30RW - 30RWA - Acare

1 30rw - 30 RWAPRO-DIALOG ControlOperation and maintenance instructionsAQUASNAP2 The cover graphics are solely for illustration and forms no part of any offer for sale or any sale contract. The manufacturerreserves the right to change the design at any time without LEGENDEach of the following drawings is replaced in the whole document by the corresponding explanation:Up arrowDown arrowReturn keyStart/stop buttonDELTA T. Example: temperature difference between entering and leaving heat exchanger temperaturesmeans character is flashingTABLE OF CONTENTS1 - SAFETY CONSIDERATIONS .. - General .. - Avoid electrocution .. 42 - GENERAL DESCRIPTION .. - General .. - Abbreviations used .. 43 - HARDWARE DESCRIPTION .. - General .. - Electrical supply to boards .. - Light emitting diodes on boards .. - The sensors .. - The controls .. - Connections at the user's terminal block .. 64 - SETTING UP PRO-DIALOG PLUS CONTROL .. - Local interface general features.

2 - Unit start/stop control .. - Menus .. 105 - PRO-DIALOG PLUS CONTROL OPERATION .. - Start/stop control .. - Heating/cooling operation .. - Evaporator water pump control .. - Condenser water pump control .. - Control interlock contact .. - Control point .. - Demand limit .. - Night mode .. - Capacity control .. - Head pressure control .. - Control of a boiler .. - Master/slave assembly .. - Controlling Pro-Dialog Plus units with a System Manager .. 316 - DIAGNOSTICS - TROUBLESHOOTING .. - General .. - Displaying alarms .. - Resetting alarms .. - Alarm codes .. 3341 - SAFETY - GeneralInstallation, start-up and servicing of equipment can behazardous if certain factors particular to the installation are notconsidered: operating pressures, presence of electricalcomponents and voltages and the installation site (elevatedplinths and built-up up structures). Only properly qualifiedinstallation engineers and highly qualified installers andtechnicians, fully trained for the product, are authorised toinstall and start-up the equipment safely.

3 During all servicingoperations all instructions and recommendations which appearin the installation and service instructions for the product, aswell as on tags and labels fixed to the equipment and componentsand accompanying parts supplied separately, must be read,understood and followed. Apply all standard safety codes and practices. Wear safety glasses and gloves. Use the proper tools to move heavy objects. Move unitscarefully and set them down - Avoid electrocutionOnly personnel qualified in accordance with IEC (InternationalElectrotechnical Commission) recommendations may bepermitted access to electrical components. It is particularlyrecommended that all sources of electricity to the unit be shutoff before any work is begun. Shut off the main power supplyat the main circuit breaker or : This equipment uses and emitselectromagnetic signals. Tests have shown that the equipmentconforms to all applicable codes with respect toelectromagnetic OF ELECTROCUTION: Even when the main circuitbreaker or isolator is switched off, certain circuits may stillbe energised, since they may be connected to a separate OF BURNS: Electrical currents cause components toget hot either temporarily or permanently.

4 Handle powercable, electrical cables and conduits, terminal box covers andmotor frames with great - GENERAL - GeneralPro-Dialog is a system for controlling single or dual-circuit30RW water-cooled liquid chillers (cooling only and heat pumpunits) or 30 RWA units with remote condenser. Pro-Dialogcontrols compressor start-up needed to maintain the desiredheat exchanger entering or leaving temperature. Safety devicesare constantly monitored by Pro-Dialog to ensure their safeoperation. Pro-Dialog also gives access to a Quick Testprogram covering all inputs and PRO-DIALOG Plus controls can work in accordance withthree independent modes: Local mode: the machine is controlled by commands fromthe user interface. Remote mode: the machine is controlled by remotecontacts (volt-free contacts). CCN mode: the machine is controlled by commands fromthe Carrier Comfort Network (CCN). In this case, a datacommunication cable is used to connect the unit to theCCN communication operating mode must be chosen with the Start/Stop buttondescribed in section When the PRO-DIALOG Plussystem operates autonomously (Local or Remote mode) it retainsall of its own control capabilities but does not offer any of thefeatures of the CCN - Abbreviations usedIn this manual, the refrigeration circuits are called circuit A andcircuit B.

5 The compressors in circuit A are labelled A1 and in circuit B are B1 and following abbreviations are used frequently:CCN : Carrier Comfort NetworkCCn: Operating type: CCNLED : Light Emitting DiodeLOFF : Operating type: Local OffL-On : Operating type: Local On modeL-Sc : Operating type: Local On following a time scheduleMASt : Operating type: master unit (master/slave assembly)rEM: Operating type: by remote contactsSCT: Saturated Condensing TemperatureSIO: Sensor Bus (internal communication bus linking thebasic board to the slave boards)SST: Saturated Suction TemperatureTXV : Thermal Expansion Valve53 - HARDWARE - GeneralFigure 1 - Control - Electrical supply to boardsAll boards are supplied from a common 24 V supplyreferred to : Maintain the correct polarity when connectingthe power supply to the boards, otherwise the boards may the event of a power supply interrupt, the unit restartsautomatically without the need for an external , any faults active when the supply is interrupted aresaved and may in certain cases prevent a circuit or unit - Light emitting diodes on boardsAll boards continuously check and indicate the properoperation of their electronic circuits.

6 A light emitting diode(LED) lights on each board when it is operating properly. The red LED flashing for a 2 second period on the NRCP-BASE board indicates correct operation. A different rateindicates a board or a software failure. On dual-circuit units or units equipped with optionalboard, the green LED flashes continuously on all boardsto show that the board is communicating correctly over itsinternal bus. If the LED is not flashing, this indicates aSIO bus wiring problem. On the master board, the orange LED flashes to showwhen all communication is via the CCN - The sensorsPressure sensorsTwo types of electronic sensors (low and high pressure) areused to measure the suction and discharge pressure in evaporator and condenser (option) water sensors areinstalled in the entering and leaving side. An optional watersystem temperature sensor can be used for master/slaveassembly control (in the case of leaving water control).For certain options an outdoor temperature sensor or drycoolerwater temperature sensor is connector2 Red LED, status of the board3 Green LED, communication bus SIO4 Orange LED, communication bus CCN5 Remote master board customer control connection contacts6 Remote slave board customer control connection contacts7 Master board customer connection relay outputs8 Slave board customer connection relay outputs9 Master NRCP basic board10 Slave NRCP basic boardThe control system consists of an NRCP-BASE board forsingle-circuit units and two NRCP-BASE boards (a master anda slave board) for dual-circuit units.

7 Drycooler or remote air-cooled condenser control is possible with an additionalPD-AUX1 board. All boards communicate via an internal SIObus. The NRCP-BASE boards continuously manage theinformation received from the various pressure and temperatureprobes. The NRCP-BASE master board incorporates theprogram that controls the user interface consists of two display blocks with up to 26 LEDs and 16 buttons (according to unit type). It is connected tothe main board and gives access to a full array of - Connections at the user's terminal - General descriptionThe contacts below are available at the user's terminal block onthe NRCP-BASE board (see figure 1). Some of them can onlybe used if the unit operates in remote operating type (rEM).The following table summarises the connections at the user sterminal relay outputBoiler relay outputContact 1:start/stopContact 2:heat/cool or heat reclaimselectionContact 3:demand limit selection orsetpoint selectionUser safety loop inputConnection to CCNC onnector/channelJ3 / CH24J3 / CH25J4 / CH8J4 / CH9J4 / CH10J4 / CH11aJ12 Terminal30 - 3137 - 3832 - 3363 - 6473 - 7434 - 351 - 2 - 3 BoardNRCP-BASENRCP-BASENRCP-BASENRCP-BAS ENRCP-BASENRCP-BASENRCP-BASER emarksIndicates alarmsBoiler start/stop control section contacts are used for unit start/stopand heat/cool control.

8 They are only takeninto account if the unit is under remoteoperation control (rEM).Depending on the configuration, this drycontact can be used for remote setpointselection or demand limit selection (seesections and ).- The remote setpoint selection contact isonly taken into account if the unit is inremote control operating The remote demand limit selection contactis active whatever the operating type of contact is mounted in series with thewater flow control contact. It can be usedfor any customer safety loop that requiresthat the unit is stopped, if it is it is unused this contact must be RS-485 bus is used for connection to Pin 1: signal +- Pin 2: ground- Pin 3: signal -RemarksVolt-free contact 24 V V max, 20 V ormin. 20 V , 3 A max, 80mA min, external : 4 pinWAGO 734-104 pitch ;One per board V , 20 mAConnector: 8 pinWAGO 734-168, pitch : 3 pinWAGO 231-303, pitch - The controlsEvaporator pumpThe controller can regulate one or two evaporator pumps andtakes care of the automatic change-over between pumpThe controller can regulate one or two condenser pumps (fixedor variable speed) and takes care of the automatic change-overbetween heaterIt protects the evaporator (and the pipe heater for units withoutpump) against freezing if the unit is relay output authorises start/stop of a relay outputcircuit AAlarm relay outputcircuit BBoiler relay outputContact 1:start/stopContact 2:heat/cool or heat reclaimselectionContact 3:demand limit selectionContact 4:demand limit selectionContact 5:setpoint selectionControl contact 6.

9 Setpoint selectionUser safety loop inputConnection to CCNC onnector/channelJ3 / CH24J3 / CH24J3 / CH25J4 / CH8J4 / CH9J4 / CH10J4 / CH10J4 / CH8J4 / CH9J4 / CH11aJ12 Terminal30A - 31A30B - 31B37 - 3832 - 3363 - 6473 - 7475 - 7665 - 6667 - 6834 - 351 - 2 - 3 BoardMaster NRCP-BASES lave NRCP-BASEM aster NRCP-BASEM aster NRCP-BASEM aster NRCP-BASEM aster NRCP-BASES laveNRCP-BASES laveNRCP-BASES laveNRCP-BASEM asterNRCP-BASEM asterNRCP-BASER emarksIndicates alarms, circuit AIndicates alarms, circuit BBoiler start/stop control section contacts are used for unit start/stop andheat/cool control. They are only taken intoaccount if the unit is under remote operationcontrol (rEM).These dry contacts are used for demandlimit selection. See description of thesecontacts in section remote demand limit selection contactis active whatever the operating type of dry contacts are used for are only taken into account if the unitis in remote control operating type (rEM).

10 See the description of these contacts insections contact is mounted in series with thewater flow control contact. It can be used forany customer safety loop that requires thatthe unit is stopped, if it is it is unused this contact must be RS-485 bus is used for connection to Pin 1: signal +- Pin 2: ground- Pin 3: signal -RemarksVolt-free contact 24 V V max, 20 V ormin. 20 V , 3 A max, 80mA min, external : 4 pinWAGO 734-104 pitch per board V , 20 mAConnector: 8 pinWAGO 734-168, pitch : 3 pinWAGO 231-303, pitch - Demand limit or setpoint volt-free contact for single-circuit unitsOn single-circuit units contact 3 determines the selection ofdemand limit or setpoint, based on the configuration (see UserConfiguration 1 menu).Demand limit selectionSetpoint selection100%Limit 1 Setpoint 1 Setpoint 2(no limit)Contact - Demand limit volt-free contact for dual-circuit unitsOn dual-circuit units the operation of the demand limitselection contacts is multiplexed.