Professional Documents
Culture Documents
00.89.243 v003.99.09EN
Grasso
Refrigeration Division
All rights reserved. No part of this publication may be copied or published by means of printing,
photocopying, microfilm or otherwise without prior written consent of Grasso.
This restriction also applies to the corresponding drawings and diagrams.
For extra information as to adjustments, maintenance and repair, contact the Technical
Department of your supplier.
This publication has been written with great care. However, Grasso cannot be held responsible,
neither for any errors occurring in this publication nor for their consequences.
MONITRON CR v001.98.07EN
USED SIGNS AND CLOSE READING
Grasso
Refrigeration Division
TEXT FEATURES:
Key name: the highlighted "alarm" indicates the
relevant key to be used in a procedure or meant
in a description.
Capital (display editing) text: ’ALARM ACCEPTED’
indicates a message or text in a edit screen.
Capital (display mode) text: ’AUTO’ indicates the
operational mode or state of the Monitron CR.
TYPOGRAPHIC SIGNS:
Indicates a warning or procedure to which
you should pay special attention.
READ IT CAREFULLY
v001.98.07EN MONITRON CR
USED SIGNS AND CLOSE READING
Grasso
Refrigeration Division
MONITRON CR v001.98.07EN
TABLE OF CONTENTS
Grasso
Refrigeration Division
This manual has been prepared to familiarise the PART 3: VARIOUS INFORMATION AND DATA
Operator & Installer/Contractor with the
Appendix:
Monitron CR control unit.
Chapter A.1 list’s all limits of operation and alarm
The Monitron CR is designed for use on Grasso
conditions in the system.
single-stage and two-stage reciprocating
compressors, and this manual should always be Chapter A.2 contains a record sheet to register all
used in conjunction with the basic Instruction user settings.
Manuals pertaining to the compressor series and
Chapter A.3 contains a review of all value screens
types in question.
including a explanation of all possible displayed
abbreviations
PART 1: DESCRIPTION & OPERATION (Operator
Chapter A.4 contains a parameter description of
and Installer/Contractor)
all edit screens in selection menu’s 1 to 5.
Sections 2 and 3 should be read first in order to
Chapter A.5/6 shows the menu structure of all
get a clear idea about the system’s concept.
selection menu’s and screens within the reach of
Section 2 describes the parts and features of the the Operator and Installer’s/Contractor’s level
Monitron CR system. respectively.
Section 3 explains how the user may operate a Chapter A.7 contains the system wiring diagrams
compressor unit via the Monitron CR. of the Monitron CR.
Section 4 describes the start, stop and restart
procedures when using the Monitron CR.
NOTES:
Section 5 elaborates on the various modes of
Two versions of the Monitron CR software are
capacity control ranging from manual capacity
available, a SI-version and a USA-version.
control to automatic or host capacity control.
SI - version:
Section 6 describes the various alarm messages of
the Monitron CR • All pressure figures in the Monitron CR are
displayed in bar absolute, and are equivalent to
Section 7 describes the capacity control limiting
gauge pressure plus atmospheric pressure.
functions of the Monitron CR
• All temperature figures in the Monitron CR are
Section 8 decribes the miscellaneous functions of
displayed in °C.
the Monitron CR
Temperature differences are expressed in K
Section 9 describes the additional Monitron (Kelvin).
functionality used for the Grasso Ecotron system.
Section 10 contains the procedures for trouble USA - version:
shooting.
For the USA-version all pressure figures are
PART 2: INSTALLATION (Installer/Contractor) displayed in PSI gauge pressure and all
temperature figures are displayed in °F.
Section 11 is the installation Section and contains
procedures for connecting and preparing the
Monitron CR for operation.
Section 12 is the maintenance Section and
describes and lists all exchangeable parts and
components and gives the procedure for resetting
the configuration of the Monitron CR.
IMPORTANT
2.1. Introduction
For monitoring, protecting and controlling the The housing of the steel cabinet and terminal unit
correct operation of the reciprocating have a protection class of enclosure: IP54. The
compressors, Grasso has developed a solid state Monitron CR can be used at ambient temperature
microprocessor-based control device for their ranging from 0 up to +55 °C and at a relative
single-stage and two-stage (compound) humidity of max. 95% (without any condensation).
compressors. The Monitron CR is suitable for mounting directly
on the compressor or compressor unit. The
The complete device, called Monitron CR and
terminal unit may be supplied with a standard
shown in fig. 2.1, consists of two distinct parts, viz.:
mounting support and a two meter long
• a steel cabinet (1), containing the electronic communication cable thus enabling this unit to be
control unit. positioned at the operators convenience.
• a terminal unit (2) made of synthetic fibre,
containing the keyboard and display.
4. Data exchanging by a
communication cable
two-stage standard inj injection solenoid valve for intercooling systems A and B only
additional
optional FPD Fast Pull Down solenoid valve
WARNING
DO NOT UNLOCK A PUSHED DOWN EMERGENCY STOP BUTTON.
THIS MAY ONLE BE DONE BY THE INSTALLER / CONTRACTOR
3.1 Introduction
This Chapter will familiarise the operator with the functions in the Monitron CR system. Via a step by
step procedure all modes of operation and relevant functions are discussed.
next The "next" key is used to skip to the next screen or when in EDIT mode, to select the next digit in
a parameter value.
^/v The (up) "^" and (down) "v" arrow-keys are used in EDIT mode, to respectively increase and
decrease the value of the selected digit or, in alarm mode to look at the previous alarm messages.
accept The "accept" key in EDIT mode is either used to accept the value of a parameter value in a screen
to change the mode of the Monitron CR or to accept the present alarm condition.
The first start-up screen contains information concerning the terminal unit
GRASSO MONITRON CR (keyboard/display combination). The revision number indicates what
TERMINAL REV. XX.XX software release in the terminal is installed. "Selftest....... ok" indicates the
Grasso terminal has passed the test and is now operational.
Selftest......ok
After successfully completing the first part of the selftest, the second
Fig. 3.2 start-up screen is displayed. This screen contains information concerning the
control unit. The revision number indicates what software release in the
GRASSO MONITRON CR control unit is installed. "Initialising" indicates, the control unit is now
TERMINAL REV. XX.XX operational. In the event of an unsuccesful selftest, refer to Chapter 12,
Grasso ’Maintenance’, for further instructions. After successfully completing the
Initialising selftest the Monitron CR is now ready for operation.
The system power-up is now completed and, if the Monitron CR is installed
Fig. 3.3 as per Chapter 11, ’Installing the Monitron CR’, the display mode appears.
Note: The parameters "Pint, Tint, dTm and CapH"
Psuc = ##.# Tsuc = #### Pcrk = ##.# Tsep = ### are intended for two-stage compressors only.
Pdis = ##.# Tdis = #### Imot = ### dTm = ###
Pint = ##.# Tint = #### Mv = ### STANDBY
Poil = ###% Toil = ###% CapL=###% CapH =###%
Fig. 3.3a Fig. 3.3b
3.4 Modes of operation
Three modes are available for operating the monitron CR:
— the display mode; To monitor the operation conditions in the so-called value screens
— the alarm mode; To view and accept malfunctions in the alarm file
— the edit mode; To set limits and parameters to tune the operation of the compressor
For each alarm 16 process parameters are stored at the moment the alarm occures.
Example:
When during operation the discharge pressure exceeds the maximum -ALARM PENDING-
allowed value, an alarm occurs. As a result of this the compressor will stop 12:14:34 30/03/98
and an alarm message is added to the alarm file. High Disch. Press.
This alarm message (fig. 3.4) may look as follows: Pdis 26.0
Fig. 3.4
The occurrence of a new alarm is indicated by the blinking of the alarm Led on the terminal.
As long as the alarm led is on, the compressor can not be started (except for the alarm
messages: slave station down, Monitron startup and Monitron restart).
In order to switch from display mode to alarm mode and vise versa, push the "alarm" key.
When entering the alarm mode, the display shows the most recent alarm
message. By pressing the "back" and the "next" keys, the user may look at -ALARM ACCEPTED-
the other alarm messages in the file. In order to accept an alarm, press the 12:14:34 30/03/98
"accept" key when the alarm message is displayed. Accepted alarms are High Disch. Press.
indicated by the text ’ALARM ACCEPTED’ see fig. 3.5. If all alarms are Pdis 26.0
accepted, the alarm Led will go off when switching back to display mode. If Fig. 3.5
the alarm Led remains on, there is still an unaccepted alarm pending.
Prior to accepting an alarm, first remove the cause of the alarm condition, otherwise the alarm
reoccurs. Refer to chapter 6, ’Alarm messages’, for a survey of all possible alarms.
Two alarm value screens with a total of 16 parameters are stored for each alarm message. The
parameters are stored at the moment the alarm occures. Fig. 3.4 +3.5 show the two alarm value screens.
By pressing the "^" and the "v" key the user can view the alarm value screens.
A description of these screens is given in appendix A3.
Edit screens
If a valid password is entered, the system will display the first selection
menu screen. Otherwise the mode switches back to Display mode. - SELECTION MENU 1 -
Back = Prev. Menu
SELECTION MENU 1 (fig. 3.7) gaines access to the user set-up screens. Next = Next Menu
• Push "next" to go to selection menu 2, Accept = User Setup
ENTERING A NUMBER
When a screen with the value to be changed is displayed, the current value of that parameter is shown.
E.g. SETPOINT = -20 °C
The up "^" cursor is indicating which digit might be changed. Use the "next" key to move the cursor to
the next digit to be changed. Push the "^" or "v" key to respectively increase or decrease the digit value.
Example: change a setpoint from -20 °C to -15 °C:
Setpoint = -20 push "next" twice
^
Setpoint = -20 push "v" once
^
Setpoint = -10 push "next" once
^
Setpoint = -10 push "^" five times
^
Setpoint = -15 push "accept" to validate the value
^
REMARK: In this manual all parameters of this type are indicated as a blank (#) for each digit.
ENTERING A SELECTION
When a screen with the selection to be changed is displayed, the current selection is shown. A selection
is always a descriptive word. Use the "^" or "v" key to toggle between all possible options to determine
the selection.
Example: change the parameter autostart from OFF to ON,
Autostart = OFF push "^" once
Autostart = ON push "accept" to validate the selection
In this manual, each character of an option above the cursor position is displayed as an asterisc (***)
* e.g. Start/Stop = *** (options are ON and OFF).
A review of all editable selection menu’s is given in Appendix A.4.
a sequence number, or based on the number of 5.5 AUTO and HOST-mode control parameters
running hours. (refer fig 5.1)
• Each Monitron must have a unique Network • SETPOINT (User Setup)
address. One Network Manager must be defined. Desired value in °C. The measured value is
Network address 01 means Network Manager. compared to this parameter.
value (MV) and setpoint where no action is the lowest number of running hours is started
taken first.
• Fast zone (Auto Menu) • Master (Host Setup)
When the difference between MV and Setpoint For capacity control of multiple compressors
is larger than ’Fast Zone" the minimum interval within a refrigeration circuit a master Monitron
between capacity steps is used. has to be defined. Capacity control is based on
the difference between Setpoint and measured
• D-factor (Auto Setup)
value (MV) of the Master Monitron.Also the
This value determines how fast the difference
parameters in the Auto setup of the Master
between measured value and setpoint should
Monitron are used. The above mentioned
decrease to prevent stepping up/down. The
parameters entered in "Non Master" Monitrons
higher this value, the more influence the
are not used for the capacity control.
change in pressure will have to the control. If
D-factor is set to 0 the change in pressure will • Low address (Host Setup)
have no influence at all. This parameter is used for defining a
refrigeration circuit. Enter the value of the
• PUMPDOWN DIF (Auto Setup)
lowest Network address in the circuit. For
The last compressor will be switched off only
defining a swing compressor refer to chapter
when the pressure is lower than SETPOINT
5.6.
minus PUMPDOWN DIF.
• High address (Host Setup)
• CONTROL SENSOR (Configuration Setup)
This parameters is used for defining a
This parameter is used to select either the
refrigeration circuit. Enter the value of the
suction pressure or the external pressure to be
highest Network address of the circuit. For
used as control value. This parameter must be
defining a swing compressor refer to chapter 5.6
set right by the contractor. If this parameter is
not set right the automatic control will not • Screw min step (Host Setup)
work correct. This parameter only needs to be entered in a
Master Monitron when also a Grasso Screw
For Host mode only:
compressor is used in the refrigeration system.
• Network address (Config Setup) Refer to the Manual of Grasso Screw
This is a number that identifies each Monitron compressor.
in the network. Each Monitron connected to a
• Screw max step (Host Setup)
network should have a unique network
This parameter only needs to be entered in a
address. The address 01 is reserved for the
Master Monitron when also a Grasso Screw
network manager. The Network Manager is
compressor is used in the refrigeration system.
taking care of the network communication.
Refer to the Manual of Grasso Screw
• Nbr of Monitrons (Config Setup) compressor.
This is the number of Monitrons that is
• Maxpart (Host Setup)
connected to the network. This number only
This parameter defines the maximum partload
has to be entered into the settings of the
condition and is only required when also a
Network master (Network address = 01).
Grasso Screw compressor is used in the
• Circuit (HOST SETUP) refrigeration system. Refer to chapter 5.9.
It is possible to use different refrigerant circuits,
each with there own capacity control. This
5.6 Example of setting Host Mode Parameters:
parameter can be used to define for instance a
high stage and low stage compressor system. This example is based on a refrigeration plant
The maximum number of circuits is 11. with 2 high stage and 3 low stage compressors
within one network of Monitrons. Parameters
• Sequence number (Host Setup)
have to be entered in the following way (refer
Within a refrigeration circuit the compressor
also to the table 5.2):
with the lowest sequence number is started
first. When different compressors have the • The network addresses have to be entered in
same sequence number, the compressor with such a way that Monitrons within one
refrigeration circuit are numbered upwards. booster compressors. This to assure that
booster compressors can only operate
• Low stage system defined as CIRCUIT 1 and
when the high stage compressors are
high stage as Circuit 2.
running.
• Each circuit needs to have one master Monitron
Parameters involved:
for controlling the capacity within the circuit
• Booster (Config setup)
• Sequence numbers have to entered. The
This parameter determines if a compressor is
compressors with the lowest sequence number
selected as booster compressor. The value can
is started first. Or (By using same seqnr) to
be Yes or No.
compressor with the lowest number of running
hours is started first. • P booster (Config setup)
This parameter determines the value of the
• Define the lowest and highest address within
discharge pressure required to allow the
one refrigeration circuit. (for swing compressors
compressor to start.
refer to 5.8.
5.8 Swing compressor
• The low stage compressors can be defined as
booster compressors (refer to 5.5) A swing compressor is a compressor that can be
switched from one refrigeration circuit to
Table 5.2 another. For this it is necessary to change the
position of the stop valves in the refrigeration
Low Low Low High High
stage stage stage stage stage
system. Also some Monitron parameters have to
compressor compressor compressor compressor compressor be changed.
Parameters involved:
Network 1 2 3 4 5
address • Circuit (Host setup)
Network Yes It is possible to use different refrigerant circuits,
manager each with there own capacity control. This
Circuit 1 1 1 2 2 parameter can be used to define for instance a
Master Yes No No Yes No high stage and low stage compressor system.
Sequence 2 1 1 1 1 The maximum number of circuits is 11.
number
Switching of a compressor to an other
Low 1 4 refrigeration circuit can be done by using this
address
parameter.
High 3 5
adsress • Low / High address (host setup)
Booster Yes Yes Yes This parameters is used for defining a
refrigeration circuit. Enter the value of the
highest Network address in the circuit. When
5.7 booster compressor defining a swing compressor it is allowed to
have overlap in defining the addresses.
A refrigeration system with high stage and low
Therefore a compressor that can be used in two
stage (booster) compressors is started up with
refrigeration circuits can have the parameters
only the high stage compressors in operation.
High and Low address defined in such a way as
The booster compressors may only be started
if this compressor was operating in the two
when the expected intermediate pressure remains
below the maximum limit.
Therefore the booster compressors can only be Table 5.3
started when the measured discharge pressure is LP LP LP HP HP
low enough. Network address 1 2 3 4 5
Important: Circuit 1 1 1 1-2 2
Master Yes Yes
Use digital output "Running" of the high
Low address 1 3
stage compressors and connect these
High address 4 5
with digital input "Ext. Start" of the
circuits at the same time. Therefore parameters compressor is started. When the screw
high and low address only need to be set ones, compressor stabilises in a part load position a
and do not need to be changed when calculation is made to determine if it is possible to
switching to an other circuit. reduce the capacity of the reciprocating
compressor by one step. This process can be
Example
repeated until the reciprocating compressor is
The example of chapter 5.6 is used, but now the
switched off completely.
Monitron with Network address 4 is used as a
swing compressor.
Important: Parameter involved:
As mentioned above it is allowed to have Maxpart
overlap when defining low and high The Monitron calculates the expected capacity of
address. This overlap requires "Monitron the screw compressor after a step down of the
calculation time". Therefore it is reciprocating compressor. When this calculated
important to use the overlap only for capacity is less then parameter "Maxpart" during 5
swing compressors, to avoid overloading times the reciprocating compressor step time, the
the Monitron system. reciprocating compressor is stepped down.
5.9 Combination of reciprocating and screw 3. Screw running in operation alone on low
compressors capacity
When a screw compressor is the only compressor
It is possible to connect the Monitrons of Grasso
that is in operation and the capacity of the screw
Reciprocating and Grasso Screw compressors
stabilises at a capacity lower than PGM (refer to
within one Network. Hereby it is possible to
screw compressor manual) a calculation is made
control the capacity of a refrigeration system with
to determine if the reciprocating compressor that
both reciprocating and screw compressors. For
is sequenced to start up after the screw
the capacity control of combinations of
compressor can take over the cooling capacity. If
reciprocating and screw compressors, there are
this is the case the screw compressor will be
three different control algorithms.
stopped and the reciprocating compressor will
1. Screw compressor starts first take over.
2. Reciprocating compressor starts first Parameter involved:
3. Screw in part load operation; is it possible for Maxpart:
the reciprocating compressor to take over? The Monitron calculates the expected capacity of
the reciprocating compressor after stopping the
screw compressor. When this calculated capacity
1. Screw compressor starts first is less then parameter "Maxpart" during 5 times
With increasing demand the screw compressor is the reciprocating compressor step time, the
started and stepped up to 1 00% capacity. After reciprocating compressor is started and the screw
this the reciprocating compressor is started. compressor is stopped.
When the capacity demand drops the
reciprocating compressor will be stepped down to
minimum partload. Before the reciprocating
compressor is stopped, the screw compressor will
be stepped down. When the screw compressor is
decreased with approximately the same capacity
as reciprocating compressor minimum part load,
the reciprocating compressor will be stopped.
6.1 Alarm messages this limit, the alarm message Low Motor Amp.
is stored in the alarm history file and the state
• Pre-conditions: state of operation FAILURE.
of operation is FAILURE.
For description of state of operation refer to
Detection: RUNNING, CURR.LIM and STARTING.
§4.4.
Note: If Imot limit is set to 00, motor current
protection alarm is inhibited.
6.1.1 Digital input alarms
• Thermistor protection alarm
1. Motor protection alarm The electric motor and cylinders may be
This condition is active when the motor equipped with a thermistor. This PTC device
protection input is interrupted. Normally this is protects against high temperature. If the
done by the motor starter and protection temperature arises above a certain level, alarm
circuit installed by the contractor. Alarm message TERM HIGH TEMPERATURE is stored in
message MOTOR PROTECTION is stored in the the alarm history file and the state of operation
alarm history file and the state of operation is is FAILURE.
FAILURE. Detection: in all states of operation.
Detected: in all states of operation.
• Low suction pressure
2. External safeties alarm The measured suction pressure Psuc is
The compressor will stop immediately after the compared with a min. limit, entered by the
external safeties input are interrupted. contractor. If Psuc is less than this limit, alarm
Normally this input is equip-ped with the message "LOW SUCTION" is stored in the alarm
emergency button. Other safety devices may history file and the state of operation is
be added in series for extra protection of the FAILURE.
compressor unit. When this signal becomes Detection: EXT.START, STARTING, RUNNING
active alarm message EXT. SAFETY ACTIVE is and CURR.LIM.
stored in the alarm history file and the state of
• High discharge pressure
operation is FAILURE.
The measured discharge pressure Pdis is
Detection: in all states of operation.
compared with a max. limit, entered by the
3. Motor running signal alarm contractor. If Pdis is beyond this limit, alarm
If the motor running indication disappears message "HIGH DISCH. PRES." is stored in the
while the Monitron expects the motor to run, alarm history file and the state of operation is
the alarm message NO MOTOR RUNNING FAILURE.
(STARDEL OFF) is stored in the alarm history Detection: EXT.START, STARTING, RUNNING
file and the state of operation is FAILURE. and CURR.LIM.
Activating the additional high pressure safety
• High discharge temperature
switch will also generate this alarm.
The measured discharge temperature Tdis is
Detection: RUNNING, CURR.LIM and STARTING.
compared with a maximum limit, entered by
6.1.2 Exceeding limits alarms the contractor. If Tdis is beyond this limit, alarm
message "HIGH DISCH. TEMP." is stored in the
• Maximum motor current alarm
alarm history file and the state of operation is
The measured motor current Imot is compared
FAILURE.
with a max. limit. If Imot is beyond this limit,
Detection: EXT.START, STARTING, RUNNING
alarm message "HIGH MOTOR AMP." is stored
and CURR.LIM.
in the alarm history file and the state of
operation is FAILURE. • High oil temperature
Detection: RUNNING, CURR.LIM and STARTING. The measured oil temperature Toil is compared
Note: This condition should not be confused with a max. limit, entered by the contractor. If
with the current limitation option in the Toil is beyond this limit, alarm message "HIGH
capacity control, where capacity is reduced until OIL TEMP." is stored in the alarm history file
Imot does not exeed the parameter Ilim. and the state of operation is FAILURE.
Detection: EXT.START, STARTING, RUNNING
• Minimum motor current alarm
and CURR.LIM.
The measured motor current Imot is compared
against a minimum limit. If Imot is lower than
8.1 Oil return protection 8.2 Interstage cooling system TEV-A and TEV-B
8.1.1 Oil return protection for a single compressor Two stage compressors with more than two high
stage cylinders have to be equipped with two
Refer to figure 2.2 items 12, 16 and 19. The oil
thermostatic expansion valves. One large valve
return solenoid will open when the oil level float
selected to deliver the full inter cooling capacity
switch is activated (open contact) and the
and one valve to deliver 50% of the full load
temperature sensor in the oil separator indicates a
capacity.
temperature that is more than 10 K higher than
the condensing temperature.
/ The wiring of the solenoid valves to be
mounted in front of the expansion valves and
8.1.2 Oil return protection for multiple installation of the required relays has to be
compressors with one common oil executed by the contractor.
separator
Table 8.1 can be used for compressor types RC11,
When multiple compressors are equipped with RC12, RC12E with standard capacity control and
one common oil separator each compressor has Fast Pull Down capacity control.
its own oil level float switch but only one sensor
for measuring the temperature inside the oil Table 8.1 Control of solenoid valves
separator is used. The value of parameter "central Large
Cylinders
TSEP" in Selection Menu 5 "CONFIG" has to be set Low/high
Valve: Inj Cap 1 Cap 2 Cap 3 valve
off
to "Yes"
Small X X
The separator temperature sensor has to be 6/3
Large X
connected to the master Monitron (refer to §5.4).
Via the communication port the value of the oil 8/4
Small X X
temperature is transmitted from the master to Large X
the slave Monitron(s). Small X X
Note: No read-out of oil separator temperature 9/3
Large X X
on slave Monitron(s).
inj = output inter cooling solenoid
cap = output solenoid for capacity control
For execution nr. 2 connect to input X203-14 and • Check all cabling to ensure all connections have
X204-25 been made.
Refer to appendix A7 figures CR-E04 and CR-E05
• Apply power to the Monitron CR.
• Check proper start-up sequence as per §3.3.
11.2.5 The Communication Ports
Contact Grasso when a warning screen appears.
The Monitron CR has two communication ports.
• When in display mode check sensor readings by
Port X201 is used for the terminal unit. Wiring
looking at the five value screens (refer to
connections are already made by Grasso.
appendix A3). Check also the compressor type
Refer to appendix A7, figure E07 for the wiring
and refrigerant.
diagram.
• Enter EDIT mode as described in §3.4.3; Be sure
WARNING
to enter the password for level 2 (default
Ensure the terminal is connected to X201. 3000). Check settings of the Monitron CR. Refer
Connecting the terminal to X202 will to appendix A1 for the default limits of
damage the Monitron CR. operation and to appendix A4 for a review of
all edit screens.
Refer to figure CR-E04 of the appendix A7 which The display-Eprom sticker text will show:
shows the exact cable entry location for these
PT1000 elements.
At replacing, reconnect the PT1000 sensing MONITRON CR
element on the same place on to the connector DISPLAY XX.XX ¶ Version number
⇐ Part number
X204. XX XX XXX
MONITRON CR
CONTROL XX.XX ¶ Version number
⇐ Part number
1. Shield XX XX XXX
2. Earthing strip
3. Temperature sensor IMPORTANT
Verify the part number of the new Eprom which
should be the same as from the old Eprom. Also
Fig. 12.5 Temperature transducer check the version number which should be the
same or higher as the old Eprom version number.
12.3.3 Connecting analog input sensors Replace an Eprom with other part number only
with permission of Grasso.
REMARK:
WARNING
All shields of the analog input sensors,
temperature (connector X204), pressure WRONG insertion will damage the Eprom.
(connector X203) and communication wires Never re-use a wrong inserted Eprom if power
(connectors X202 & X201) have to be earth supply has been applied.
connected. Prior to replacing an EPROM, the control unit has
It is recommended to seal the cable entry to avoid to be de-energized (disconnect power supply
entering of moisture. Close the control unit finally. connector X101). Using a pocket screwdriver
carefully remove the EPROM.
done again (refer to §12.5, "Reconfigurating a 7) Set actual time using the "next", up (^) and
Monitron CR"). down (v) keys.
Also the key-board contains an EPROM (type 8) Push "accept".
27C512). Fig. 12.7 shows the location of this
EPROM. 9) Set actual date using the "next", up (^) and
down (v) keys.
To replace this EPROM, use the same procedure
as given for the EPROM of the control unit. 10) Push "accept".
11) Select applied compressor type by scrolling
with the up (^) and down (v) keys.
12) Push "accept".
13) Select applied refrgerant by scrolling with up
(^) and down (v) keys.
14) Push "accept".
15) For two-stage compressors only: Select the
applied interstage cooling system with the up
and down arrow keys.
Fig. 12.7 Eprom of key-board
16) Push "accept"
12.5 Re-configurating A Monitron CR 17) Using the "next", up (^) and down (v) keys,
set the correct motor amperage at which the
Whenever a new EPROM in the control unit is output of the motor current transducer gives
installed, it is necessary to re-configurate the 20 mA.
Monitron CR before start up.
The re-configuration procedure is described below. 18) Push "accept".
RE-CONFIGURATION PROCEDURE 19) Fill in the running hours using the "next", up
(^) and down (v) keys.
To re-configurate the Monitron CR with the
relevant installation data carry out the complete 20) Push "accept".
step by step procedure: 21) Push "accept" again to store the configuration.
1) Remove the front cover of the control unit 22) Push "back" or "next" to select and store the
and disconnect the power supply connector applied single-stage or two-stage compressor.
X101 to de-energize the Monitron CR. The system will display the first value screen
2) Push the red "stop" key. now.
3) Hold this key down while re-connect the 23) If the alarm led is blinking, then push the
power supply connector X101/X108. "alarm" key to accept the alarm.
4) The Monitron CR will show INSTALLATION 24) Push "accept" (alarm led off).
MENU. 25) Push "alarm".
- INSTALLATION MENU - At this stage the Monitron CR is configurated and
Warning: Wrong data will show a single-stage or two-stage value screen
may damage the unit whichever compressor type has been selected.
PRESS ACCEPT KEY Proceed to the instructions given in appendix A4,
"Review of edit screens", to tune the Monitron CR
5) After the Installation Menu Screen will with the desired settings using (default) password
appear, release the red "stop" key. 3000 (level 2).
6) Push "accept".
12.6 Unsuccesful selftest of monitron CR d) Check the connection to X201. Measure the
voltage between pin 4 and pin 1; this must be
Normally when power is applied, the Monitron CR
5 Volt DC. When the voltage is low, remove
will show a sequence of two initialising screens.
the connector and measure the voltage on
The first screen is displayed by the terminal unit
connector X201 again. When the voltage is 5
itself and indicates that this unit has passed its
Volt, the terminal unit is broken and must be
internal selftest.
replaced.
The next screen is displayed when the control unit
e) When no voltage is present on connector X201,
initialises the terminal unit. This indicates that the
the control unit is broken and must be
communication between control unit and
replaced.
terminal unit is functioning.
2) The display only shows the first screen. Check
Possible malfunctions:
the connection X201 pin 2 and pin 3. When
1) The display does not show any text these are OK, the communication between
control unit and terminal unit is broken. This
a) Check if power is supplied to the Monitron CR.
may be caused by a broken display or a broken
Measure the power on X101 pin 2 and pin 3.
control unit. First try a new display unit on the
This must be 115V AC or 230V AC depending
mounted control unit, otherwise replace the
on the jumpers connected. When no power is
control unit.
available, check the mains.
3) The display is showing the first and second
b) When mains is available, check the fuses F1 and
screen repeatedly:
F2. When the fuses are blown, replace the
The communication between terminal unit and
fuses. When the fuses are blown again, replace
control unit is bad. Check the connections at
the control unit.
connector X201. If the connections seems to
c) When the fuses F1 and F2 are correct, check be good, remove the wires, cut the wires one
fuses F3 and F4. These fuses can be checked by centimeter and re-connect the wires to the
measuring the voltage over the two big, blue connector. If the communication still fails, act
condensators near the transformer. Across as in point 2).
each condensator a voltage of 10 Volt must
be measured. When a fuse fails, replace it.
12.7 Spare parts list
DESCRIPTION LOCATION REFERENCE NUMBER
EPROM 27C010 or 27C020 Control unit 12.97.822 (incl. software)
EPROM 27C512 Key-board display unit 12.97.830 (incl. software)
Backup battery Control unit 13.87.332
Display Stand alone or comp. 12.98.123
Pressure transducer -1/9 bar (e) Compressor 12.63.609
Pressure transducer -1/24 bar (e) Compressor 12.63.624
Sensing element PT1000 Compressor 12.56.288
Motor current transducer Main starter 13.79.711
Emergency stop button Control unit 02.49.540 + 13.27.226
Control unit Compressor 12.97.123
Dummy resistor Control unit 13.75.133
Fuse (F1, F2) 0.315x5 250 V Control unit 13.70.031
Fuse (F3, F4) 1.25x8.5 250 V Control unit 13.70.112
Fuse (F5) 0.315AF 24 V Control unit 13.70.036
Transducer PT1000/4-20mA Installation 13.79.810
Connectors Control unit 13.60.901
Expansion board Ecotron Control unit 12.97.040
One of the most important tasks of the Monitron CR is to protect the compressor against conditions
outside the normal field of application. In order to do so, the Monitron CR is equipped with a number
of sensors to check on the correct operation of the compressor package.
In the table below the limits of operation of all Grasso reciprocating compressors are listed, exceeding
these limits will result in a compressor shut-down and an alarm message will be added to the alarm file.
Refer to chapter 6, Alarm messages, for a survey of all possible alarms.
Compressor series
Limit
RC6 RC9 RC11 RC12(E) (S)AC80R Comment
Min.Psuc 0.3 bar 4.35 psia 0.3 bar 4.35 psia 0.3 bar 4.35 psia 0.3 bar 4.35 psia 4.2 bar 61 psia Min. suction pressure
Max.Psuc:/
Max Pint 1)
2 2
NH3 6.2 bar 90 psia 6.2 bar 90 psia 6.2 bar 90 psia 7.0 bar 102 psia ) ) Max. suction pressure 3)/
R22 6.8 bar 99 psia 6.8 bar 99 psia 6.8 bar 99 psia 7.0 bar 102 psia 6.8 bar 99 psia Max. intermediate
R134a 6.2 bar 90 psia 6.2 bar 90 psia 6.2 bar 90 psia 6.2 bar 90 psia 6.2 bar 90 psia pressure
R404A 6.0 bar 87 psia 6.0 bar 87 psia 6.0 bar 87 psia 6.0 bar 87 psia 6.0 bar 87 psia
R507 5.8 bar 84 psia 5.8 bar 84 psia 5.8 bar 84 psia 5.8 bar 84 psia 5.8 bar 84 psia
Max.Pdis 26 bar 377 psia 22 bar 305 psia 22 bar 305 psia 24 bar 348 psia 24 bar 348 psia Max. discharge pressure
Min.dOil 1.5 bar 22 psia 1.0 bar 15 psia 1.3 bar 19 psia 1.3 bar 19 psia 1.5 bar 22 psia Min. oil differential
pressure
1) Two-stage only,
2) not applicable,
3) an alarm is inhibited during five minutes after compressor start.
IMPORTANT
Compressor operation is also limited by high
oil temperature.
The maximum allowable oil temperature depends
on the oil type and operating conditions.
Consult Grasso for more information.
v002.98.10EN MONITRON CR 1
A. 2 RE CO RD SH EE T FOR U SER SE TT IN GS
Grasso
Refrigeration Division
WARRANTY
2 MONITRON CR v002.98.10EN
A.2 RECORD SHEET FOR USER SETTINGS
Grasso
Refrigeration Division
WARRANTY
v002.98.10EN MONITRON CR 3
A.3 REVIEW OF VALUE SCREENS
Grasso
Refrigeration Division
This page lists all five value screens with ’live’ values of all relevant variables in the system.
The displayed values in the screens below, represents actual information for single-stage compressors
(left row) and for two stage compressor types (right row).
The value screens require no special authorisation level.
4 MONITRON CR v002.98.10EN
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
v002.98.10EN MONITRON CR 5
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
6 MONITRON CR v002.98.10EN
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
v002.98.10EN MONITRON CR 7
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
8 MONITRON CR v002.98.10EN
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
v002.98.10EN MONITRON CR 9
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
10 MONITRON CR v002.98.10EN
A.4 REVIEW OF EDIT SCREENS
Grasso
Refrigeration Division
increase when discharge value of the discharge pressure down capacity steps only (refer
pressure in bar is higher than required to allow the to chapter 7)
this limit. Refer to chapter 7 for compressor to start.
more information. Tdis correction screen (for two
Remote setpoint screen stage compressors only)
Tdis safety screen (single stage - REMOTE SETPOINT- - TDIS SAFETY -
only
- TDIS SAFETY - Remote setpoint = *** Ccorrection = ##.# oC
^ ^
Safety = ***
Remote setpoint: Tdis correction:
^
This parameter determines if Correction of Tdis calculation.
Tdis safety in °C: the setpoint can be entered Refer to chapter 7 for more
This parameter determines if manually via the keyboard/ information.
discharge temperature display or externally via a
4-20mA input. Reset password screen
limitation control is active. The
value yes or no. Refer to - CONFIGURATION -
4mA equals screen
chapter 7 for more information.
- REMOTE SETPOINT - RESET PASSWORD *
Tdis margin screen (single 4 mA equals = ##.# oC
stage only) ^ RESET PASSWORD:
- TDIS SAFETY - In case of an unkown level 1 -
4mA equals: password, the authorizator of
Margin = ##.# K When the setpoint is entered level 2 can reset this level 1 to
^ externally, this parameter the default password (2000).
determines the minimum value The authorizator of level 3 can
Tdis margin in K of setpoint than can be used. reset both lower levels to their
Margin for discharge gas default passwords.
temperature limitation. Refer to 20mA equals screen
chapter 7 for more information. - REMOTE SETPOINT -
Booster mode screen 20 mA equals = ##.# oC
- BOOSTER MODE- ^
v002.98.10EN MONITRON CR 11
A.5 FLOW CHART OF OPERATOR’S LEVEL
Grasso
Refrigeration Division
This chart gives the operator a quick review of all accessible menu screens, interaction screens and key
operations. The operator gaines access to:
— Non password protected screens or modes (value screens and alarm screens)
— Password protected screens or modes (Editing screens)
The (default) password of the operator gaines access to:
• Selection menu 1 in which the operator may change the User setup settings
• Selection menu 2 in which the operator may alterate his current password.
12 MONITRON CR v002.98.10EN
A.6 FLOW CHART OF INSTALLER’S LEVEL
Grasso
Refrigeration Division
v002.98.10EN MONITRON CR 13
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
CONTENTS
CR-E01 EARTH CONNECTIONS
CR-E02 CONNECTOR POSITIONS
CR-E03 CONNECTIONS X102 - X103 - X104 - X105 - X301
CR-E04 ANALOG INPUTS X204
CR-E05 ANALOG INPUTS X203
CR-E06 COMMUNCATION WITH OTHER MONITRONS
CR-E07 DISPLAY CONNECTIONS
14 MONITRON CR v002.98.10EN
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
v002.98.10EN MONITRON CR 15
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
16 MONITRON CR v002.98.10EN
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
v002.98.10EN MONITRON CR 17
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
18 MONITRON CR v002.98.10EN
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
v002.98.10EN MONITRON CR 19
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
20 MONITRON CR v002.98.10EN
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
v002.98.10EN MONITRON CR 21
A7. SYSTEM WIRING DIAGRAMS
Grasso AND CABLE ENTRIES
Refrigeration Division
22 MONITRON CR v002.98.10EN
Grasso
Refrigeration Division
v001.98.07EN MONITRON CR
Please contact your office:
Grasso Products B.V. P.O. Box 343 • 5201 AH ’s-Hertogenbosch • The Netherlands
Phone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286 • E-Mail: products@grasso.nl