-RS01)...................................................................................................27 2.9 Optional Analog-to-Digital (AD) Converter Board (REF-CX100-AD01) ........................................................................28 Chapter 3 Operation ...................................................................................................................................................................29 3.1 Display Screens ...........................................................................................................................................................29 3.1.1 Acronyms and Abbreviations Used for Indicated Items.........................................................................................29 3.1.2 Main Graphic Screen ............................................................................................................................................32 3.1.3 Main Status Screen...............................................................................................................................................33 3.2 To Make Settings – Selection from Options..................................................................................................................39 3.3 To Make Setting – Entry Using Keys ............................................................................................................................40 3.4 Software Resetting Method ..........................................................................................................................................42 3.5 Special Booting.............................................................................................................................................................43 Chapter 4 Setups (‘SETUP’ Menu (F6))......................................................................................................................................46 4.1 Setting in ‘SYSTEM SETUP’ Window (Option 1 of ‘SETUP’ Menu (F6)) ......................................................................46 4.2 Settings in ‘ANALOG INPUT SCALING’ Window (Option 2 of ‘SETUP’ Menu (F6)).....................................................48 4.3 Settings in ‘OPTION ANALOG INPUT’ Window (Option 3 of ‘SETUP’ Menu (F6)).......................................................49 4.4 Settings in ‘OPTION SETUP 1/2’ Window (Option 4 of ‘SETUP’ Menu (F6)) ...............................................................51 4.5 Setting in ‘OPTION SETUP 2/2’ Window (Option 5 of ‘SETUP’ Menu (F6)) .................................................................53 4.6 Settings in ‘OPTION SELECT’ Window (Option 6 of ‘SETUP’ Menu (F6)) ...................................................................55 Chapter 5 Adjustments (‘ADJUSTMENT’ Menu (F5)) .................................................................................................................57 5.1 Settings in ‘SLIDE VALVE SETUP’ Window (Option 1 of ‘ADJUSTMENT’ Menu (F5)) ................................................57 5.2 Settings in ‘SET TIME’ Windows (Option 2 of ‘ADJUSTMENT’ Menu (F5)) .................................................................66 5.3 Settings in ‘PASSWORD’ Window (Option 3 of ‘ADJUSTMENT’ Menu (F5)) ...............................................................68 5.4 Settings in ‘ANALOG INPUT ADJUSTMENT’ Window (Option 4 of ‘ADJUSTMENT’ Menu (F5)) ................................69 5.5 Settings in ‘ANALOG OUTPUT ADJUSTMENT’ Window (Option 5 of ‘ADJUSTMENT’ Menu (F5)) ............................70 5.6 Settings in ‘ANALOG OUTPUT ASSIGNMENT’ Window (Option 6 of ‘ADJUSTMENT Menu (F5))’.............................71 QT108300 - 4 - 5.7 Settings in ‘AUXILIARY INPUT TIMER’ Window (Option 7 of ‘ADJUSTMENT’ Menu (F5)) .........................................74 5.8 Adjustments in ‘COMMUNICATION SETUP’ Window (Option 8 of ‘ADJUSTMENT’ Menu (F5)) .................................75 Chapter 6 Control Selections (‘SETPOINTS’ Menu (F1)) ...........................................................................................................77 6.1 Settings in ‘OPERATION MODE’ Window (Option 1 of ‘SETPOINTS’ Menu (F1)) .......................................................77 6.2 Manual Control from ‘D/O TEST OPERATION’ Window (Option 2 of ‘SETPOINTS’ Menu (F1))..................................78 6.3 Settings in ‘SET POINTS’ Window (Option 3 of ‘SETPOINTS’ Menu (F1)) ..................................................................80 6.4 Settings in ‘SCHEDULER’ Window (Option 4 of ‘SETPOINTS’ Menu (F1)) .................................................................81 6.5 Setting in ‘OTHER SETPOINT’ Window (Option 5 of ‘SETPOINTS’ Menu (F1))..........................................................84 6.6 Settings in ‘AUTO Vi’ Window (Option 6 of ‘SETPOINTS’ Menu (F1)) .........................................................................86 6.7 Settings in ‘AUTO STAGE’ Window (Option 7 of ‘SETPOINTS’ Menu (F1)).................................................................88 Chapter 7 Alarms (‘LIMITS’ Menu (F3)) ......................................................................................................................................95 7.1 Settings in ‘ALARM/FAILURE’ Windows 1/3 to 3/3 ......................................................................................................95 7.1.1 ‘ALARM/FAILURE 1/3’ Window ............................................................................................................................95 7.1.2 ‘ALARM/FAILURE 2/3’ Window ............................................................................................................................97 7.1.3 ‘ALARM/FAILURE3/3’ Window ............................................................................................................................98 7.2 Settings in ‘OEM LIMITS 1/2’ and ‘OEM LIMITS 2/2’ Windows (Options 4 and 5 of ‘LIMITS’ Menu (F3)) ....................99 7.2.1 ‘ALARM/FAILURE & OEM LIMITS 1/2’ Window ...................................................................................................99 7.2.2 ‘ALARM/FAILURE & OEM LIMITS 2/2’ Window .................................................................................................100 7.3 Settings in ‘RANGE OVER’ Window (Option 6 of ‘LIMITS’ Menu (F3)) ......................................................................100 Chapter 8 Operation .................................................................................................................................................................102 8.1 Control of Compressor Unit Operation .......................................................................................................................102 8.1.1 Start/Stop Control in Different Operation Control Modes.....................................................................................102 8.1.2 Compressor Capacity Control Settings in ‘CAPACITY CONTROL’ Window (Option 1 of ‘CONTROLLER’ Menu (F2)) ............................................................................................................104 8.1.3 Settings in ‘VFD COMPRESSOR CONTROL’ window (Option 2 of ‘CONTROLLER’ Menu (F2)) ......................107 8.1.4 Settings in ‘VFD SETUP’ Window (SHIFT 3 of ‘CONTROLLER’ Menu (F2))......................................................108 8.1.5 Settings in ‘CONDENSER CONTROL’ Window (Option 0 of ‘CONTROLLER’ Menu (F2)).................................109 8.2 Communications.........................................................................................................................................................112 8.2.1 System Configuration .........................................................................................................................................112 8.2.2 Remote Communication Device and Communication Protocols.........................................................................112 8.2.3 Connecting Communication Terminating Resistors ............................................................................................113 8.2.4 MODBUS Protocol..............................................................................................................................................114 Chapter 9 Maintenance (‘LOGS’ Menu (F4)) ............................................................................................................................116 9.1 Display in ‘TRENO LOG’ Window (Option 1 of ‘LOGS’ Menu (F4))............................................................................116 9.2 Display in ‘TREND GRAPH’ Window (SHIFT 1 of ‘LOGS’ Menu (F4)) .......................................................................117 9.3 Settings in ‘GRAPH ASSIGNMENT’ Window (SHIFT2 of ‘LOGS’ Menu (F4))............................................................118 9.4 Displays in ‘ALARM LOG’ Window (Option 2 of ‘LOGS’ Menu (F4)) ..........................................................................119 9.5 Display in ‘EVENT LOG’ Window (Option 3 of ‘LOGS’ Menu (F4)).............................................................................121 9.6 Display in ‘DEVICE COUNTER MONITOR’ Window (Option 4 of ‘LOGS’ Menu (F4)) ...............................................122 9.7 Resetting Made in ‘DEVICE COUNTER SET’ Window (Option 5 of ‘LOGS’ Menu (F4) )...........................................123 Chapter 10 Analysis (‘DIAGNOSTIC’ Menu (F7)) .....................................................................................................................124 10.1 Display in ‘SHOW SYSTEM SETUP’ Window (Option 1 of ‘DIAGNOSTIC’ Menu (F7)) ..........................................124 10.2 Display in ‘SHOW ANALOG INPUT SCALINGT’ Window (Option 2 of ‘DIAGNOSTIC’ Menu (F7)).........................124 10.3 Display in ‘SHOW OPTION ANALOG INPUT’ Window (Option 3 of ‘DIAGNOSTIC’ Menu (F7)).............................125 10.4 Display in ‘SHOW DIGITAL I/O STATUS’ Window (Option 4 of ‘DIAGNOSTIC’ Menu (F7)) ....................................125 10.5 Display in ‘SHOW OPTION SETUP 1/2’ Window (Option 5 of ‘DIAGNOSTIC’ Menu (F7)) .....................................126 10.6 Display in ‘SHOW OPTION SETUP 2/2’ Window (Option 6 of ‘DIAGNOSTIC’ Menu (F7)) .....................................126 10.7 Display in ‘SHOW PROGRAM VERSION’ Window (Option 7 of ‘DIAGNOSTIC’ Menu (F7)) ..................................127 10.8 Display in ‘READ REGISTER’ Window (Option 8 of ‘DIAGNOSTIC’ Menu (F7)).....................................................127 10.9 Display in ‘READ BIT’ Window (Option 9 of ‘DIAGNOSTIC’ Menu (F7)) .................................................................128 10.10 Display in ‘READ TIMER/COUNTER’ Window (Option 0 in ‘DIAGNOSTIC’ Menu (F7)) .............................................128 Chapter 11 Troubleshooting......................................................................................................................................................129 Chapter 12 Specifications .........................................................................................................................................................133 QT108300 - 5 - Device List ............................................................................................................................................................................136 List of Replaceable Parts ......................................................................................................................................................242 Software Revision Record 1..................................................................................................................................................243 Software Revision Record 2..................................................................................................................................................244 QT108300 - 6 - Chapter 0 Information on This Manual 0.1 This Manual and Other Related Manuals This manual is one of the four manuals each containing information about MYPRO-CPIV (CP4) as follows: - COMPRESSOR CONTROL PANEL (Model MYPRO-CPIV/E) MANUAL Contains information necessary for the engineering staff in charge of operation, maintenance, and communications of CP4. The information includes description on the CP4’s functions and specifications, instructions for wiring/connections, setting and operation, method for troubleshooting, and other data necessary for maintenance service. - MYPRO-CPIV (MYCOM SCREW UNIT CONTROLLER) MANUAL Provides information on transportation, installation, setting up for operation, maintenance, and disposal of the MYCOM Screw Compressor Unit Control Panel Model MYPRO-CPIV/E. - MYPRO-CPIV (MYCOM SCREW UNIT CONTROLLER) START-UP MANUAL Describes the start-up procedures of CP4 in a simplified form, beginning with the initialization. - MYPRO-CPIV (MYCOM SCREW UNIT CONTROLLER) FACTORY MANUAL Contains instructions for the setting to be made on CP4 before shipment from the factory. 0.2 Organization of This Manual This manual consists of the following three groups of chapters. Chapters 1 to 3 These chapters contain the following introductory information for the use of CP4. Chapter 1 shows the function menus (hereafter simply called “menu”) and the function windows (hereafter simply called “windows”) that can be accessed from each menu (menu tree). The functions available as factory options are also shown in this chapter. Chapter 2 contains the following items of information about CP4: thefunctions and operation of the individual keys on the front panel; description of the CPU board including the operations you need to perform on it; and the optional extension circuit boards. Chapter 3 contains the following items of information: how to make appear a desired display on the front panel screen and read the displayed data; how to make selections or entries to set parameters; and how to perform “special booting” required when making some settings and initialization/resetting. Chapters 4 to 10 These chapters contain detailed description of individual windows, including the methods of setting for the parameter items in each window, limitations applied to certain settings, and detailed explanation of special function-related items, such as the communication protocol, automatic staging (AUTO STAGE) control, etc. Chapters 11 and 12 Chapter 11 provides troubleshooting information. Chapter 12 contains the specifications and other miscellaneous information including the replacement parts list, software version list, device lists etc. QT108300 - 7 - 0.3 Glossary of Special Terms The special terms used in this manual are defined below. ALARM ALARM is a non-critical alarm that does not involve any compressor unit shutdown. Automatic staging control (AUTO STAGE) The automatic staging control works on multiple compressor units with their CP4s inter-connected through communication ports. Of these CP4s, one is assigned to the “master station”. The master station issues commands to start or stop the compressor under control of each of the other CP4s (called the “slave stations”) to properly adjust the number of operating compressors according to the required gas compressing capacity for the refrigerating system. Compressor unit Compressor unit refers to a system consisting of a compressor, condenser, expansion values, chiller, and driving motors. Each compressor unit operates under control of one CP4. FAILURE FAILURE is a critical alarm that involves compressor unit shutdown. Hardware key The hardware key is a special device that is not supplied with the product. It is used for adjustments necessary before shipment of the product from the factory. Main Graphic Screen This screen appears first when CP4 is turned on and shows the compressor’s status using graphics. Main Status Screen This screen shows the compressor’s status using alphanumeric characters. This screen appears when the TAB key is pressed on the front panel when the Main Graphic Screen is displayed. Manipulating value The amount of control expressed in a sum of the proportional, integral, and derivative controls (PID control) concerning with the capacity, speed, and other controls. Mask time Mask time refers to the time set by the user during which no determination to or not to issue an alarm takes place. Master station “Master station” is defined differently according to the control configuration using PC4s. - In the case of the automatic staging control (AUTO STAGE), the master station is the CP4 that gives operational commands to the other CP4s according to information of its own as well as that it receives from the slave CP4s. - In the case of the control using a remote control device such as a computer through communications, the master station refers to the remote control device controlling the CP4s in the network. Menu Each function of CP4 has a menu that provides options to make access to individual windows. Each menu can be selected by pressing one of the function keys on the front panel. OEM limit OEM limit refers to the upper or lower limit of each alarm set value. QT108300 - 8 - Offset If analog input values are too small or too large for processing over the entire range of measurement, a positive or negative offset value is added for proper processing and indication. You can specify offset values as part of settings. Passwords You must enter a password of the specified level before you can make settings in some special windows. Three different levels of password (LEVEL-1, LEVEL-2, and LEVEL-3) must be registered beforehand to be able to access these windows, each requiring a specific level of password for authorization. See Section 5.3 Settings in ‘PASSWORD’ Window (Option 3 of ‘ADJUSTMENT’ Menu (F5)) for further details. Scaling Scaling means a setting to specify the range (upper and lower limits) for input values from each sensor. Special booting Special booting is the method for booting CP4 that is required before performing the system setup and initializing individual control settings. Trimming data With CP4, “trimming,” means “output adjustment”. The value for the adjustment is written in a non-volatile memory. Window A screen that is accessed from each menu. It is used for making parameter settings and for checking the status of settings or operation of the compressor unit. Some windows include multiple sub-windows. 0.4 Units Unless otherwise specified, all pressures are indicated in MPa (gauge readings) and temperatures in °C. 0.5 Words Displayed on Screen In this manual, the words displayed on the screen (menus, windows, parameter items, selective options, etc.) are indicated in all capital letters enclosed by single quotation marks like ‘SETUP’ (although quotation marks are basically omitted in tables). 0.6 Acronyms and Abbreviations For interpretation of the acronyms and abbreviations used in display, see Section 3.1 Display Screens. QT108300 - 9 - Chapter 1 General Description 1.1 Functions and Features CP4 is a controller developed for controlling operation of the Mayekawa-produced screw compressor units. The controller has the following standard features: • Sequence control and process control inputs/outputs - 16 digital inputs/outputs No-voltage contact signals or under-voltage solid-state relay (SSR) signals - 16 analog inputs 4 to 20 mA DC inputs, 1 to 5 V DC inputs, or 1-kΩ potentiometer inputs • User-controller interface - Backlit color LCD capable of displaying 80 digits x 30 lines alphanumeric characters - Keypad with numeric keys, function keys, and control keys (33 keys in total) The LCD can collectively display multiple measurements and concurrently display settings and actual measurements. The key groups are arranged efficiently, allowing easy screen switching and change of settings. • Communication ports The following communication ports are standard provisions: - One serial communication port with a round connector conforming to special-purpose RS-232C - One half-duplex, 4-wire serial communication port conforming to RS-485 The serial communications function allows remotely monitoring the operating conditions of compressor units, making their start/stop control, and changing various parameter settings. The MODBUS protocol employed is world standard protocol for serial communications in industry and allows for the use of commercially available supervisory control and data acquisition (SCADA) software as well as connection to and communication with PLC MODBUS communications units of various manufacturers. • Optional extension boards for additional inputs/outputs channels and communication ports The following optional items are available for expanded connections to CP4. - Extension digital/analog converter (DA) board for additional 4 analog outputs - Extension analog input board for additional 16 analog inputs - Extension digital input/output board for additional 14 digital output channels and 2 digital input channels - Extension communication board for additional 2 communication ports • Either of two status windows is selectable: “Main Graphic” and “Main Status”. (A function key is used on the menu screen for selecting each window.) 1.2 Menu-WindowOrganization (Menu Tree) The individual function menus are associated with the function keys F1 to F7 (see Section 2.1). Each menu includes the windows to which specific names are given together with Option numbers as shown below. The section number in parentheses after each window menu indicates the section of this manual containing the information on the window. QT108300 - 10 - Menu Tree 1. OPERATION MODE (Section 6.1) 2. D/O TEST OPERATION (Section 6.2) 3. SET POINTS (Section 6.3) 4. SCHEDULER (Section 6.4) 5. OTHER SET POINTS (Section 6.5) 6. AUTO Vi (Section 6.6) 7. AUTO STAGE (Section 6.7) 1. CAPACITY CONTROL (Section 8.1.2) 2. VFD COMPRESSOR CONTROL (Section 8.1.3) 3 .HIGH STAGE CONTROL 4. EXPANSION VALVE (SH) CONTROL (4.LIQUID SUPPLY CONTROL) 5. EXPANSION VALVE (SP) CONTROL 6. EXPANSION VALVE (LB) CONTROL 7. ECONOMIZER/INTER COOLER EXPANSION VALVE CONTROL (7.ECONOMIZER/INTERCOOLER SV) 8. LIQUID INJECTION OIL COOLING (8.LIQUID INJECTION SV) 9. CHILLER LB TEMPERATURE CONTROL 0. CONDENSER CONTROL (Section 8.1.5) SHIFT1. LEVEL CONTROL SHIFT3. VFD SETUP (Section 8.1.4) 1. ALARM/FAILURE 1/3 (Section 7.1) 2. ALARM/FAILURE 2/3 (Section 7.1) 3. ALARM/FAILURE 3/3 (Section 7.1) 4. OEM LIMITS 1/2 (Section 7.2) 5. OEM LIMITS 2/2 (Section 7.2) 6. RANGE OVER (Section 7.3) 1. TREND LOG (Section 9.1) 2. ALARM LOG (Section 9.4) 3. EVENT LOG (Section 9.5) 4. DEVICE COUNTER MONITOR (Section 9.6) 5. DEVICE COUNTER SET (Section 9.7) SHIFT1. TREND GRAPH SHIFT2. GRAPH ASSIGNMENT 1. SLIDE VALVE SETUP (Section 5.1) 2. SET TIME (Section 5.2) 3. PASSWORD (Section 5.3) 4. ANALOG INPUT ADJUSTMENT (Section 5.4) 5. ANALOG OUTPUT ADJUSTMENT (Section 5.5) 6. ANALOG OUTPUT ASSINGMENT (Section 5.6) 7. AUXILIARY INPUT TIMER (Section 5.7) 8. COMMUNICATION SETUP (Section 5.8) 1. SYSTEM SETUP (Section 4.1) 2. ANALOG INPUT SCALING (Section 4.2) 3. OPTION ANALOG INPUT (Section 4.3) 4. OPTION SETUP 1/2 (Section 4.4) 5. OPTION SETUP 2/2 (Section 4.5) 6. OPTION SELECT (Section 4.6) 1. SHOW SYSTEM SETUP (Section 10.1) 2. SHOW ANALOG INPUT SCALING (Section 10.2) 3. SHOW OPTION ANALOG INPUT (Section 10.3) 4. SHOW DIGITAL I/O STATUS (Section 10.4) 5. SHOW OPTION SETUP 1/2 (Section 10.5) 6. SHOW OPTION SETUP 2/2 (Section 10.6) 7. SHOW PROGRAM VERSION (Section 10.7) 8. READ REGISTER (Section 10.8) 9. READ BIT (Section 10.9) 0. READ TIMER/COUNTER (Section 10.10) “Main Graphic” and “Main Status” windows F1 SETPOINTS F2 CONTROLLER F3 LIMITS F4 LOGS F5 ADJUSTMENT F6 SETUP F7 DIAGNOSTIC QT108300 - 11 - 1.3 Usable Control Functions Depending on Selected Factory Options You can use any control functions listed in the ‘OPTION SETUP’ column in the table below according to your selection in the ‘Item’ column if the corresponding functions in the ‘OPTION SELECT’ column have been enabled for your specific CP4 before its shipment from the factory (factory option). Any setups you make is invalid if they are for those ‘OPTION SETUP’ items that correspond to the disabled ‘OPTION SELECT’ functions. You cannot enable any disabled ‘OPTION SELECT’ functions yourself. (see Chapter 4 for details of the ‘OPTION SELECT’ and ‘OPTION SETUP’ windows) NOTE: In the table below, marked * in the “Item” column are the default selections. Usable Control Functions ‘OPTION SELECT’ ‘OPTION SETUP’ Item * NONE DIGITAL ‘REMOTE CAPACITY CONTROL’ REMOTE CAPACITY CONTROL ANALOG * NOT USE CONDENSER CONTROL USE * LOCAL DISCHARGE PRESSURE CONDENSER VFD CONTROL CONDENSER CONTROL TARGET SYSTEM DISCHARGE PRESSURE * NOT USE CONDENSER CONTROL USE * LOCAL DISCHARGE PRESSURE CONDENSER CONTROL TARGET SYSTEM DISCHARGE PRESSURE * ON/OFF SIGNAL SET CONDENSER 3STEPS CONTROL or CONDENSER 6STEPS CONTROL CONDENSER CONTROL METHOD ON/OFF MULTI SET * NOT USE CHILLER CONTROL USE * 1 2 LIQUID SUPPLY SV 3 NONE/THERMAL EXPANSION YOSAKU 1-VALVE YOSAKU 2-VALVES YOSAKU 3-VALVES * 1-MOTORIZED CONTROL VALVE EXPANSION VALVES 2-MOTORIZED CONTROL VALVES * NO CHILLER GAS TEMP. SENSOR YES * NO CHILLER ENTERING TEMP. SENSOR YES * NO CHILLER LEAVING TEMP. SENSOR YES * NOT USE CHILLER LEAVING TEMP. CONTROL USE CONTINUOUS CHILLER CONTROL CHILLER PUMP MODE * AUTO START/STOP * NOT USE AUTO STAGING (Control of the number of operating compressors) AUTO STAGER 2 UNITS - 8 UNITS * NOT USE VFD COMPRESSOR USE * NOT USE VFD COMPRESSOR (Inverter control) VFD COMPRESSOR OUTPUT LIMIT USE QT108300 - 12 - Usable Control Functions (continued) ‘OPTION SELECT’ ‘OPTION SETUP’ Item * NOT USE HIGH STAGE CAPACITY CONTROL (Control of the high stage capacity of compound type two stage compressors) HIGH STAGE CAPACITY CONTROL USE * NOT USE USE Y10,11,12,16,17(UD-V) USE Y19,1A,1B,1C,1D(UD-V) AUTO Vi CONTROL AUTO Vi CONTROL USE J SERIES * NOT USE LIQUID INJECTION OIL COOLING CONTROL USE NONE/THERMAL EXPANSION * YOSAKU 1-VALVE YOSAKU 2-VALVES INJECTION VALVES MOTORIZED CONTROL VALVE * DISCHARGE TEMPERATURE LIQUID INJECTION CONTROL (Oil cooling control) CONTROL TARGET DISCHARGE SUPERHEAT * NOT USE HOT GAS BYPASS CONTROL HOT GAS BYPASS CONTROL USE * NOT USE STARTING BYPASS CONTROL STARTING BYPASS CONTROL USE * LSV & SP ECONOMIZER/INTERCOOLER LIQUID SUPPLY CONTROL HSV & IP * NOT USE ECONOMIZER/INTERCOOLER EXPANSION VALVE CONTROL USE NONE * YOSAKU ECONOMIZER/INTERCOOLER EXPANSION VALVE CONTROL EXPANSION VALVES MOTORIZED CONTROL VALVE * NOT USE LEVEL CONTROL (Liquid level control) LEVEL CONTROL USE * NOT USE COMPRESSOR OIL SEAL CONTROL COMPRESSOR OIL SEAL CONTROL USE 400 SERIES COMPRESSOR CONTROL --- --- * LOCAL SUCTION PRESSURE SYSTEM SUCTION PRESSURE CHILLER ENTERING TEMPERATURE --- CONTROL TARGET (CUT IN/OUT) (Target of start/stop control) CHILLER LEAVING TEMPERATURE * LOCAL SUCTION PRESSURE SYSTEM SUCTION PRESSURE CHILLER LEAVING TEMPERATURE COMBINED LOCAL SP/LB COMBINED SYSTEM SP/LB LOCAL DISCHARGE PRESSURE --- CONTROL TARGET (CAPACITY CONTROL) (Target of capacity control) SYSTEM DISCHARGE PRESSURE QT108300 - 13 - Chapter 2 Components and Their Functions 2.1 Front Panel Keys on Front Panel No. Key Function 1 Function keys Press one of the F1 to F7 keys to display the corresponding menu. If you press the same function key while the menu is displayed, the menu will close (see Section 1.1 for the key-to-menu correspondence). 2 ESC key Press this key to close a menu or window. 3 SHIFT key Press this key in combination with an arrow key to make an up-down or right-left shift between items in the same window. (This key has no effect when pressed independently.) 4 ALT key Press this key in combination with the TAB key to make a shift between items across different windows/windows or with the SHIFT key to make a shift between items within the same window/window (it has no effect when pressed independently). 5 DELETE key Use this key when correcting entries. 6 Arrow keys Use these keys to move the cursor (in reverse video) from one item to another within a menu or window. 7 TAB key Use this key to move the cursor (in reverse video) from an item in a window/sub-window to an item in another window/sub-window. 8 ENTER key Used to confirm a selection or entry. When confirmed by pressing this key, the selected option or entry turns red. Even when confirmed, the selection or entry is not saved in memory. 9 SAVE key Pressing this key saves selections or entries in memory. Stored in memory are the new/altered selections or entries that have been confirmed by pressing the ENTER key. The characters that have turned red by the confirmation now turn white. 10 Numeric keys Use these keys to selecta window in each menu or make entries in each window. F1 START STOP CLEAR ALARM F2 F3 F4 F5 F6 F7 1 2 3 4 5 6 7 8 9 0 . - ALT ESC SAVE ENTER SH IFT DELETE TAB MYPRO-CPⅣ 1 2 3 5 4 6 8 7 9 11 12 13 10 QT108300 - 14 - Keys on Front Panel (continued) No. Key Function 11 START key Used to start the compressor only when the LOCAL mode (operation control mode) is selected. This key does not work in the REMOTE, COMM, or AUTO STAGE mode (see Section 6.1). 12 STOP key This key can be used to stop the compressor regardless of the operation mode selected (see CAUTION below). 13 CLEAR ALARM key Use this key to clear an alarm if the compressor has stopped by issuance of an alarm (FAILURE). According to the selection for the ‘OPERATION’ item in the ‘OPERATION MODE’ window, the following conditions automatically take place when the STOP key is pressed on the front panel of PC4. - When the ‘LOCAL’, ‘REMOTE’, or ‘COMM’ mode (not the ‘AUTO STAGE’ mode) has been selected, pressing the STOP key causes no change to the operation control mode in the case of the ‘LOCAL’ mode, but the mode automatically changes to ‘LOCAL’ in the case of the ‘REMOTE’ and ‘COMM’ modes. The compressor, if operating, will then stop after the liquid recovering sequence. (It remains stopped thereafter.) To restart the compressor, simply press the START key if you need not change the mode from ‘LOCAL’ to another, or turn ON the relevant operation control command after changing the mode from ‘LOCAL’ to the desired mode. - When the ‘AUTO STAGE’ mode has been selected, pressing the STOP key does not cause any change to the setting for the ‘OPERATION’ item in the ‘OPERATION MODE’ window, but the selection of ‘ENABLE’ you made for the ‘CONTROL’ item in the ‘AUTO STAGE’ window automatically changes to ‘DISABLE’. In this case, if the compressor under control is running when the STOP key is pressed, the compressor will then stop after completing the liquid recovering sequence. Even the STOP key is pressed on the master station and its ‘CONTROL’ item setting in the ‘AUTO STAGE’ window is consequently changed to ‘DISABLE’, the automatic staging control continues to work on all the other stations (slave stations). To recover the ‘AUTO STAGE’ mode control after pressing the ‘STOP’ key, it is necessary (for the case of the master station and the case of a slave station) to perform the steps below. (Simply pressing the START key on the station does not recover the automatic staging control.) 1. From the ‘SETPOINTS’ menu (F1), open the ‘AUTO STAGE’ window. 2. Select ‘ENABLE’ for the ‘CONTROL’ item in the window. QT108300 - 15 - 2.2 Parts on CPU Board (REF-CX100-PR01) The above figure shows the CPU board used in CP4 and the locations of the circuit boards, switches, connectors, and other parts on it. These parts are explained in the following table. Parts on CPU Boards No. Parts Function 1 Analog input board connector Used to connect the two different analog input boards to the CPU board. (Use cable “REF-CX100-C1201-U” for connection.) 2 LCD board connector Used to connect the LCD interface board to the CPU board. (Use cable “REF-CX100-C0901-U” for connection.) 3 ROM board connector Used to connect the ROM board to the CPU board. 4 DC (5V) board connector Used to supply 5 V DC from the CPU circuit power supply to the CPU board. (Use cable “REF-CX100-C0312-U” for connection.) 5 Extension communication board connector Used to connect an extension communication board (option) to the CPU board. 6 Digital input/output drive connector Used to connect digital input/output drive boards. The connectors are provided on the CPU board and can accommodate a maximum of four digital input/output drive boards (16 inputs/outputs). The #1 connector is for switch inputs/outputs 1 to 4, #2 for digital inputs/outputs 5 to 8, #3 for switch inputs/outputs 9 to 12, and #4 for switch inputs/outputs 13 to 16. 7 KP board connector Used to connect the KP board to the CPU board. (Use cable “REF-CX100-C1000-U” for connection.) 8 Communication power connector Used to supply power from the CPU board power supply to an extension communication board (option). (Use cable “REF-CX100-C0100-U” for connection.) 9 DB board connector Used to connect a digital input/output driver base (DB) board (option) to the CPU board. 10 DB board power connector Used to supply power from the CPU board power supply to the connected DB board (option). (Use cable “REF-CX100-C0100-U” for connection.) 11 DC (12V) connector Used to supply 12 V DC from the power supply of the analog/digital and digital input/output circuits to the CPU board. (Use cable “REF-CX100-C0322-U” for connection.) 12 Digital input/output board connector Used to connect the digital input/output board to the CPU board with a cable. (Use cable “REF-CX100-C1301-U” for connection.) 1 14 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 19 18 20 21 23 24 25 26 22 QT108300 - 16 - Parts on CPU Boards (continued) No. Parts Function 13 Analog output board connector Used to connect an analog output board (option) to the CPU board. 14 Extension AD board connector Used to connect an extension AD converter board (option) to the CPU board. 15 Analog/digital board power connector Used to supply power from the CPU board to an extension analog/digital board (option). (Use cable “REF-CX100-C0100-U” for connection.) 16 Battery holder Used to hold the memory backup battery (lithium primary cell CR2032). 17 Reset switch Used to reset CP4 system. Operate the reset switch carefully. 18 CPU lamp Blinks red at regular intervals while the CPU is running normally. 19 DIP switch The top switch is numbered “1” and the bottom one is numbered “8”. Slide each switch to the right to set it to ON. Slide each switch until it clicks. 20 Input selector switch for CH 15 and CH 16 Used to switch between terminal blocks 15A and 15B for analog input CH15 and between 16A and 16B for analog input CH16.(15B and 16B are selected by default.) Moving the switch to the right selects terminal block 15A/16A, and moving it to the left selects terminal block 15B/16B. Move the switch until it clicks. 21 Heat sink The heat sink is hot. Do not touch it by hand. 22 COM 0 operation lamp Lights green during transmission; lights red during reception. 23 COM 1 terminal block Provides terminals for 4-wire RS-485 communication ports. QT108300 - 17 - Parts on CPU Boards (continued) No. Parts Function 24 COM 1 terminating resistor switches These switches turn ON/OFF the terminating resistors in the CPU board. They provides termination for the transmission and receiving lines independently. Move the switch up to turn ON the terminating resister. Move the switch until it clicks. 25 COM 1 operation lamp Lights green during transmission; lights red during reception. 26 COM 0 connector Provides RS-232C Communication Ports. For setting for the ports, see Section 5.8 Adjustments in ‘COMMUNICATION SETUP’ Window (Option 8 of ‘ADJUSTMENT’ Menu (F5)). 2.2.1 Reset Switch on CPU Board CP4 requires system resetting if the stored setting data is lost or before newly setting up the system. There are the following two methods for the system resetting. • Hardware resetting method • Software resetting method This section explains the hardware method. (For the software method, see Section 3.4 Software Resetting Method.) The reset switch is in the location encircled in the above figure. Press and release the switch to reset CP4. CP4 will be rebooted (but the systemis not set up by simply pressing this switch). The system can also be reset by turning OFF and then ON the CP4 power supply. Resetting CP4 brings the controller in a momentary instable condition, following which CP4 is placed in a condition that would result just after turning power ON. As this condition is detrimental to the compressor unit if it occurs during operation, never perform system resetting while the compressor and accessory is in operation. QT108300 - 18 - 2.2.2 Replacement of Memory Backup Battery on CPU Board CP4 uses a primary cell as a power source to retain the setting data and keep driving the internal clock in the event of a power failure. The battery can supply power enough to back up the memory of setting data for about three years. The battery starts running down immediately after it is produced even if it is not used. If power failure occurs when the battery is completely discharged, all data including the setting and log data will be lost and the internal clock will be reset to zero. NOTE: The battery life may be shorter than three years in high-temperature or other unfavorable environments. To prevent this kind of problem, CP4 has a low battery detection function. If a low battery condition is detected, this function causes the “BATTERY ALARM” message to blink at the center of the top line in both status display screens (see Section 3.1 Display Screens). If the “BATTERY ALARM” message is blinking, replace the battery immediately. If the CPU is reset following such an operation as turning on the power supply with the internal battery discharged, PC4 will automatically be restarted by “special booting” for the sake of safety. Once this has occurred, the compressor cannot be operated any further unless the memory backup battery is replaced with a battery of the normal voltage (see Section 3.5 Special Booting). The memory backup battery can be replaced regardless of whether the system is under power or not. The setting data are not lost as long as the battery is replaced while the system is under power. However, if the battery is replaced while power is out, all stored setting data are lost and the internal clock is initialized. Use the following method to replace the internal battery. Do this operation carefully not to let the battery touch any of the nearby components. (1) Insert your fingernail into the part indicated by the arrow and, while holding the old battery by its top and bottom, disengage only the clip on the left side of the holder. Now the battery is free for removal. Be sure to hold the battery; otherwise, it will drop from the board when the clip is released. (The right figure shows the holder after removal of the battery.) QT108300 - 19 - (2) While holding a new battery by its top and bottom, engage the battery with the clip (indicated by the arrow) at the right part in the holder. (The right figure shows the battery engaged with the clips. You should still keep holding the battery as it can drop out of the board if it is released.) (3) Set the battery into its horizontal position in the holder. (4) Lightly press the part indicated by the arrow to fit the battery snugly into position in the holder. 2.3 EPROM Board (REF-CX100-RM01) The EPROM board to be installed on the CPU board has the following connector and sockets. NOTE: The 32-megabit EPROM (software-written circuit board) is installed on the standard version. (The 40-pin socket for 4-megabit ROM is not used.) Parts on EPROM Board No. Parts Function 1 ROM board connector Used to connect the ROM board to the CPU board. The connector is provided on the back of the CPU board. 2 40-pin socket for 4-megabit ROM This socket is for mounting a programmable ROM circuit board. Mount the ROM board with the recess facing up. A ROM equivalent to 27C4002 (4 megabits) is connectable to this socket. (The use of an ST Micro M27C4002-12F1 is recommended.) Mount/demount the ROM board carefully. 1 2 3 QT108300 - 20 - Parts on EPROM Board (continued) No. Parts Function 3 42-pin socket for 32-megabit EPROM This socket is for mounting a programmable ROM circuit board. Mount the ROM board with the recess facing up. An EPROM equivalent to 27C322 (32 megabits) is connectable to this socket. (The use of an ST Micro M27C322-100F1 is recommended.) Mount/demount the ROM board carefully. 2.3.1 Replacement of EPROM on CPU Board Follow the procedure below when replacing (updating) the EPROM (software-written circuit). (1) Take a note of the settings and other data. (This step may be not necessary depending on the type of the EPROM to be replaced.) (2) Turn off the power supply of CP4. (3) Check that the CPU lamp on the CPU board is OFF. (This is necessary to make sure the power supply has been turned off.) (4) Using an EPROM extractor, remove the EPROM carefully from the ROM board. Do not pry the EPROM using a flat head screwdriver or a similar tool; this may damage the ROM board. (5) Connect a new EPROM to the IC socket on the left side (as viewed from the front), with the recess facing upward (see the figure below). Incorrect connection can cause an operational failure. (6) Reconfirm that the EPROM is installed correctly. QT108300 - 21 - (7) Turn on the power supply of CP4. (According to the condition, CP4 may need to be initialized.) 2.4 Analog Input Boards (REF-CX100-AI01, REF-CX100-AI11) The analog input boards for installation on the CPU board have the following terminal blocks and connectors. Parts on Analog Input Boards No. Name Function 1 Analog input board connector The connector on each analog input board is used to connect it to the CPU board. The connector is a 20-pin connector for both analog input boards. (Use cable “REF-CX100-C1201-U” for connection.) 2 24 V DC connectors Used to connect 24 V DC from the analog input/output circuit power supply to the analog input board. (Use cable “REF-CX100-C0401-U” for connection; use cable “REF-CX100-C0501-U” for connection between the AI01 and AI11 boards.) 4 (CH1 to CH3) 4 (CH4 to CH6) 4 (CH7 to CH9) 3 1 2 2 4 (CH16A - CH16B) 4 (CH13 - CH15A) 4 (CH10 - CH12) 3 1 2 2 Insert the EPROM while aligning its recess with the recess in the IC socket. M Y P R O -C P IV V er.A .B C N ot used QT108300 - 22 - Parts on Analog Input Boards (continued) No. Name Function 3 Current/voltage selector switches (JP1 to 9 and JP1 to 7) for analog inputs Each of these switches selects either voltage or current for analog inputs. Set each switch to ON for current input or OFF for voltage input. (All of these switches are defaulted to OFF.) Move the switch to each position until it clicks. 4 Analog input terminal blocks Used to connect analog input wires. Each terminal block can supply sensors with power (although the power level is limited). Either current/voltage input or potentiometer input is selectable for CH15 and CH16. CH15A and CH16A are assigned to current/voltage inputs. CH15B is assigned to low-stage potentiometer inputs, and CH16B is assigned to high-stage potentiometer inputs. To use CH15 and CH16, connect desired input lines to the corresponding terminal blocks and then set the current/voltage selector switches for on the CPU board CH 15 and CH 16 as appropriate (see Section 2.2). NOTE: Use also the above analog input boards when adding analog input channels (AD CH17 to CH32). 2.4.1 Current / Voltage Selection and Terminal BlockConnections for Analog Input Boards Set switches JP1 to JP9 (for CH1 to CH9) and switches JP1 to JP7 (for CH10 to CH14, CH15A, and CH16A) on the associated analog input boards to ON when the analog input sources provide current signals. Set these switches to OFF for voltage signal inputs. The analog input circuits (internal circuit of CP4) are schematically shown below. When the current/voltage selector switch is set to ON, a 250-ohm resistor is connected to the input circuit as shown in the above diagram. DC current signals of 4 to 20 mA are then converted into 1 to 5 V DC voltage signals before being input to the analog-to-digital (A/D) converter circuit. When the selector switch is set to OFF, the current signals are input directly to the A/D converter circuit. Make connections on each terminal block as follows: Analog input boards To A/D converter circuit AG FG 24V 250Ω 1 24V 2 1+ 3 1- 4 FG Input filter circuit Current/voltage selector switch Internal circuits of CP4 QT108300 - 23 - - Current signal sources using CP4’s power supply: Connect “+” side of the input source to the 24V terminal of the terminal block and the “-” side to an appropriate one of the “+” terminals 1 to 16 on the terminal block. - Current signal sources using an outside power supply: Connect the “+” side of the input source to an appropriate one of the “+” terminals 1 to 16 on the terminal block and the “-” side to an appropriate one of the “-” terminals 1 to 16 on the terminal block. - Voltage signal sources: Connect the “+” side of the input source to an appropriate one of the “+” terminals 1 to 16 on the terminal block and the “-” side to an appropriate one of the “-” terminals 1 to 16 on the terminal block. Move the switch until it clicks. NOTE: The switch is set to OFF before shipment from the factory. 2.4.2 Input Type Selection for Channels 15 and 16 of Analog Input Boards Like with the Mayekawa’s controller MYPRO-CPIII, CP4 has a means for setting the analog input channels 15 and 16 (CH15 and CH16) for receiving current/voltage inputs or potentiometer inputs. When the lever of the analog input selector switch marked “JP3” on the CPU board is moved to the “15A” side, Channel 15 is set for receiving current/voltage inputs (analog input terminal block CH15A is enabled). When the lever is moved to the 15B side, Channel 15 is set for receiving potentiometer inputs (analog input terminal block CH15B is enabled). The same applies to Channel 16 although the switch number and terminal board designations are different accordingly (see NOTE under the table below). The diagram below shows the analog-to-digital (A/D) converter circuit (internal circuit of CP4) to schematically depict the above explanation taking Channel 15 for example. CPU board Current/voltage inputs CH15A from analog input board 15BPotentiometer converter circuit Analog-to- digital converter circuit Analog input selector switch JP3 Potentiometer inputs CH15B from analog input board 15A QT108300 - 24 - Selection of Input Source Type for Channel 15 (in the case of position inputs for low-stage unloader slide valve) Input Source Connection JP6 switch position on analog input board JP3 switch position on CPU board Potentiometer Potentiometer inputs 1 to 3 are connected to terminals LF1 to LF3 of terminal block CH15B on analog input board. Any position 15B Current input source with power supplied from CP4 Connect “+” side to terminal 24V on CH15A terminal block of analog input board, and “-” side to terminal15A+. ON 15A Current input source with power supplied from outside Connect “+” side of input to terminal 15A+ on CH15A terminal block of analog input board, and “-” side to terminal 15A-. ON 15A Voltage input source Connect “+” side of input to terminal 15A+ on CH15A terminal block of analog input board, and “-” side to terminal 15A-. OFF 15A NOTE: The above table also applies to selection of analog input type for channel 16 if channel number “15” is read as “16”, switch number “JP6” of the AI board as “JP7”, and switch number “JP3” of CPU board as “JP4”. Move the switch lever until it clicks. 2.5 Optional Analog Output Board (REF-CX100-DA01) Parts on Analog Output Board No. Name Function 1 Analog output board connector Used to connect this analog output board to the CPU board. The CPU board’s connector is located on its back. 2 24 V DC connector Used to supply 24 V DC from the analog input/output circuit power supply to this analog output board. (Use cable “REF-CX100-C0322-U” for connection.) 3 Trimming data memory The trimming data (output adjustment data) for the analog section of the analog output circuit is written in a non-volatile memory. As each analog output board has this data memory, re-trimming is not necessary even if an analog output board is added or replaced. 4 Analog output terminal block Used to connect wires for analog outputs (4 to 20 mA DC). 2 1 3 4 QT108300 - 25 - 2.6 Optional Digital Input/Output Drive Base (DB) Board (REF-CX100-DB01) Parts on Optional Digital Input/Output DB Board No. Name Function 1 DB board connector Used to connect this DB board to the CPU board. 2 12 V DC connector Used to supply 12 V DC from AD digital input/output circuit power supply via the CPU board. (Use cable “REF-CX100-C0100-U” for connection.) 3 DIO driver connectors Used to connect digital input/output driver (DIOD) boards. Connectors for four DIOD boards (16 terminals) are provided on this DB board. The #1 connector corresponds to I/O terminals 17 to 20, the #2 connector corresponds to I/O terminals 21 to 24, and so on. DIOD boards for connection to the connectors are as follows: #1 : REF-MCS200-SO* (4 outputs) #2 : REF-MCS200-SO* (4 outputs) #3 : REF-MCS200-SO* (4 outputs) #4 : REF-MCS200-SC2* (2 outputs and 2 inputs) (* indicates a revision number.) 4 Rotary switch Used to set the ID (station number) of the DB board. Do not move the switch from position 1. 5 Digital input/output board connector Used to connect a digital input/output board and DB board with a cable. Digital input/output boards and cables used are the same as those for the CPU board. (Use cable “REF-CX100-C1301-U” for connection.) 6 Reserved Currently not used 2 5 3 1 4 6 QT108300 - 26 - 2.7 Digital Input/Output Board (REF-MCS200-OIA0, REF-MCS200-OIE0 (Optional)) Parts on Digital Input/Output Board No. Name Function 1 Digital input/output board connector Used to connect an optional DB board to the CPU board or to a digital input/output board using a cable. (Use cable “REF-CX100-C1301-U” for connection.) 2 Digital input/output terminal block Used to connect digital input/output wires. Terminals 1A and 1B correspond to digital input/output CH 1; terminals 16A and 16B correspond to digital input/output CH 16. 3 Digital input/output lamp Indicates whether digital input/output is ON or OFF (goes on when input/output is ON and goes off when input/output is OFF). LED 1 corresponds to digital input/output CH1; LED 16 corresponds to digital input/output CH16. 4 Digital output circuit On the REF-MCS200-0IA0 board, digital input/output channels CH1 to CH10 are assigned to digital outputs. On the REF-MCS200-0IE0 board (option), digital input/output channels CH1 to CH14 are assigned to digital outputs (switch outputs). 5 Digital input circuit On the REF-MCS200-0IA0 board, digital input/output channels CH11 to CH16 are assigned to digital inputs. On the REF-MCS200-0IE0 board(option), digital input/output channels CH15 and CH16 are assigned to digital inputs. 6 Relay sockets These relay sockets provided for digital outputs allow the use of mechanical relays or solid state relays. 7 Relay The following relays are usable. Mechanical relay: OMRON G6B-1114P-US, 12 V DC (rated output load: 5A at 250 V AC/30 V DC) Solid state relay: G3S-201PL-PD-US, 12 V DC (rated output load: 1.2 A at 100 to 240 V AC) 8 TNR (ceramic variable resistor) Provided to protect contacts of the relays. 9 Circuit protector Provided to protect the relays from overcurrent. Output is interrupted if current exceeding 1 A flows through relay contacts. Remove the overcurrent condition first and then push in the white knob of the circuit protector to recover relay outputs. 1 3 6, 7 4 5 8 9 2 10 REF-MCS200-OIA0 REF-MCS200-OIE0 (optional) 4 5 QT108300 - 27 - Parts on Digital Input/Output Board (continued) No. Name Function 10 Frame ground (FG) terminal Provided to keep continuity between ground (terminal) and the printed circuit board. Securely connect the FG terminal to ground (terminal); otherwise, the digital input/output board does not work normally. NOTE: This digital input/output board is not installed on the back surface of the MYPRO-CPIV Control Panel. 2.8 Optional Communication Board (REF-CX100-RS01) Parts on Optical Communication Board No. Name Function 1 Extension Communication board connector Used to connect this optional extension communication board to the CPU board. 2 COM2 and COM3 lamps Left lamp is for COM2 port and right lamp is for COM3 port. Each lamp lights green during transmission and lights red during reception. 3 Communication power supply connector Used to supply power from CPU board power supply to this extension communication board. (Use cable “REF-CX100-C0100-U” for connection.) 4 COM2 terminal block Terminal block for 4-wire RS-485 communication ports 5 COM2 terminating switch Used to terminate the transmission and receiving line independently. Moving the switch up terminates the line. Move the switch until it clicks. 6 COM3 terminal block Terminal block for 4-wire RS-485 communication ports 1 2 3 5 7 6 4 QT108300 - 28 - Parts on Optical Communication Board (continued) No. Name Function 7 COM3 terminating switch Used to terminate transmission and receiving lines independently. Moving the switch up terminates the line. Move the switch until it clicks. 2.9 Optional Analog-to-Digital (AD) Converter Board (REF-CX100-AD01) Parts on Optical AD Converter Board No. Name Function 1 Extension AD converter board connector Used to connect this extension AD converter board to the CPU board. 2 Analog input board connector Used to connect the two types of analog input board and the AD converter board like with the CPU board. (Use cable “REF-CX100-C1201-U” for connection.) 3 Input selector switch for CH15 and CH16 This switch is used to switch analog input between 15A and 15B terminal boards and between 16A and 16B terminal boards. Moving the switch to the right selects 15A or 16A; moving it to the left selects 15B or 16B. Move the switch until it clicks. 4 AD board power supply connector Used to supply power from the CPU board to this AD converter board. (Use cable “REF-CX100-C0100-U” for connection.) 2 3 1 4 QT108300 - 29 - Chapter 3 Operation 3.1 Display Screens CP4 has two types of status display screen: the “Main Graphic Screen” and “Main Status Screen”. You can swap these screens by pressing the TAB key while no function menu and windows are displayed. 3.1.1 Acronyms and Abbreviations Used for Indicated Items In these two screens, the indicated items are represented using the acronyms and abbreviations shown in the following tables. The tables also show the channel numbers for analog and digital inputs and outputs. For digital input/output channel numbers, their aliases are also shown. Real analog inputs Acronym Full Spelling Input Channel No. SP SUCTION PRESSURE AI 1 DP DISCHARGE PRESSURE AI 2 OP OIL SUPPLY PRESSURE AI 3 AFP AFTER FILTER PRESSURE AI 4 ST SUCTION TEMPERATURE AI 5 DT DISCHARGE TEMPERATURE AI 6 OT OIL SUPPLY TEMPERATURE AI 7 OS OIL SEPARETER TEMPERATURE AI 8 AFFP AFTER FINE FILTER PRESSURE AI 8 IP IMTERMEDIATE PRESSURE AI 9 IT INTERMEDIATE TEMPERTURE AI10 SDP SYSTEM DISCHARGE PRESSURE AI11 LVL LIQUID LEVEL AI11 MA MOTOR ELECTRIC CURRENT AI12 EBT ENTERING BRINE TEMPERATURE AI13 LBT LEAVING BRINE TEMPERATURE AI14 LSV (LOW STAGE) SLIDE VALVE POSITION AI15 HSV HIGH STAGE SLIDE VALVE POSITION AI16 SSP SYTEM SUCTION PRESURE AI16 or AI19 SVOP SLIDE VALVE OIL SUPPLY PRESSURE AI16 PSV Vi PORT SLIDE VALVE POSITION AI16 SP1 SUCTION PRESSURE1 AI17 GT1 CHILLER GAS TEMPERATURE1 AI18 RLD REMOTE CAPACITY CONTROL TARGET AI20 SP2 SUCTION PRESSURE2 AI25 GT2 CHILLER GAS TEMPERATURE2 AI26 OPT1 OPTION ANALOG INPUT 1/4 AI8, AI9, AI10, AI11, AI13, AI14, AI21, AI22, AI23 or AI24 OPT2 OPTION ANALOG INPUT 2/4 AI8, AI9, AI10, AI11, AI13, AI14, AI21, AI22, AI23 or AI24 OPT3 OPTION ANALOG INPUT 2/4 AI8, AI9, AI10, AI11, AI13, AI14, AI21, AI22, AI23 or AI24 OPT4 OPTION ANALOG INPUT 4/4 AI8, AI9, AI10, AI11, AI13, AI14, AI21, AI22, AI23 or AI24 QT108300 - 30 - Virtual analog inputs (derived from real analog inputs through calculation) Acronym Full Spelling Assigned Input Channel No. ⊿OP OIL DIFFERENTIAL PRESSURE AI65 ⊿FP FILTER DIFFERENTIAL PRESSURE AI66 ⊿P DIFFERENTIAL PRESSURE AI67 SSH SUCTION SUPERHEAT AI68 ISH INTERMEDIATE SUPERHEAT AI69 DSH DISCHARGE SUPERHEAT AI70 D/S DISCHARGE/SUCTION PRESSURE RATIO AI71 Vi CALCULATED Vi AI72 CRVi CURRENT Vi AI73 CAP COMPRESSOR CAPACITY AI74 SVP SLIDE VALVE PERCENTAGE AI75 ATP AUTO STAGE TARGET PRESSURE AI76 ⊿OP2 OIL DIFFERENTIAL PRESSURE2 AI77 SH2 SUCTION SUPERHEAT2 AI78 ⊿FFP FINE FILTER DIFFERENTIAL PRESSURE AI79 N.C. NOT CONNECTED Digital inputs/outputs Acronym Full Spelling Input/Output Cannel No. Alias COMP COMPRESSOR DO1 Y 0 OILP OILPUMP DO2 or DO20 Y 1 or Y13 I/CS LIQUID SUPPLY SOLENOID VALVE for ECONOMIZER/INTERCOOLER DO2 or DO8 Y 1 or Y 7 LOAD (LOW STAGE) LOADING SOLENOID VALVE DO3 Y 2 UNLD (LOW STAGE) UNLOADING SOLENOID VALVE DO4 Y 3 HILD HIGH STAGE LOADING SOLENOID VALVE DO5 Y 4 INJS LIQUID SUPPLY SOLENOID VALVE for LIQUID INJECTION DO5 Y 4 HIUL HIGH STAGE UNLOADING SOLENOID VALVE DO6 Y 5 INJY YOSAKU EXPANSION VALVE for LIQUID INJECTION DO6 Y 5 OILH OIL HEATER DO7 Y 6 EVPS LIQUID SUPPLY SOLENOID VALVE for CHILLER DO7 or DO17 Y 6 or Y10 ViBP BYPASS SOLENOID VALVE for Vi PORT DO7 Y 6 ViLD LOADING SOLENOID VALVE for Vi PORT DO8 Y 7 OILD OIL DRAIN SOLENOID VALVE DO9 Y 8 OILF OIL FEED SOLENOID VALVE DO9 Y 8 OILR OIL RETURN SOLENOID VALVE DO9 Y 8 ViUL UNLOADING SOLENOID VALVE for Vi PORT DO9 Y 8 FAIL FAILURE DO10 Y 9 EMGC EMERGENCY STOP DI11 X A MSRB MAIN STARTER READ BACK DI12 X B ITL1 INTERLOCK-1 DI13 X C ITL2 INTERLOCK-2 DI14 X D ITL3 INTERLOCK-3 DI15 X E RMST REMOTE START INPUT DI16 X F MPLD LOADING SOLENOID VALVE for PORT-M DO17 or DO26 Y10 or Y19 EVPY YOSAKU EXPANSION VALVE for CHILLER DO18 Y11 MPUL UNLOADING SOLENOID VALVE for PORT-M DO18 or DO27 Y11 or Y1A CHLP CHILLER PUMP DO19 Y12 SVBP BYPASS SOLENOID VALVE for Vi SLIDE VALVE DO19 Y12 SBYP BYPASS SOLENOID VALVE for STARTING DO20 or DO28 Y13 or Y1B HBYP BYPASS SOLENOID VALVE for HOT GAS DO20 Y13 I/CY YOSAKU EXPANSION VALVE for ECONOMIZER/INTERCOOLER DO21 Y14 O/P2 OIL PUMP2 DO21 Y14 ALRM ALARM DO22 Y15 EVS2 LIQUID SUPPLY SOLENOID VALVE2 for CHILLER DO23 Y16 LHLD LOADING SOLENOID VALVE for PORT-L/H DO23 or DO29 Y16 or Y1C EVY2 YOSAKU EXPANSION VALVE2 for CHILLER DO24 Y17 LHUL UNLOADING SOLENOID VALVEfor PORT-L/H DO24 or DO30 Y17 or Y1D CND1 OUTPUT1 for CONDENSER(VFD) DO25 Y18 AUX AUXILIARY DO25 Y18 QT108300 - 31 - Digital inputs/outputs (continued) Acronym Full Spelling Input/Output Cannel No. Alias CND2 OUTPUT2 for CONDENSER DO26 Y19 CND3 OUTPUT3 for CONDENSER DO27 Y1A CND4 OUTPUT4 for CONDENSER DO28 Y1B IJY2 YOSAKU EXPANSION VALVE2 for LIQUID INJECTION DO28 Y1B CND5 OUTPUT5 for CONDENSER DO29 Y1C EVS3 LIQUID SUPPLY SOLENOID VALVE3 for CHILLER DO29 Y1C CND6 OUTPUT6 for CONDENSER DO30 Y1D EVY3 YOSAKU EXPANSION VALVE3 for CHILLER DO30 Y1D RMLD REMOTE LOAD INPUT DI31 X1E RMUL REMOTE UNLOAD INPUT DI32 X1F PID controller Acronym Full Spelling LSV P (LOW STAGE) SLIDE VALVE on PRESSURE LSV T (LOW STAGE) SLIDE VALVE on CHILLER LEAVING BRINE TEMPERATURE SCTSH CHILLER EXPANSION VALVE on SUCTION SUPERHEAT SPLMT LIMIT on SUCTION PRESSURE for CHILLER EXPANSIN VALVE LBLMT LIMIT on CHILLER LEAVING BRINE TEMPERATURE for CHILLER EXPANSIN VALVE INTSH ECONOMIZER/INTERCOOLER EXPANSION VALVE on INTERMEDIATE SUPERHEAT INJCT LIQUID INJECTION LVGBT FLOW CONTROL VALVE on CHILLER LEAVING BRINE TEMPERATURE CNDNS VFD CONDENSER FAN HI SV HIGH STAGE SLIDE VALVE on INTERMEDIATE PRESSURE VFD P VFD COMPRESSOR on PRESSURE VFD T VFD COMPRESSOR on CHILLER LEAVING BRINE TEMPERATURE SCSH2 CHILLER EXPANSION VALVE2 on SUCTION SUPERHEAT2 SP2LM LIMIT on SUCTION PRESSURE2 for CHILLER EXPANSIN VALVE2 LEVEL LEVEL SV SET VALUE MV MANIPULATION VALUE Others Acronym Full Spelling A/O, AO ANALOG OUTPUT AI ANALOG INPUT C7 CHARACTER BIT 7 C8 CHARACTER BIT 8 CH. CHANNEL COM, COMM COMMUNICATION COMP. COMPRESSOR CTRL CONTROL D/O DIGITAL OUTPUT ECONO. ECONOMIZER/INTER COOLER EXP.VALVE EXPANSION VALVE H.SLIDE VALVE HIGH STAGE SLIDE VALVE HI HIGH HRS HOURS HSV HIGH STAGE SLIDE VALVE POSITION I/O INPUT/OUTPUT INTER INTERMEDIATE L.SLIDE VALVE LOW STAGE SLIDE VALVE LB CHILLER LEAVING BRINE TEMPERATURE LO LOW MV MANIPURATING VALUE MVH MANIPULATING VALUE HIGH LIMIT MVL MANIPULATING VALUE LOW LIMIT OIL P. OIL PUMP P. PAGE QT108300 - 32 - Others (continued) Acronym Full Spelling PE EVEN PARITY PN NON PARITY PO ODD PARITY PRES. PRESSURE PRESS. PRESSURE S1 STOP BIT 1 S2 STOP BIT 2 SETPT SET POINT SH SUPERHEAT SP SUCTION PRESSURE SV SLIDE VALVE POSITION or SOLENOID VALVE TEMP TEMPERATURE VFD VARIABLE FREQUNCY DRIVE W/ WITH W/O WITHOUT 3.1.2 Main Graphic Screen The “Main Graphic Screen” shows the compressor’s current status using graphics. Colors and symbols help you to check the compressor’s operating conditions and alarms. The Main Graphic Screen has priority over the “Main Status Screen”, the other compressor status screen. To select the Main Status Screen, press the TAB key when no function menu or window is displayed. Colors and symbols are used as follows: Refrigerating system and oil pump in operation: Displayed in green. Refrigerating system and oil pump not in operation: Displayed in gray. Refrigerating system automatically stopped: Displayed in red. In FAILURE (critical failure) condition: Indicated by a blinking symbol. In ALARM (non-critical failure) condition: Indicated by a blinking symbol. Title block Warning display Timer ALARM/FAILURE display Function menu display DATE Status display Low battery alarm QT108300 - 33 - • If a low battery alarm “BATTERY ALARM” is displayed showing that the memory backup battery is discharged, replace the battery immediately (see Section 2.2.2 Replacement of Memory Backup Battery on CPU Board). • If the CPU is reset following such an operation as turning on the power supply with the internal battery discharged, PC4 will automatically be restarted by “special booting” for the sake of safety. Once this has occurred, the compressor cannot be operated any further unless the memory backup battery is replaced with a battery of the normal voltage (see Section 3.5 Special Booting). 3.1.3 Main Status Screen The “Main Status Screen” shows the current status related to operation of the compressor unit using letters and numeric values. To change the display to the Main Graphics Screen, press the TAB key when no function menu or window is displayed. Display of Main Status Screen No. Name Function 1 Title block Displays controller’s name. 2 DATE Displays current date and time. Also indicates panel inside temperature. 3 OPERATION MODE window Displays current operation control mode, compressor status, and operation start/stop settings. 4 CAPACITY CONTROL window Displays current status of capacity control. This window also gives an indication if increase of the compressor’s capacity is prohibited or it is forcedly reduced. 5 MAIN STATUS window Displays current values of individual analog inputs, calculated values derived from analog inputs, total operating time count, and day’s operating time count. 6 COMMUNICATION window Displays current communication status. 1 3 4 6 7 8 2 5 9 QT108300 - 34 - Display of Main Status Screen (continued) No. Name Function 7 ALARM/FAILURE display area Displays currently issued alarms. The alarms cannot be cleared unless the ALARM CLEAR key is pressed (certain alarms cannot be cleared by the ALARM CLEAR key.). This field is blank if no alarm is issued. (see Section 7.1 Settings in ‘ALARM/FAILURE’ Windows 1/3 to 3/3) 8 Function display area Displays function menus corresponding to function keys (F1 to F7). (see Section 1.2 Menu-Window Organization (Menu Tree)) 9 Low battery alarm Displays “BATTERY ALARM” warning when the memory backup battery is discharged. If the low battery alarm “BATTERY ALARM” is displayed, replace the memory backup battery immediately. ‘OPERATION MODE’ window The ‘OPERATION MODE’ window indicates the current selections and states concerning the operation control mode and other items related to control of the compressor. Items of ‘OPERATION MODE’ Window Item Selection/State Description NO ‘D/O TEST OPERATION’ is disabled (automatic operation is possible). D/O TEST OPERATION (Manual operation (see Section 6.2)) YES ‘D/O TEST OPERATION’ is enabled (automatic operation is impossible). -ON LOCAL -OFF START and STOP keys on the front panel are used to start and stop the compressor. -ON REMOTE -OFF Compressor starts/stops according to the remote start/stop inputs at DI-16. -ON COMM -OFF Compressor starts/stops according to commands given by a remote device through communications. -ON MODE (Operation control mode (see Section 6.1)) STAGE -OFF Compressor starts/stops according to the “automatic staging” (‘AUTO STAGE’) control (option). (see Section 6.7) NO Automatic start/stop control of the compressor according to the set values is disabled. YES Automatic start/stop control of the compressor according to the set values is enabled. AUTO START/STOP (Automatic operation (see Section 6.1)) STG Automatic start/stop control according to the “automatic staging” (‘AUTO STAGE’) control (option) is enabled. STOP Compressor is stopped. ANTI CYCLE Compressor is in “anti-cycle” state. AUTO STOP Compressor is automatically stopped. CUT IN Operation sequence of compressor is started. SYSTEM START System is being activated. OIL PUMP START Oil pump is started. START Compressor is being started. RUN Compressor is running. CUT OUT Stop control sequence is started. COMP STATE (Compressor state) PUMP OUT Liquid recovery is in progress. QT108300 - 35 - Items of ‘OPERATION MODE’ Window (continued) Item Selection/State Description CUT IN (Operation start pressure) Pressure or temperature Indicates current setting for the start (CUT IN) pressure/temperature. This item also indicates new setting resulting from switching/change
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