york arp 1000 users manual

Users manual Air-condition Refrigeration Plant 1000 System description

YORK Marine, Controls/ the people to talk to

Users manual

YORK Marine ApS

Copyright YORK Marine ApS All Rights Reserved

Table of Contents YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 2 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

Users manual Table of Contents

1 INTRODUCTION 3 1.1 System description 3 1.2 Plant design 3 1.3 Control Components 3

2 PICTURE HIERARCHY 10 2.1 Menu structure 10 2.2 Main menu 11 2.3 Plant overview 12 2.4 Compressor control 15 2.5 AHU CONTROL 26 2.6 AHU detail view 32 2.7 Plant setup 47

3 PI REGULATOR FUNCTION 57

4 ALARM LIST 58

DOCUMENT REVISION RECORD 60

Users manual

Introduction YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 3 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

1 INTRODUCTION

1.1 System description This manual describes the functionality and control of a Standard ARP plant. The layout of the sections in this manual is as follows:

List of shutdowns and interlocks, if any. Function description or control description. Display pictures and functionality.

All the values on the display pictures are only examples and cannot be used as actual values.

1.2 Plant design The air conditioning plant may consist of one or two compressors, which supply one or two AHU units each fitted with one or two cooling coils. Each coil is mounted with one or two cooling circuits (interwinded).

1.3 Control Components The control system for the AHU unit consists of one temperature sensor in the outdoor chamber (On plants with two AHUs the sensor is only placed in unit 1), and one in the supply air chamber of the AHU. Up to two expansion valves in the refrigeration lines, one for each cooler or two for an interwinded cooler, and a capacity controllable compressor. The control includes the following:

Compressor control. AHU fan control. AHU pre-heating regulation. AHU cooling regulation. Expansion valve control. AHU re-heating regulation. AHU Exhaust fan control. AHU Enthalpy exchanger control. Twin pipe supply. Outdoor compensation. Humidity regulation. Alarm system. Cross connected control.

Users manual


PLC A FX2N PLC and a MAC E410 operator panel control the air-condition plant. The inputs on the PLC are both digital and analogue. All outputs on the PLC are digital. On the PLC there are LEDs indicating the status of the PLC inputs and outputs. Four LEDs on the PLC front indicate the status of the PLC itself. POWER Is alight when control voltage is connected RUN Is alight when the program is running BATT-V Is alight when battery is missing or low voltage. ERROR Is alight/flashing when there is an error in the software or in the hardware.

Operator Panel From the operator panel, the operator may start/stop all fans and compressors, all the measuring values can be read and the set point and limit values for the control may be entered. From the remote operator panel it is, for safety reasons, only possible to monitor values and start/stop the fans. See the technical documentation on http://www.mitsubishi-automation.de/products.html for further information.

Starter & control panel Remote operator panel

PLC

Users manual


1.3.1 Using the operator panel The MAC E410 operator panel is a 3.8 monochrome touch display. Use the tip of a finger or the end of a pen to operate the display.

1.3.2 Common objects

A movement key. Tap this key to jump to (in this case) the PLANT menu.

On this symbol (a reciprocating compressor) there is attached a small *. This indicates that a sub menu is available. Tap on the symbol to access the sub menu.

A status text. Example: Status of the compressor.

A monitored value. Example: Actual temperature.

An input field. Can be a selection box, numeric or an alphanumeric field. Example: Temperature set point. Tap on the field to access the keyboard. Some fields are protected by a password.

Push buttons. Example: Stop / start of a compressor. Tap button to activate.

PS: Pressure switch. TS: Temperature switch. Closed contact.

PS: Pressure switch. TS: Temperature switch. Open contact.

Users manual


1.3.3 Using the input fields. There are four different input fields: A selection box, a confirmation, numeric or an alphanumeric field. To alter a value, tap the field. This will display the input keyboard or selection box. Some fields require confirmation of the new value before it is changed.

Numeric input Alphanumeric input

Selection box Confirmation box

1.3.3.1 Password

Some inputs require a password. This password is YORK. A requester similar to the alphanumeric input field pops up when the password is required.

Users manual


1.3.4 Short-cut keys The short-cut keys are found on most displays and always have the same function.

1 2

3 4 5 6 7

1 Main menu key. Returns to main menu.

2 Alarm list key. Displays the alarm list.

3 Level up key. Moves one menu level up. Example: Jumps from control level to monitoring level.

4 Plant overview key. Jumps to a graphical overview of the plant.

5 Compressor key. Displays the compressor display. Note: The key is drawn differently from the other keys to indicate that this menu is now being displayed.

6 AHU key. Jumps to the AHU display.

7 Next key. Moves to next menu of the same component in same level. Example: Moves from Compressor 1 to Compressor 2

Users manual


1.3.5 Alarm system The system comprises a complete alarm system, which supervises both analogue and digital values called alarm points. Sensor failures will always activate an alarm and will be explained in an error message code. When an alarm occurs the alarm lamp, on the front of the switchboard, flashes. The lamp will continue to flash as long as at least one of the present alarms remain unacknowledged. After all alarms have been acknowledged, the alarm lamp will remain lid until all failures is fixed. In case that new alarms do occur, the alarm lamp will start to flash again. All alarms will activate the common alarm relay, which is a digital outlet to the central alarm system of the ship. The common alarm is "high" as long as there is no alarm, and goes "low" when there comes an alarm and stays "low" until the alarm is acknowledged in the RCM system. If another alarm occurs before the system has been acknowledged, the output goes high for 5 seconds and then low again, as shown on the figure below.

No alarm

New alarmoccurs

5 sec

Another newalarm occurs

All alarmsacknowledged

Users manual


Main

TapALARM

ALARM

1

2

3

4

5

6

7

8

1

Escape Returns to the previous display.

2 Page up Moves the cursor 1 page up.

3 Acknowledged Acknowledges the alarm under the cursor.

4 Magnify Changes the text size.

5 Timestamp Time and date for the occurrence of the alarm under the cursor.

6 Page down Moves the cursor 1 page down.

7 Unacknowledged alarm White text on a black background indicates an unacknowledged alarm.

8 Acknowledged alarm Black text on a white background indicates an acknowledged alarm.

Users manual

Picture hierarchy YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 10 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

2 PICTURE HIERARCHY

2.1 Menu structure

MAIN

TREND PLANT

COMPR1 COMPR2 AHU1 AHU2

START/STOP START/STOPSET-POINTS

PARAM PARAM

START/STOP

PARAM

START/STOPSET-POINTS

PARAMSETUP

TRENDS

Plant level

Monitoring level

Control level

Parameter level

Top level

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2.2 Main menu 1

2

3

4

5

1 Time (24 hours) and date (YY-MM-DD).

2 Indication of whether this panel is the local (mounted on the switchboard) or an optional remote panel.

3 Plant type indicator: First digit: Number of compressors. Second digit: Number of AHUs. Third digit: Number of expansion valves pr. AHU. In this case: 2 compressors, 2 AHUs and 2 expansion valves on each AHU. (Four expansion valves on the plant).

4 Trend curves menu key.

5 Setup menu key.

Users manual


2.3 Plant overview

Main

TapPLANT

Plantoverview

Depending on plant configuration, four different plant overviews are displayed. The functions are the same on all four overviews. The number of expansion valves does not inflict on the plant overview displays.. The four displays are: Plant type 11x -1 compressor and 1 AHU Plant type 12x - 1 compressor and 2 AHUs

Plant type 21x - 2 compressors and 1 AHU Plant type 22x - 2 compressors and 2 AHUs

Users manual


2.3.1 Plant type 22x

1

2

3 5

7

4

6

8 9

1

Compressor 1. Tap to access the compressor display, Symbol Description

The compressor is stopped.

The compressor is running

The compressor is prohibited to start due to low suction pressure.

Maximum Operation Pressure excided. Expansion valves are closed to reduce the pressure.

The compressor is ready for automatic start.

The compressor is prohibited from start due to anti-recycling timer.Minimum 5 minutes between starts.

The compressor is stopped due to an error. See alarm list.

2 AHU 1 Tap to access the AHU display.

3 AHU 1 fan. Symbol Description

The fan is stopped.

The fan is running

The fan is interlocked.

The fan is ready for start.

The fan is stopped due to an error. See alarm list.

4 AHU 1 supply air temperature.

5 Common outdoor air temperature.

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6 Compressor 2. Tap to access the compressor display, Symbol Description

The compressor is stopped.

The compressor is running

The compressor is prohibited to start due to low suction pressure.

Maximum Operation Pressure excided. Expansion valves are closed to reduce the pressure.

The compressor is ready for automatic start.

The compressor is prohibited from start due to anti-recycling timer.Minimum 5 minutes between starts.

The compressor is stopped due to an error. See alarm list.

7 AHU 2 Tap to access the AHU display.

8 AHU 2 fan. Symbol Description

The fan is stopped.

The fan is running




9 AHU 2 supply air temperature.

Users manual


2.4 Compressor control

2.4.1 Shut-downs The compressor is fitted with five shutdown functions. On the switches KP2, KP61, KP98 and motor winding protection the wiring is made fail-safe (all switches are normally closed when they are error free). - High discharge pressure - High oil/discharge temperature (SMC only). Fail-safe. - Low lubrication oil pressure (delay 60 sec) - Low cooling water pressure (KP2). Fail-safe. - Running failure / over current relay. Fail-safe. - Motor winding temperature too high. Fail-safe. If one of the above-mentioned limits cuts out, the input on the PLC is shut down, the compressor will stop, and alarm is given. If the over current relay has switched off, or the interlock signal is open, the compressor will be stopped, and the alarm list will indicate Compr1 Running feedback Alarm. All alarms must be reset on the operator panel and/or on the component. Following components, require local reset after alarm: - Over current relays. - KP98 (High oil/discharge temperature)

2.4.2 Anti-recycling On the compressor start an anti-recycling timer is started. If a restart of the compressor is attempted within five minutes of last start, the system rejects to carry out the restart command. In auto mode the compressor is restarted when the timer runs out. The anti-recycling timer is implanted to protect the motor from the consequences of many repeating starts.

Users manual


2.4.3 Manual Mode When the compressor is set for manual operation, (see 2.4.5.1 Compressor control for more information), the compressor capacity is exclusively controlled by the operator. All safety functions remain active. The AHUs are forced to superheat-mode.

2.4.4 Automatic Mode The compressor may be automatically controlled by selection automatic-mode. See 2.4.5.1 Compressor control for more information. Regulation of compressor: During cooling down the expansion valve will regulate according to the lowest calculated superheat in the suction lines. When the temperature is below supply air set point + supply air offset, the expansion valve will regulate according to supply air temperature. When the temperature is above SP+offset, the expansion valve will again regulate according to the lowest superheat in the suction lines. (See 2.5.4 Cooler Regulation) The compressor regulation is reverse to the expansion valve regulation.

Sup

erhe

at [

C]

Master valve

Time

Line A

Line B

Line A

Line B

Users manual


2.4.4.1 Start of Compressor

If the supply air temperature is higher than the Start coolingmode high limit and the fan are running, the expansion valves will start to open. When the suction pressure is higher than the Suction pressure low limit, the compressor will be started. See 2.4.5.2.2 Capacity control parameters for more information.

2.4.4.2 Stop of Compressor (Pump down)

If the supply air temperature at the AHU unit is lower than the set point and the expansion valves are closed, the compressor will be stopped when the suction pressure has been below the Suction pressure low limit for Low pressure cut-out delay seconds. See 2.4.5.2.2 Capacity control parameters for more information.

2.4.4.3 Capacity Step Controller

Increase of capacity

AHU mode Superheat The compressor will test every Capacity change delay seconds, if the supply air temperature is above the supply air set point. If so, the capacity is increased by one step.

AHU mode Supply air: If the lowest suction superheat temperature is lower than Increase capacity low limit for Increase delay seconds, the capacity increases by one step.

Decrease of capacity

AHU mode Superheat The compressor will not decrease while the AHU is in Superheat mode.

AHU mode Supply air If the lowest suction superheat temperature is higher than Increase capacity high limit for Decrease delay seconds, the capacity decreases by one step. If the compressor is at its lowest capacity step, it will not decrease and thereby stop.

See 2.4.5.2.2 Capacity control parameters for more information.

Users manual


2.4.5 Compressor

Main

TapCOMPR1

Compr 1

1

2

3 4

5

6

7 8

9

1

Compressor status. Text Symbol Description Stopped The compressor is stopped. Running The compressor is running LP Suction The compressor is shut down due to low suction pressure.

MOP Maximum Operation Pressure excided. Expansion valves are closed to reduce the pressure.

Ready The compressor is ready for automatic start.

Pause The compressor is prohibited from start due to anti-recycling timer. Minimum 5 minutes between starts.

Shut-down The compressor is stopped due to an error. See alarm list.

2 Tap to access the compressor display, If compressor symbol is placed in a grey square, the compressor is in automatic-mode. Status symbols as described in 1

3 Suction pressure gauges. Top gauge: Suction line pressure. Bottom gauge: Saturated vapour temperature in the suction line. Calculated value.

4 Discharge pressure gauge.

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5 Compressor lubrication oil pressure.

6 Compressor capacity level.

7 Combined oil and discharge gas temperature switch. Shuts down the compressor in case of too high oil or high discharge gas temperature. Only shown when the plant is fitted with SMC compressors.

8 The condenser.

9 The condenser cooling water pressure switch. Shuts down the compressor in case too low cooling water pressure. Only shown if the Cooling water supervision option is selected.

Users manual


2.4.5.1 Compressor control

Main

Compr 2

Tap

TapCOMPR1

Tap on thecompressor

Compr 2Control

Tap

Compr 1

Compr 1Control

1

2

34

5

6 7

8

9

10

1

Compressor status. Text Symbol Description Stopped The compressor is stopped. Running The compressor is running LP Suction The compressor is prohibited to start due to low suction pressure.

MOP Maximum Operation Pressure excided. Expansion valves are closed to reduce the pressure.

Ready The compressor is ready for automatic start.

Pause The compressor is prohibited from start due to anti-recycling timer. Minimum 5 minutes between starts.

Shut-down The compressor is stopped due to an error. See alarm list.

2 If compressor symbol is placed in a grey square, the compressor is in automatic-mode. Status symbols as described in 1

3 Suction pressure gauges. Top gauge:

Suction line pressure. Bottom gauge:

Saturated vapour temperature in the suction line. The saturated vapour temperature is calculated by the PLC.

Users manual


4 Discharge pressure gauge.

5 Compressor capacity level.

6 Manual controls. Not useable when the compressor is in automatic-mode. Compressor decrease/increase capacity buttons. Tapping the DECR button will decrease capacity by one step. If the compressor is running at the lowest capacity level, tapping the DECR will cause the compressor to stop. When stopped, tapping the INCR button will cause the compressor to start in the lowest capacity level. Additional taps on INCR will increase capacity by one step until 100% of the capacity has been reached.

7 Automatic/manual mode toggle button. Changes control method from manual to automatic and vise versa. The compressor will be enclosed by a grey square when set to automatic mode.

8 Compressor running hour counter. Accumulated running time in hours.

9 Number of starts. Accumulated number of compressor starts.

10 PARAM-key. Tap to access the compressor parameter menu.

Users manual


2.4.5.2 Compressor parameters

Main

Compr 2

Tap

TapCOMPR

Tap on thecompressor

Compr 2Control

Tap

Compr 1

Compr 1Control

Tap onParam

Compr 1Parameter

2.4.5.2.1 Alarm limits

12

3

4

5

6

7

8

1

Navigation keys for the parameter pages.

2 Lubrication oil pressure shutdown limit. If the lubrication oil pressure drops below this value for 60 sec, the compressor will be stopped and an alarm will be given.

3 Discharge gas pressure shutdown limit. If the discharge gas pressure rises above this value, the compressor will be stopped and an alarm will be given.

4 Suction gas pressure stop limit. The compressor will be stopped if the suction gas pressure drops below this value for 5 sec. No alarm will be given.

5 Suction gas low-pressure stop delay. The stop of the compressor at the low suction gas pressure limit is delayed in the selected number of seconds.

Users manual


6 Hour counter warning limit for service. A warning is given when the compressor hour counter value is greater than this value. Enter value for next service to reset the warning. This warning is mend as an internal service interval. It is up to the owner of the plant to decide if a YORK service engineer is needed.

7 Maximum operation pressure limit. Maximum allowed suction gas pressure. If pressure rises above the limit, the expansion valves will close. When the pressure again is below the limit, the valves are reopened after a delay 8 . See 2.5.4.7 MOP for more information.

8 MOP cut-in delay. Delay before reopening the expansion valve after a MOP 7 .

Users manual


2.4.5.2.2 Capacity control parameters

1 2

3

4

5

6

1


2 Only valid when the compressor is in automatic mode. Temperature limit for decrement of capacity when the compressor is regulated according to superheat. If the superheat temperature is above the limit for Decrease delay 4 seconds then the capacity is reduced by one step, unless the compressor already is at its lowest step.

3 Only valid when the compressor is in automatic mode. Temperature limit for increment of capacity when the compressor is regulated according to superheat. If the superheat temperature is below the limit for Increase delay 5 seconds then the capacity is increased by one step, unless the compressor already is at its highest step.

4 Decrease delay in seconds.

5 Increase delay in seconds.

6 Only valid when the compressor is in automatic mode. Delay for increment of capacity when the compressor is regulating according to the supply air temperature.

Users manual


2.4.5.2.3 Reset counters

1 2

3

1


2 Adjust field for compressor hour counter. The Super-user password is required.

3 Adjust field for compressor start counter. The Super-user password is required.

Users manual


2.5 AHU CONTROL The temperature in the supply air chamber is controlled by a temperature sensor, which - according to the set point and neutral zone - controls the cooling capacity or heating capacity.

2.5.1 Supply air regulation

The supply air is heated or cooled depending on the outdoor temperature, but only one is active at a time. When the outdoor temperature is higher than Cooling on, the cooling regulation will be started, and the motor valve to the pre-heater will be closed. When the outdoor temperature is lower than the Heating on, the heating regulation will be started, and the expansion valves in the refrigeration line will be closed. The regulation set points will be calculated in the summer/winter compensation program. A temperature sensor in the supply air duct regulates both cooling and heating, so the set point is active for both of the regulations. When the fan is stopped, the motor valve to the heater will be forced to close, and the expansion valve in the refrigeration line will be closed.

C

Outdoor temperature

t

Start coolingmode high limit

Start heatingmode low limit

Heating mode Heating modeCooling mode

Users manual


2.5.2 Heat regulation If the actual supply air temperature is higher than the "Supply SP", the PI regulating algorithm in the PLC will activate the electrically operated motor valve in downward direction. The opposite will be the case if the actual temperature is lower than the set point. When the actual temperature is within the "neutral zone" the motor valve will not be activated.

2.5.3 Motor valve for heater on the AHU unit Function: If the air temperature diverges from the set point, the controller, located in the control panel, will gradually open or close the valve, via the valve actuator, as a function of the diverging signal, until the set point has been reached. The heating coil is frost protected by the thermostat type KP-61/5 When the freezing thermostat measures low temperature, the following will happen: There will be an alarm on the operator display. The fan will stop. The motor valve for the heating coil will fully open. This insures that the coil will have maximum flow in case of freezing risk. The fan cannot be restarted before the KP61 temperature switch is reset and alarm is acknowledged. The valve will be closed automatically at normal stop of the air-handling unit.

Users manual


2.5.4 Cooler Regulation

2.5.4.1 Expansion valve

The expansion valve is a Danfoss AKV pulse-modulated electronic expansion valve. The PI loop calculates the time, in which the valve is open, as a percentage of the regulation sampling time. Example: Sampling time (Ts) = 5 s and valve 25% open => Open time = 5 * 0.25 = 1.25 s.

2.5.4.2 Supply Air Regulation/Compressor Auto Mode

When the supply air temperature is higher than the supply air set point + offset [Supply air offset] in [Superheat mode delay] sec the compressor will regulate according to the supply air temperature. The expansion valves will regulate the superheat of each cooler block. When the supply air temperature is below set point + offset, the compressor will regulate after the superheat of the cooler with the lowest superheat. The expansion valves will be regulating after the supply air temperature, and the expansion valves will have the same degree of opening.

C

Set point+ Offset

t

Set point

AKV: Superheat modeComp.: Delevery air mode

AKV: Delevery air modeComp.: Superheat mode

2.5.4.3 Superheat/Compressor manual mode

If the compressors are in manual mode, the expansion valves will regulate according to the superheat in the cooler. If the superheat is higher than the set point and is outside the neutral zone, the expansion valve will be regulated to have a longer opening time for each sampling. If the superheat is lower than the set point and is outside the neutral zone, the expansion valve will be regulated to have a shorter opening time for each sampling. Low Superheat Limits If the superheat of the cooler is lower than the low limit superheat limit, the valve will be closed. When the superheat has become higher than the low limit superheat, the valve will be switched back in the regulation.

2.5.4.4 Compressor Regulation

The compressor capacity will be regulated according to the superheat of the cooler.

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2.5.4.5 Start position

The start position is the initial position for the expansion valve. The expansion will take this position when starting the compressor. This makes the regulator a bit faster, because the regulator does not have to calculate and set the expansion all the way from 0% to start position. However, this operation demands a higher refrigerant flow from the compressor.

2.5.4.6 Feed Forward (FF)

To avoid a disturbance of the superheat temperature by fluctuating compressor capacity, a feed-forward function has been built-on to the superheat regulator. This feed-forward function will change the position of the expansion valve, if there is a sudden change of the compressor capacity. The expansion valve position will then be changed before the superheat temperature regulator is able to measure this disturbance in the compressor capacity, and it will result in a more stable superheat regulation. The size of the feed-forward contribution is changed by the FF gain fortification. The formula is: (Compressor capacity at this Ts - Compressor capacity at latest Ts) * FF gain / 100 Example increased If FF gain is 50.0 and the compressor capacity difference between the two latest samplings is 25.0%, the position of the valve will be moved by the following percentage: Change of the position = 25.0 * 50.0 /100 = 12.5% Valve position = 47% New position = 47 + 12,5 = 59,5% Example decreased If FF gain is 50.0 and the compressor capacity difference between the two latest samplings is 33.0%, the position of the valve will be moved by the following percentage: Change of the position = 33.0 * 50.0 /100 = 16.5% Valve position = 71% New position = 71 - 16,5 = 54,5%

Users manual


2.5.4.7 MOP

Maximum Operation Pressure To protect the compressor a MOP function is implanted. When the suction pressure is greater than MOP high limit (set in compressor parameter menu), the expansion valves are forced to close (interlocked). When the suction pressure has dropped below the MOP high limit, and the timer runs out (MOP cut-in delay), the valve returns to normal operation.

Suct

ion

Pre

ssur

e [B

ar]

TimeValveinterlocked

MOP high Limit

MOP cut-in delay

Users manual


2.5.5 Outdoor Compensation The outdoor temperature may give a compensation factor to the supply air temperature set point. This is made to insure a comfortable temperature difference between outdoor and indoor temperature in the accommodation.

Winterstop

Summerstop

Winterstart

Summerstart

Winter factor Summer factor

Outdoor temp [C]

Compensated set point [C]

Compensation applies to both cooling, heating and reheating. Two different parameter set. One set for summer and one set winter compensation. The regulation set point for the supply air will be increased by a percentage of the temperature difference between the outdoor temperature and the start temperature for compensation.

2.5.5.1 Summer Compensation

The compensation calculation is started when the outdoors temperature is higher than summer start and lower than summer stop.

2.5.5.2 Winter Compensation

The compensation calculation is started when the outdoor temperature is lower than winter start and higher than winter stop. The formula for the set point for the supply air temperature regulation is:

2.5.5.3 Formula

SUPPLYFACTORSTARTTEMPDCOMPENSATE SPSummerSummerOutdoorABSSP += 01.0)( The formula is identical for summer and winter compensation. When the outdoor temperature is -20.0C, winter start is 14.0C, winter stop is -30.0C, winter factor is 25 and supply air set point is 15.0C, the regulation supply air set point will be:

CSPABSSP DCOMPENSATEDCOMPENSATE =+=+= 5.160.1501.02560.1501.025)0.140.20( The supply air temperature will be changed to 16.5C. Maximum compensation is:

CABS =+ 0.190.1501.025)0.140.30( or 15.0C + 25% of 16C = 15.0+4.0 = 19.0C If the factor value is negative the curves lowers the SP instead of raising it.

Users manual


2.6 AHU detail view

Main

AHU 2

Tap

TapAHU1

AHU 1

1 2

3

45

67

8

9 10

11

12

13

1

Outdoors air temperature. Measured in inlet duct.

2 Supply air temperature. Measured at the end of the AHU.

3 Reheated air temperature. Measured after the reheating coil. Only shown when the Reheater option is enabled.

4 Return air humidity (percent relative humidity). Measured in the return air duct. Only shown when the Humidity option is Internal or External. Tap to access the exhaust fan / enthalpy exchanger, if available.

5 AHU status text. Text Description Fan stopped The fan is stopped. Ready for cooling. The fan is running, cooling conditions are achieved, but the

compressor is not started. Heating The fan is running and the heating system is activated. Superheat regulation The cooling system is activated in superheat-mode. Supply regulation The cooling system is activated in supply air-mode. Sensor error One or more sensors are failing. See alarm list.

Users manual


6 AHU main fan. Symbol Description

The fan is stopped.

The fan is running




7 Heating coil.

8 Frost protection thermostat. Danfoss type KP61. If temperature on the backside of the heating coil is lower than the switch is set for, the heating valve is fully opened and the fan is stopped to prevent damage on the coil. It is not possible to start the fan until the temperature on the coil is above the alarm limit and the alarm is acknowledged from the operator panel.

9 Humidity system.

10 & 12 The opening percentage of the expansion valves. Expansion valve 12 is only shown on plant types xx2.

11 & 13 Evaporators for the cooling system. Tap to access the expansion valve menus. Evaporator 13 is only shown on plant types xx2.

Users manual


2.6.1 AHU fan control

Main

AHU 2

Tap

TapAHU1

Tap on thefan

AHU 2Control

Tap

AHU 1

AHU 1Control

1

2

3

4

5

6

7

8 9

10

1

Parameter-key. Tap to access the AHU parameter menus.

2 Supply air temperature set point. Tap to adjust the set point.

3 Compensated supply air set point. The supply air will be regulated according this value.

4 Reheat air temperature set point. Tap to adjust the set point. Only shown when the Reheater option is enabled.

5 Compensated reheat air set point. The supply air will be regulated according to this value. Only shown when the Reheater option is enabled.

Users manual


6 AHU main fan. Text Symbol Description Stopped The fan is stopped. Running The fan is running. Interlock The fan is interlocked. Stopped from remote box The fan is stopped from the remote control box. Ready The fan is ready to be started. Shut-down The fan is stopped due to an error. See alarm list.

7

Fan status. Status text as described in 6 .

8 Fan running hour counter. Accumulated running time in hours.

9 Fan motor starts counter. Accumulated number of starts.

10 Stop/start controls for the fan.

Users manual


2.6.2 AHU parameter menu

Main

AHU 2

Tap

TapAHU1

Tap on thefan

AHU 2Control

Tap

AHU 1

AHU 1Control

Tap onParam

AHU 1Parameter

2.6.2.1 Alarm limits

1

2

3

5

4

1

Alarm limits for the outdoor temperature.

2 Alarm limits for the supply air temperature.

3 Alarm limits for the reheated air temperature. Only shown when the Reheater option is enabled.

4 Hour counter warning limit for service. A warning is given when the fan hour counter value is greater than this value. Enter value for next service to reset the warning. This warning is mend as an internal service interval. It is up to the owner of the plant to decide if a YORK service engineer is needed.

5 Navigation keys for the configuration pages.

Users manual


2.6.2.2 PI parameters

1

2

3

1

Superheat regulation PI parameters. See 3 PI REGULATOR FUNCTION for more information.

2 Supply air regulation PI parameters. See 3 PI REGULATOR FUNCTION for more information.


Users manual


2.6.2.3 Expansion valve

1

2

3

1

Lowest allowed superheat temperature. If superheat temperature drops below this level, the expansion valves are closed immediately to prevent additional liquid to lower the superheat. The compressor will continue to pump gas away from the evaporator and thereby cause the superheat temperature to rise.

2 The initial opening percentage of the expansion valve. While starting the cooling system, it may be necessary to boost the liquid flow to prevent the compressor to immaturely stop due to low suction pressure.

3 This feed-forward function will change the position of the expansion valve, if there is a sudden change of the compressor capacity. The expansion valve position will then be changed before the superheat temperature regulator is able to measure this disturbance in the compressor capacity, and it will result in a more stable superheat regulation. See 2.5.4.6 Feed Forward (FF) for more information.


Users manual


2.6.2.4 General parameters

1

2

3

4

5

6

7

1

Delay for shifting from supply air to superheat regulation. Prevents too rapid changes in regulation mode.

2 Offset for supply air SP for choosing supply air- or superheat-regulation mode. See 2.5.4.2 Supply Air Regulation/Compressor Auto Mode for more information.

3 & 4 In order for the software to determine whether the supply air is to be cooled or heated, two outdoor temperature limits is set. When the outdoor temperature is below Start heating low limit, the heating system is activated and the cooling system is disabled. The opposite happens when the outdoor temperature rises above the Start cooling high limit; the cooling system is enabled and the heating system is disabled. See 2.5.1 Supply air regulation for more information.

5 Adjust field for fan hour counter. The Super-user password is required.

6 Adjust field for fan start counter. The Super-user password is required.


Users manual


2.6.2.5 Heating system

1

2

3

1

Heater regulation PI parameters. See 3 PI REGULATOR FUNCTION for more information.

2 Reheater regulation PI parameters. See 3 PI REGULATOR FUNCTION for more information. Only shown when the Reheater option is enabled.


Users manual


2.6.2.6 Temperature compensation

1

2

3

4

1

Parameters for the summer compensation. 2

Parameters for the winter compensation. 3

Page 2 contains parameters for the compensation of the reheated air. Only shown when the Reheater option is enabled.


Users manual


2.6.2.7 Humidity system

1

2

3

4

1

System status. Text Description Inactive The AHU main fan is stopped or outdoor temperature is between limits. Dose Humidity system is applying moisture to the air. Pause Humidity system is active, but awaiting dose conditions. External External humidity system is activated. Error Humidity sensor or outdoor sensor is failing.

2

Humidity measured in the return air duct. The value is relative humidity percentage (%rH).

3 The humidity system is activated outside the upper and lower start limit. Examples: Outdoor temperature is 20.0C, upper limit is 28.0, lower limit is 14.0 System is not activated. Outdoor temperature is 35.0C, upper limit is 28.0, lower limit is 14.0 System is activated. Outdoor temperature is 10.0C, upper limit is 28.0, lower limit is 14.0 System is activated.


Users manual


2.6.3 AHU exhaust fan / enthalpy exchanger

Main

AHU 2

Tap

TapAHU1

Tap on thereturn air

duct

AHU 1

AHU 1Exhaust

1

23

4

1

Fresh air duct with the out door air temperature.

2 Return air duct and temperature.

3 Exhaust fan. Tap to access the control menu. Symbol Description

The fan is stopped.

The fan is running.




4 Enthalpy exchanger. Symbol Description

The exchanger is stopped.

The exchanger is running. Note: When the exhaust fan is running, the enthalpy exchanger is automatically started every 12 hours for 5 minutes to remove any condensate that may have build up on the exchanger wheel.

Users manual


2.6.3.1 AHU exhaust fan / enthalpy exchanger

Main

AHU 2

Tap

TapAHU1

AHU 1

AHU 1Exhaust

Tap on theexhaust fan

Exhaustcontrol


duct

1

2

3 4

5

6

1

Exhaust fan. Text Symbol Description Stopped The fan is stopped. Running The fan is running. Interlock The fan is interlocked. Stopped from remote box The fan is stopped from the remote control box. Ready The fan is ready for start. Shut-down The fan is stopped due to an error. See alarm list.

2

Exhaust fan status. Status text as described in 1 .

Users manual


3 Fan running hour counter. Accumulated running time in hours.

4 Number of starts. Accumulated number of fan starts.

5 Stop Stop the exhaust fan. Start Start the exhaust fan. Auto Place the fan in automatic mode. The fan will start and stop with the main fan.

6 PARAM-key. Tap to access the compressor parameter menu.

Users manual


2.6.3.2 AHU exhaust fan / enthalpy exchanger

Main

AHU 2

Tap

TapAHU1

AHU 1

AHU 1Exhaust

Tap on theexhaust fan

Exhaustcontrol


duct

ExhaustparameterTap on

PARAM

1

2

3

4

5

1

High start limit for the enthalpy exchanger. The exchanger will be started, if the outdoor temperature is above this limit and the exhaust fan is running.

2 Low start limit for the enthalpy exchanger. The exchanger will be started, if the outdoor temperature is below this limit and the exhaust fan is running.

3 Hour counter warning limit for service. A warning is given when the exhaust fan hour counter value is greater than this value. Enter value for next service to reset the warning. This warning is mend as an internal service interval. It is up to the owner of the plant to decide if a YORK service engineer is needed.

4 Adjust field for compressor hour counter. The Super-user password is required.

5 Adjust field for compressor start counter. The Super-user password is required.

Users manual


2.7 Plant setup

Main

TapSETUP

Plantconfig

2.7.1 System

1

2

3

4

1

Clock. 24 hours. Date is displayed in YY-MM-DD format.

2 Displayed language. This line will always be shown in English for easy recovery.

3 HMI software version: 1000 is the major version number. 1.0 is the revision number. HMI software version: 1000 is the major version number. 1.1 is the revision number. Project number: The internal YORK Marine project number. When contacting YORK, all these values must be supplied.


Users manual


2.7.2 Plant layout

1

2

3

4

5

1

Plant type. Text Description ARP 111 One compressor, one AHU with one expansion valve. ARP 112 One compressor, one AHU with two expansion valves. ARP 121 One compressor, two AHU with one expansion valve. ARP 122 One compressor, two AHU with two expansion valves. ARP 211 Two compressors, one AHU with one expansion valve. ARP 212 Two compressors, one AHU with two expansion valves. ARP 221 Two compressors, two AHU with one expansion valve. ARP 222 Two compressors, two AHU with two expansion valves.

2

Compressor type. Text Description CMO 24 YORK type Sabroe CMO 24. 4 capacity steps (25%, 50%, 75%, 100%). CMO 26 YORK type Sabroe CMO 26. 4 capacity steps (33%, 50%, 67%, 100%). CMP 28 YORK type Sabroe CMO 28. 4 capacity steps (25%, 50%, 75%, 100%). SMC 106 YORK type Sabroe SMC 106. 3 capacity steps (33%, 67%, 100%). SMC 108 YORK type Sabroe SMC 108. 4 capacity steps (25%, 50%, 75%, 100%). Bitzer Bitzer semi-hermetic compressor. 1 capacity step (100%). Bitzer w/cap Bitzer semi-hermetic compressor. 2 capacity steps (50% 100%).

3

Refrigerant type. Not adjustable. Supported types:

R 22. R 404 A. R 407 C. R 507. R 134 A.

Users manual


4 Cross-connection mode. Mode Description Disabled Normal operation.

Each compressor supplies its own AHU. Compressor 1 to all AHUs Compressor 1 is taking over for compressor 2.

Compressor 1 is supplies both AHUs. Compressor 2 is disabled.

Compressor 2 to all AHUs Compressor 2 is taking over for compressor 1. Compressor 2 is supplies both AHUs. Compressor 1 is disabled.

5

Navigation keys for the room configuration pages. Only available on ARP 2xx systems. When cross connection is enabled, the compressor selected as cross connector will take the control of both of the AHUs The cross connection is useful, if one compressor breaks down and operation of the AHU is needed. ATTENTION! To prevent damage, plant must be stopped, and all valves must be manually set to correct position for the decided cross connection mode before selecting the mode.

AHU 1 AHU 2

Compr 1

AHU 1 AHU 2 AHU 1 AHU 2

Mode: Disabled (No cross connection) Mode: Compressor 1 to all AHUs Mode: Compressor 1 to all AHUs

Compr 2 Compr 1 Compr 2 Compr 1 Compr 2

Users manual


2.7.3 Options

1

2

3

4

5

6

7

8

9

1

Humidity system. Enable, if the compressors are equipped with capacity control.

2 Cooling water pressure. Enable, if condenser cooling water monitoring is available.

3 Frost supervision. Enable, if plant is equipped with frost protection thermostat on the heating coil.

4 Reheating system. Enable, if the plant is equipped with a reheating system.

5 Remote start/stop unit. Enable, if the plant is equipped with a remote start/stop box.

6 Exhaust/enthalpy system. Enable, if the plant is equipped with an exhaust fan and enthalpy exchanger.

7 Motor winding protection. Enable, if compressor motors are equipped with a motor winding protection device.

8 Restart after blackout. Enable, to automatically restart the plant after switching on the power supply.

9 Navigation keys for the room configuration pages.

Users manual


2.7.4 Plant settings WARNING! Before loading it is recommended to shut down all AHUs and compressors.

1 2

3 4

5

6

1

Load profile. Tap key to load the user defined plant configuration. WARNING: Changes will take place immediately.

2 Save profile. Tap key to save the user defined plant configuration. May be used as a backup function when adjusting the configuration.

3 Factory defaults. Tap key to load the factory default plant configuration. Normally this contains the settings made at the plant commission. WARNING: Changes will take place immediately.

4 Save factory defaults. Tap key to save the factory default plant configuration. Only available to YORK personnel and/or representatives.

5 Dates for last use of the save functions.


Users manual


2.7.5 Network

1

2

3

1

Local panel network information. Tap to display the IP/TCP panel.

2 PLC configuration. Tap to view PLC statuses and analogue configurations.


Users manual


2.7.5.1 Local panel network information

1

2

1

Local panel IP/TCP network information. Tap to display the IP-address information.


Users manual


2.7.5.2 PLC configuration

1

2

3

2

9

1

PLC CPU information. Error code Normal condition: Value = 0. Contact YORK in all other cases. CPU Normal condition is running. Condition stopped: To the left of the circular plug is placed a Run / Stop switch. The switch must be in Run position. Flipping the switch from Run to Stop and back may solve the problem.

2 Analogue input configuration. Settings for temperature offsets. Tap on a module to access the configuration page.


Users manual


2.7.5.3 Temperature off-set

9

1 2

3

4

1

Temperature offset value. Used to calibrate the temperature sensors.

2 Measured values after offset are added.

3 Filter factor. Number of samplings to calculate a mean value. Used to stabilize the readings.


Users manual


2.7.5.4 Analogue input configuration.

5

1 2 3

4

1

4 mA calibration value.

2 20 mA calibration value.

3 The scaled analogue sensor value.

4 Filter factor. Number of samplings to calculate a mean value. Used to stabilize the readings.


Users manual

PI REGULATOR FUNCTION YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 57 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

3 PI REGULATOR FUNCTION The regulator calculates the difference between the set point and the actual temperature. The output from the regulator is a new calculated position set point for the actuator.

Regulator Algorithm After each Ts a new value (un) for the actuator is calculated according to the following formula: un = (P + I) gain + un-1 P = en - en-1 I = en * Ts/Ti Input from keyboard Ts = sampling time Ti = integral time Gain = gain factor Calculated values e = Regulation error (actual temperature set-point) en = Regulation error this sampling en-1 = Regulation error last sampling un-1 = Actuator position last sampling un = Calculated PI value

+

-

e uPI

Process value feed-back (Temperature, pressure, etc)

SP

Users manual

Alarm list YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 58 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

4 ALARM LIST Alarm text Description AHU1 Enthalpy exchanger feedback Alarm The motor has tripped the over current relay.

The relay must be manually reset inside the switchboard. AHU1 Evaporator 1 suction temp Error Temperature sensor failing or missing signal.

Check sensor and wires. AHU1 Evaporator 2 suction temp Error Temperature sensor failing or missing signal.

Check sensor and wires. AHU1 Exhaust fan feedback Alarm The motor has tripped the over current relay.

The relay must be manually reset inside the switchboard. AHU1 Exhaust fan service Warning Service reminder.

Reset by altering the limit. AHU1 Fan start failure Alarm The motor has tripped the over current relay.

The relay must be manually reset inside the switchboard. AHU1 Heating coil freezing risk Alarm Temperature on heating coil is too cold.

Risk of severe freezing damage to the coil is imminent. AHU1 Humidity sensor Error Humidity sensor failing or missing signal.

Check sensor and wires. AHU1 Outdoor temperature sensor Error Temperature sensor failing or missing signal.

Check sensor and wires. AHU1 Reheat air temperature HT Alarm Reheated air temperature is higher than alarm limit. AHU1 Reheat air temperature LT Alarm Reheated air temperature is lower than alarm limit. AHU1 Reheat temperature sensor Error Temperature sensor failing or missing signal.

Check sensor and wires. AHU1 Service interval Warning Service reminder.

Reset by altering the limit. AHU1 Supply air temperature HT Alarm Supply air temperature is higher than alarm limit. AHU1 Supply air temperature LT Alarm Supply air temperature is lower than alarm limit. AHU1 Supply temperature sensor Error Temperature sensor failing or missing signal.

Check sensor and wires. Compr1 Cooling water LP Alarm No condenser cooling water flow or too low pressure. Compr1 Discharge HP Discharge pressure above alarm limit. Compr1 Discharge pressure sensor Error Pressure sensor failing or missing signal.

Check sensor and wires. Compr1 Lube oil LP Alarm Low lubrication oil pressure.

Low or missing oil level. Compr1 Motor winding protection Alarm Motor winding temperature too high.

Motor must be cool off before restarting. Compr1 Oil Filter Warning Oil filter is blocked. Replace or clean. Compr1 Oil pressure sensor Error Pressure sensor failing or missing signal.

Check sensor and wires. Compr1 Oil/Discharge HT Alarm Compr1 Running feedback Alarm The motor has tripped the over current relay.

The relay must be manually reset inside the switchboard. Compr1 Service interval Warning Service reminder.

Reset by altering the limit. Compr1 Suction pressure sensor Error Pressure sensor failing or missing signal.

Check sensor and wires. Outdoor Temperature HT Alarm Outdoor air temperature is higher than alarm limit. Outdoor Temperature LT Alarm Outdoor air temperature is lower than alarm limit. PLC Battery low - To be replaced The PLC CPU memory backup battery is low on power.

Replace according to the panel manual.

Users manual

Alarm list YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 59 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

Alarm text Description PLC CPU Error The PLC CPU is failing. Contact YORK. PLC CPU is not in run-mode The PLC CPU is stopped.

To the left of the circular plug is placed a Run / Stop switch. The switch must be in Run position. Flipping the switch from Run to Stop and back may solve the problem.

PLC Internal 24VDC failure Internal PLC power supply is defective. Contact YORK. Alarms for Compr2 are identical with alarm for Compr1. Alarms for AHU2 are identical with alarm for AHU1.

Users manual

Document Revision Record YORK Marine, Controls Revision: 1.0 Updated: 050503 Author: Erik Holland Owner: Erik Holland Project 658452: Air-condition Refrigeration Plant 1000 Page 60 of 60 File: h:\standard products\552463-standard ac\manuals\arp system description e410\release\arp 1000 users manual 1.0.doc

Document Revision Record Rev. Date Author Brief description of change Pages affected 1.0 050503 EHL Original issue All

york arp 1000 users manual

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