CP4 Mycom Manual

INSTRUCTION MANUAL FOR SCREW COMPRESSOR UNIT CONTROLLER MYPRO-CPIV

F2

F1

START

F3

F4

F5

1

2

3

4

5

6

7

8

9

0

.

-

STOP

F6

F7

ESC

DELETE

SH IFT

ALT

MYPRO -CPⅣ

CLEAR ALARM

TAB

MYPRO-CPIV

SAVE

ENTER

(standard version)

Read this manual carefully before you can use and service MYPRO-CPIV safely and properly.

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Important Notice • 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 working on your MYPRO-CPIV. MYPRO-CPIV. • If the manual is lost or damaged, contact any of the Mayekawa offices or sales/service sales/service centers in your area to order a new copy. • This manual must remain remain with the product when you resell it to another user. user. • Mayekawa reserves reserves the right to make changes to the specifications 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, 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:

DANGER

WARNING

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

CAUTION

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 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 compressor units produced by Mayekawa Mayekawa Mfg. Co., Ltd.

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Important Notice • 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 working on your MYPRO-CPIV. MYPRO-CPIV. • If the manual is lost or damaged, contact any of the Mayekawa offices or sales/service sales/service centers in your area to order a new copy. • This manual must remain remain with the product when you resell it to another user. user. • Mayekawa reserves reserves the right to make changes to the specifications 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, 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:

DANGER

WARNING

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

CAUTION

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 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 compressor units produced by Mayekawa Mayekawa Mfg. Co., Ltd.

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Preface Thank you for your purchase of Mayekawa Screw Unit Controller MYPRO-CPIV MYPRO-CPIV (hereafter called ‘CP4’ in this manual). Before installing and putting your CP4 into service, check the following points: a. Is your CP4 CP4 exactly exactly of the factory-option factory-option variation you specified? CP4 is available from the following 12 factory-option variations: CPIV-1 CPIV-110 10 (standard version): version): 16 digital inputs/outputs; 16 analog inputs; 2 communication ports CPIV-111: CPIV-111:

16 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports

CPIV-110C: CPIV-110C:

16 digital inputs/outputs; 16 analog inputs; 2 communication ports; 2 extension communication ports


16 digital inputs/outputs; 16 analog inputs; 4 analog outputs; 2 communication ports; 2 extension communication ports

CPIV-210: CPIV-210:

32 digital inputs/outputs; 16 analog inputs; 2 communication ports

CPIV-211: CPIV-211:






CPIV-220: CPIV-220:

32 digital inputs/outputs; 32 analog inputs; 2 communication ports

CPIV-221: CPIV-221:






b. Are all all necessary 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 followi ng 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) 4)

‘ADJUSTMENT’ ‘ADJUSTMENT’ menu windows (F5):

Is the scaling setting setting for each sensor sensor correct? correct? (seeChapter (see Chapter 5) 5)

‘LIMITS’ menu windows (F3):

Are the settings for each alarm appropriate? (seeChapter (seeChapter 7) 7)

‘SETPOINT’ menu window (F1):

Are the start/stop (‘CUT IN / CUT OUT’) settings appropriate? (see Chapter 6) 6)

Mayekawa Mayekawa Mfg. Co., Lt d. -2-

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Table of Contents Con tents Prefac Preface e ......................................................................................................................................................................................... .........................................................................................................................................................................................2 2 Table of Contents .......................................................................................................................................................................... ..........................................................................................................................................................................3 3 Chapter 0 Information on This Manual.......................................................................................................................................... Manual..........................................................................................................................................6 6 0.1

This Manual and Other Related Manuals ....................................................................................................................... .......................................................................................................................6 6

0.2

Organization of This Manual........................................................................................................................................... Manual...........................................................................................................................................6 6

0.3

Glossary of Special Terms.. erms .............................................................................................................................................. ............................................................................................................................................7 7

0.4

Units Units ............................................................................................................................................................................... ...............................................................................................................................................................................8 8

0.5

Words Displayed on Screen ........................................................................................................................................... ...........................................................................................................................................8 8

0.6

Acronyms and Abbreviations.......................................................................................................................................... Abbreviations..........................................................................................................................................8 8

Chapter 1 General Description Description ..................................................................................................................................................... .....................................................................................................................................................9 9 1.1

Functions and Features.................................................................................................................................................. Features..................................................................................................................................................9 9

1.2

Menu-Window Organization (Menu Tree)....................................................................................................................... Tree).......................................................................................................................9 9

1.3

Usable Control Functions Depending on Selected Factory Options............................................................................. Options.............................................................................11 11

Chapter 2 Components and Their Their Functions Functions .............................................................................................................................. ..............................................................................................................................13 13 2.1

Front Panel................................................................................................................................................................... Panel...................................................................................................................................................................13 13

2.2

Parts on CPU Board (REF-CX100-PR01) .................................................................................................................... ....................................................................................................................15 15

2.2.1

Reset Switch on CPU Board................................................................................................................................ Board................................................................................................................................17 17

2.2.2

Replacement of Memory Backup Battery on CPU Board ..................................................................................... .....................................................................................18 18

2.3

EPROM Board (REF-CX100-RM01) (REF-CX100-RM01) ............................................................................................................................ ............................................................................................................................19 19

2.3.1 2.4

Replacement of EPROM on CPU Board .............................................................................................................. ..............................................................................................................20 20

Analog Input Boards (REF-CX100-AI01, REF-CX100-AI11) REF-CX100-AI11) ........................................................................................ ........................................................................................21 21

2.4.1

Current / Voltage Selection and Terminal Block Connections for Analog Input Boards... Boards .........................................22 ......................................22

2.4.2

Input Type Type Selection for Channels 15 and 16 of Analog Input Boards ..................................................................23 ...............................................................23

2.5

Optional Analog Output Board (REF-CX100-DA01) (REF-CX100-DA01) .....................................................................................................24 ..................................................................................................24

2.6

Optional Digital Input/Output Drive Base (DB) Board (REF-CX100-DB01) ..................................................................25 ...............................................................25

2.7

Digital Input/Output Board (REF-MCS200-OIA0, (REF-MCS200-OIA0, REF-MCS200-OIE0 REF-MCS200-OIE0 (Optional)) .......................................................26 ....................................................26

2.8

Optional Communication Board (REF-CX100-RS01)... (REF-CX100-RS01)................................................................................................... ................................................................................................27 27

2.9

Optional Analog-to-Digital (AD) Converter Board (REF-CX100-AD01) ........................................................................28 .....................................................................28

Chapter Chapter 3 Operation Operation ................................................................................................................................................................... ...................................................................................................................................................................29 29 3.1

Display Screens ........................................................................................................................................................... ...........................................................................................................................................................29 29

3.1.1

Acronyms and Abbreviations Used for Indicated Items......................................................................................... Items.........................................................................................29 29

3.1.2

Main Graphic Screen ............................................................................................................................................ ............................................................................................................................................32 32

3.1.3

Main Status Screen............................................................................................................................................... Screen...............................................................................................................................................33 33

3.2

To Make Settings – Selection from Options.................................................................................................................. Options..................................................................................................................39 39

3.3

To Make Setting – Entry Using Keys ............................................................................................................................ ............................................................................................................................40 40

3.4

Software Resetting Method .......................................................................................................................................... ..........................................................................................................................................42 42

3.5

Special Special Booting............................................................................................................................................................. Booting.............................................................................................................................................................43 43

Chapter 4 Setups (‘SETUP’ Menu (F6))...................................................................................................................................... (F6))......................................................................................................................................46 46 4.1

Setting in ‘SYSTEM SETUP’ Window (Option 1 of ‘SETUP’ Menu (F6)) ......................................................................46 ...................................................................46

4.2

Settings in ‘ANALOG ‘ANALOG INPUT SCALING’ Window (Option 2 of ‘SETUP’ Menu (F6)).....................................................48 ..................................................48

4.3

Settings in ‘OPTION ‘OPTION ANALOG INPUT’ Window (Option 3 of ‘SETUP’ Menu (F6)).......................................................49 ....................................................49

4.4

Settings in ‘OPTION SETUP 1/2’ Window (Option 4 of ‘SETUP’ Menu (F6)) ...............................................................51 ............................................................51

4.5

Setting in ‘OPTION SETUP 2/2’ Window (Option 5 of ‘SETUP’ Menu (F6)) .................................................................53 ..............................................................53

4.6

Settings in ‘OPTION SELECT’ Window (Option 6 of ‘SETUP’ Menu (F6)) ...................................................................55 ................................................................55

Chapter 5 Adjustments (‘ADJUSTMENT’ (‘ADJUSTMENT’ Menu Menu (F5)) ................................................................................................................. .................................................................................................................57 57 5.1

Settings in ‘SLIDE VALV VALVE E SETUP’ Window (Option 1 of ‘ADJUSTMENT’ ‘ADJUSTMENT’ Menu (F5)) ................................................57 .............................................57

5.2

Settings in ‘SET TIME’ Windows (Option 2 of ‘ADJUSTMENT’ ‘ADJUSTMENT’ Menu (F5)) .................................................................66 ..............................................................66

5.3

Settings in ‘PASSWORD’ ‘PASSWORD’ Window (Option 3 of ‘ADJUSTMENT’ ‘ADJUSTMENT’ Menu (F5)) ...............................................................68 ............................................................68

5.4

Settings in ‘ANALOG ‘ANALOG INPUT ADJUSTMENT’ ADJUSTMENT’ Window (Option 4 of ‘ADJUSTMENT’ ‘ADJUSTMENT’ Menu (F5)) ................................69 .............................69

5.5

Settings in ‘ANALOG ‘ANALOG OUTPUT ADJUSTMENT’ ADJUSTMENT’ Window (Option 5 of ‘ADJUSTMENT’ ‘ADJUSTMENT’ Menu (F5)) ............................70 .........................70

5.6

Settings in ‘ANALOG ‘ANALOG OUTPUT ASSIGNMENT’ ASSIGNMENT’ Window (Option 6 of ‘ADJUSTMENT ‘ADJUSTMENT Menu (F5))’............................. (F5))’.............................71 71

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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


7.1.3


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 -4-

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Device List ............................................................................................................................................................................136 List of Replaceable Parts ......................................................................................................................................................242 Software Revision Record 1..................................................................................................................................................243 Software Revision Record 2..................................................................................................................................................244

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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 initi alization. - 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 Organizatio n 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: the functions 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.

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0.3 Glossary of Special Terms The special terms used in this manual are defined below. AL ARM ALARM is a non-critical alarm that does not involve any compressor unit shutdown. Auto matic st agi ng cont ro l (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. Hardw are 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 Graphi c 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 t ime 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.

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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 d ata 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 Section3.1 Display Screens.

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Chapter 1 General Descriptio n 1.1 Functio ns and Features CP4 is a controller developed for controlling operation of the Mayekawa-produced screw compressor units. The controller has the follo wing 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-Window Organi zation (Menu Tree) The individual function menus are associated with the function keys F1 to F7 (seeSection 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.

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Menu Tree

“Main Graphic” and “Main Status” windows 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)

F1

SETPOINTS

F2

CONTROLLER

F3

LIMITS

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)

F4

LOGS

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

F5

ADJUSTMENT

F6

SETUP

F7

DIAGNOSTIC

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. 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)

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1.3 Usable Contro l Funct ions Depending on Selected Facto ry Opti ons 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

‘REMOTE CAPACITY CONTROL’

REMOTE CAPACITY CONTROL

DIGITAL ANALOG

CONDENSER CONTROL CONDENSER VFD CONTROL CONDENSER CONTROL TARGET CONDENSER 3STEPS CONTROL or

CONDENSER CONTROL CONDENSER CONTROL TARGET

CONDENSER 6STEPS CONTROL CONDENSER CONTROL METHOD CHILLER CONTROL

* NOT USE USE * LOCAL DISCHARGE PRESSURE SYSTEM DISCHARGE PRESSURE * NOT USE USE * LOCAL DISCHARGE PRESSURE SYSTEM DISCHARGE PRESSURE * ON/OFF SIGNAL SET ON/OFF MULTI SET * NOT USE USE * 1

LIQUID SUPPLY SV

2 3 NONE/THERMAL EXPANSION YOSAKU 1-VALVE

EXPANSION VALVES

YOSAKU 2-VALVES YOSAKU 3-VALVES * 1-MOTORIZED CONTROL VALVE 2-MOTORIZED CONTROL VALVES

CHILLER CONTROL CHILLER GAS TEMP. SENSOR CHILLER ENTERING TEMP. SENSOR CHILLER LEAVING TEMP. SENSOR CHILLER LEAVING TEMP. CONTROL CHILLER PUMP MODE AUTO STAGING (Control of the number of operating AUTO STAGER compressors) VFD COMPRESSOR (Inverter control)

* NO YES * NO YES * NO YES * NOT USE USE CONTINUOUS * AUTO START/STOP * NOT USE 2 UNITS - 8 UNITS

VFD COMPRESSOR VFD COMPRESSOR OUTPUT LIMIT

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* NOT USE USE * NOT USE USE

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Usable Control Functions (continued) ‘OPTION SELECT’ HIGH STAGE CAPACITY CONTROL (Control of the high stage capacity of compound type two stage compressors)

‘OPTION SETUP’

Item *

NOT USE

HIGH STAGE CAPACITY CONTROL

USE *

AUTO Vi CONTROL

NOT USE USE Y10,11,12,16,17(UD-V)

AUTO Vi CONTROL

USE Y19,1A,1B,1C,1D(UD-V) USE J SERIES

LIQUID INJECTION OIL COOLING CONTROL

* NOT USE USE NONE/THERMAL EXPANSION

LIQUID INJECTION CONTROL (Oil cooling control)

INJECTION VALVES

* YOSAKU 1-VALVE YOSAKU 2-VALVES MOTORIZED CONTROL VALVE

CONTROL TARGET HOT GAS BYPASS CONTROL

HOT GAS BYPASS CONTROL

STARTING BYPASS CONTROL

STARTING BYPASS CONTROL

ECONOMIZER/INTERCOOLER EXPANSION VALVE CONTROL

* DISCHARGE TEMPERATURE DISCHARGE SUPERHEAT * NOT USE USE * NOT USE USE

ECONOMIZER/INTERCOOLER LIQUID SUPPLY CONTROL

* LSV & SP

ECONOMIZER/INTERCOOLER EXPANSION VALVE CONTROL

* NOT USE

HSV & IP USE NONE

EXPANSION VALVES

* YOSAKU MOTORIZED CONTROL VALVE

LEVEL CONTROL (Liquid level control)

LEVEL CONTROL

COMPRESSOR OIL SEAL CONTROL

COMPRESSOR OIL SEAL CONTROL

400 SERIES COMPRESSOR CONTROL

---

* NOT USE USE * NOT USE USE --* LOCAL SUCTION PRESSURE

---

CONTROL TARGET (CUT IN/OUT) (Target of start/stop control)

SYSTEM SUCTION PRESSURE CHILLER ENTERING TEMPERATURE CHILLER LEAVING TEMPERATURE * LOCAL SUCTION PRESSURE SYSTEM SUCTION PRESSURE

---

CONTROL TARGET (CAPACITY CONTROL) (Target of capacity control)

CHILLER LEAVING TEMPERATURE COMBINED LOCAL SP/LB COMBINED SYSTEM SP/LB LOCAL DISCHARGE PRESSURE SYSTEM DISCHARGE PRESSURE

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Chapter 2 Components and Their Functions 2.1 Front Panel

1 2 11 12

3 F2

F1

F3

F4

F5

F6

F7

5 4

START

13

1

2

3

4

5

6

7

8

9

0

.

-

STOP

ESC

DELETE

SH IFT

ALT

MYPRO-CPⅣ

CLEAR ALA RM

6

TAB

SAVE

ENTER

7 8

10

9

Keys on Front Panel No.

Key

Function

1

Function keys

2

ESC key

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). Press this key to close a menu or window.

3

SHIFT key

4

AL T key

5

DELETE key

6

Arrow k eys

7

TAB key

8

ENTER key

9

SAVE key

10

Numeric keys

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.) 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). Use this key when correcting entries. Use these keys to move the cursor (in reverse video) from one item to another within a menu or window. 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. 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. 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. Use these keys to select a window in each menu or make entries in each window.

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Keys on Front Panel (continued) No.

Key

Function

11

START key

12

STOP key

13

CLEAR ALARM 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). This key can be used to stop the compressor regardless of the operation mode selected (see CAUTION below). 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. 2.

From the ‘SETPOINTS’ menu (F1), open the ‘AUTO STAGE’ window. Select ‘ENABLE’ for the ‘CONTROL’ item in the window.

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2.2 Parts on CPU Board (REF-CX100-PR01) 17

2

16 4 1 18

3

19 5

15 14 21

7

11 22

6

25 8

12

24 26 10

23

9

13

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

1

Analog input board connector

2

LCD board connector

3

ROM board connector

4 5

Functio n Used to connect the two different analog input boards to the CPU board. (Use cable “REF-CX100-C1201-U” for connection.) Used to connect the LCD interface board to the CPU board. (Use cable “REF-CX100-C0901-U” for connection.) Used to connect the ROM board to the CPU board.

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.) Extension communication Used to connect an extension communication board (option) to the CPU board. board connector

6

Digital input/output drive connector

7

KP board connector

8

Communication power connector

9

DB board connector

10

DB board power connector

11

DC (12V) connector

12

Digital input/output board 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. Used to connect the KP board to the CPU board. (Use cable “REF-CX100-C1000-U” for connection.) Used to supply power from the CPU board power supply to an e xtension communication board (option). (Use cable “REF-CX100-C0100-U” for connection.) Used to connect a digital input/output driver base (DB) board (option) to the CPU board. Used to supply power from the CPU board power supply to the connected DB board (option). (Use cable “REF-CX100-C0100-U” for connection.) 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.) Used to connect the digital input/output board to the CPU board with a cable. (Use cable “REF-CX100-C1301-U” for connection.)

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Parts o n CPU Boards (continu ed) No.

Parts

13

Analog output board

Functio n Used to connect an analog output board (option) to the CPU board.

connector 14

Extension AD board

Used to connect an extension AD converter board (option) to the CPU board.

connector 15

Analog/digital board power connector

16

Battery holder

17

Reset switch

Used to supply power from the CPU board to an extension analog/digital board (option). (Use cable “REF-CX100-C0100-U” for connection.) Used to hold the memory backup battery (lithium primary cell CR2032). 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.

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Parts o n CPU Boards (continu ed) No.

Parts

Functio n

24

COM 1 terminating

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.

resistor switches

Move the switch until it clicks.

25

COM 1 operation lamp

26

COM 0 connector

2.2.1

Lights green during transmission; lights red during reception. 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)).

Reset Swit ch on CPU Board

CP4 requires system resetting if the stored setting data is lost or before ne wly setting up the system. There are the follo wing two methods for the system resetting. • Hardware resetting method • Software resetting method This section explains the hardware method. (For the software method, see Section3.4 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 system is 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.

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CP4 Mycom Manual

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