ELREHA Compound Control Central Software User Guide

ELREHA Compound Control Central Software

Specifications

• Brand: ELEKTRONISCHE REGELUNGEN GMBH
• Model : VPR 5340
• Software Version: S 03.05.00

Product Description / Application

The  PR 5340 control system is the new generation of the Compound control system, equipped with modern functions. It is essential to familiarize yourself with the system before operating it due to the extensive settings available.

• Compound control system for cooling plants Capability for control of 3 Compounds or up to 3 Brine Chiller systems
• Control of Compressors / VCondensers / Gascooler and up to 128 networked Cold Storage Controllers
• Heatpump control is also covered
• TFT-Display for display/operation of all plant data
• Cold Storage Controllers are included in optimization functions
• Integrated error messaging system
• Integrated 12-channel annual time switch
• Communication by Ethernet, E-Mail, USB

Dear customer!
By purchasing a VPR 5340 control system, you have the new generation of our Compound control system in your hands, which is equipped with modern functions. We think it is mandatory to make yourself familiar with the system prior to take it into operation, as the amount of possible settings may be too much to be overseen at first sight.

The present document is a short overview that just covers the general operation and the required technical data. More detailed info about the parameters and control functions are provided in a separate documentation.
If you have any questions, please do not hesitate to contact us.

In this documentation you will find:

• General instructions for use of the device.
• The structure of the user interface and the screens and menus.
• Connection diagram and safety instructions.

This document does not contain

• Tables of all parameters and value ranges.
• Functional descriptions of the controlling algorithms.

This additional info is covered by separate documentation.

WARNING: Please observe safety instructions !
Please note that the descriptions herein are only valid for units that are running the above-mentioned software version. The software version is noted on the screen Configuration‘.

How to configure and order a VPR 5340 central unit
When you are planning an application, you will know about the needed resources regarding Compressors, Condensation fans or Pumps, or which message input signals need to be served. The input and output signals are assigned dynamically, depending on the configuration of your application. Therefore you will not see at first glance, which I/O modules will be needed and how to do the connections. This information is served by the free Configuration tool VPR53Plan. How to proceed:

1. Get the VPR-Configuration tool VPR53Plan started on your PC. This Program is running on MS-Windows. You may request it from us or directly download it from our homepage at “www.elreha.de” ==> Download ==> Software.
2. Enter all the basic data of your application into the software: Amounts of Compressors / Condenser fans, Error message processing, Pressure transmitters, Temperature probes etc.
3. As an output, you will get:
   • An overview of all the needed resources of the VPR-System
   • A terminal listing, which can be used to set up the plant plans
   • A list of needed items, which serves as the basis for your purchase order.
   • A parameter listing of the most important data for starting up your application.

Accessories (not included with the central unit)

• Expansion modules BMO 3011 / BMO 3031 BMR 3001 BMA 3251/ BMA 3206

Terminal assignment

Technical data

• Operation voltage …………………………………………………………85-264V AC, 50/60 Hz
• Power consumption ……………………………………………………………………..max. 50 VA
• Operating temperature ………………………………………………………………….-10…+50°C
• Storage temperature …………………………………………………………………….-30…+60°C
• Ambient humidity ………………………………………………max. 80% r.H. non-condensng
• Overvoltage category ……………………………………………………………………………….III, max. 2000 m
• Switching power of the relays ………………………………………..8 A cos phi = 1 / 250VAC
• Electrical Connectors ………………………………………………..Screw terminals, 2,5mm²
• Housing …………………………………………….. Metall/Plastic for Cabinet door mounting
• Protection class ………………………………………………………………………IP 54 from front

Interfaces

• Data bus PC / Gateway etc …………………………..(RS-485) Screw terminals, 2,5mm²
• Date bus LINE 1 for Subcontrollers ……………….(RS-485) Screw terminals, 2,5mm²
• Date bus LINE 2 for Subcontrollers ……………….(RS-485) Screw terminals, 2,5mm²
• Date bus ICOM für I/O-Busmodules ………………(RS-485) Screw terminals, 2,5mm²
• USB Connector ………………………………………………………….(USB 2.0) A-type socket
• USB Connector ………………………………………………….(USB 2.0) Micro B type socket
• Network Connector ………………………………………………….(Ethernet 100 MBit) RJ-45
• Memory card slot ……………………………….Standard SD/MMC card slot (Push/Push)

Connection and safety instructions

This manual needs to be accessible to the user at any time. We are not liable in case of damages, caused by improper usage or handling or by not paying attention to the manual and the safety instructions! Any warranty will be void in such cases.

The proper and safe operation of the unit depends on proper transportation, storage, installation, and mounting, as well as meticulous operation.
When it is assumed that a safe operation of the unit is no longer possible, i.e. :

• when the device shows visible damage,

• if the device no longer works despite an intact power supply,

• after prolonged storage under unfavorable conditions,

• in case of heavy dirt or moisture,

• after heavy transport loads,

• after falling from a great height, even without visible external damage, the device muAst be taken out of operation immediately and secured against unintentional commissioning. There is a danger to life!

• The installation and commissioning of the device may only be carried out by a qualified electrician or under the supervision of a qualified electrician.

• Keep the device safely unplugged during installation!
  Risk of electric shock!

• Never operate the device without a case. Risk of electric shock!

• For reasons of touch safety, the device may only be operated in a closed control cabinet or control box.

• At least one of the Ground terminals 3 and 4 must be connected to earth potential!Risk of electric shock!
  The internal filtering of electromagnetic interference will not work properly without a ground connection, which can result in faulty displays.

CAUTION”
The device may only be used for the purpose described on page 1.
Please observe the safety regulations and standards prescribed at the place of use.

For safety reasons, inserting and removing USB sticks, SD cards, LAN cables, etc. should only be carried out when the device is in a power-off state.

DANGER: Before using the controller, please check its technical limits (see Technical Data), e.g.:

• Power supply (printed on the nameplate)

• Prescribed environmental conditions (temperature or humidity limits)

• Maximum load on the relay contacts in connection with the maximum starting currents of the consumers (e.g. motors, heaters).
  Failure to do so may result in malfunctions or damage.

• Avoid installation near large contactors (strong interference possible).

• When installing data cables, please note the requirements, e.g. cable types, shielding, cable length, etc.

Maintenance

• Testing: The device is subjected to various tests before delivery. If a device is opened, all tests must be repeated.
• Attention! No warranty can be given for devices that have been opened by the customer.
• Repair and adjustment: Repair and adjustment work can only be carried out at the manufacturer’s factory.
• Frontfoil / Cleaning: The front foil can be cleaned with a soft cloth and standard household cleaning agents. Acids and acidic agents must not be used for cleaning

Operation

The entire operation is carried out via the large TFT display with the touch- sensitive ‘touch screen’
The contents are color-coded:

Coloured display

• White font stands for descriptive texts and actual values that cannot be changed.
• The blue font is used for adjustable values, and buttons for navigation are also blue.
• Fields colored Red indicate error messages.
• Yellow Text marks headings of screen pages or function blocks.
• Active fields: To change screen pages, touch the respective fields with corresponding texts. Fields with white font and light blue background will take you to the respective screen.
• Arrow sysmols for scrolling: On the right side of the screen, fields with directional arrows are displayed if necessary. These are only visible if the screen can be moved down or up to display more content.
• Startup display: When the device is switched on, a start screen with ELREHA lettering appears, a gray bar shows the status of the starting process, which takes a total of about 20 seconds
• Energy saving mode;’ If the device is not used for several minutes, the display will dim and a ‘screensaver’ graphic will be displayed.

Display and control elements

Programming numerical values
Keyboard panel for programming numeric values

Programming Texts
Keyboard panel for programming texts

Programming Selection Parameters
Keyboard panel for programming selection parameters

Depending on the parameter type, one or more values can be selected.

Abort programming

• To cancel the programming of a parameter, tap the screen in a location where there are no active elements, such as arrow icons or programmable values, child sides of the screen, or the keyboard or selection table that is currently active.
• Preferably, use the areas on the left or right edge.

Overview of the screen pages

(For a larger version, see appendix)

Direct accessable from any screen.
<–These four buttons are located at the bottom of the screen.

Screen ‚Configuration‘

Structure of the individual categories (For a larger version, see appendix)

Language selection

The VPR comes with two languages out of the box. If required, additional languages can be installed via the update function. You can switch to the installed languages during operation, and all predefined texts and error messages are then displayed in the selected language.

Note : User-specific texts, such as custom sensor names or message texts, are not switched.

Select language
On the Configuration screen, select the  General button. Here you can select the desired language.

User accounts
The VPR is a complex system in which there are many setting options and thus also sources of error. Therefore, it is necessary to restrict access to the parameters and protect against unintentional changes or modifications without appropriate expertise.
To regulate appropriate access rights, the VPR system includes a user management system that can be used to determine which rights up to 10 users have. If a user tries to change a parameter, the login screen may appear if the user is not already logged in or has insufficient access rights.

On the Configuration screen, select the User Management button

• A name, an authorization level, and a PIN number (password) are defined here for each user with which this user can log in.
• The authorization levels determine which parameters or parameter groups the respective user is allowed to change.
• User 10 has a special position; he always has full access rights.

User permissions

1. Read only Permitted to anyone, no login required
2. Sub-Controller-Setpoints Like 1. + Programming of Sub-controller setpoints
3. Setpoints Like 2. + Programming of Compound setpoints
4. Configuration parameters like 3. + Programming of Configuration parameters
   + Programming of PINs for Users with access levels 1-3

Unlimited access
+ Programming of access levels up to level 4 Programming of all parameters and settings
The PIN corresponds to a password. Please remember carefully!

• Every user login is recorded in the error history
• Each user can change their username and PIN
• A user cannot change his or her authorization level
• After 15 minutes of inactivity, a new PIN entry is required.
• If the user enters an invalid PIN for themselves, the user is logged out immediately.

User logout

Reset User settings to factory defaults
If necessary, the user management can be reset to factory settings. All user entries and PINs are lost. The process is only intended for service cases and is therefore not described here. The process is logged by an entry in the error history.

Factory defaults

Error Information Pages

The VPR displays information about error events under ‘Current Errors’. The error information can be accessed from any screen page using the button at the bottom left.

The error information is divided into the following areas:

• Actual errors: After pressing ‘Current Errors’, all currently pending errors are listed. The order depends on the respective error number. Each entry in the current error list is displayed with error text and error number.
• Historical errors: After clicking on ‘Error history’, the historical error list is displayed. It shows the last 300 error events chronologically, with time and error text. A red triangle at the beginning of the line signals the occurrence of a fault, a green dot signals a good message.
• Status messages: The ‘Status messages’ screen page shows any currently pending signals from the additional message inputs. Signals are only displayed here if no error priority has been specified for the relevant message input.

List of error codes
You can find a list of all possible error messages with their error codes in the appendix. Certain error codes, such as warnings from subcontrollers, are supplemented with more detailed information. We have printed the extended error codes for these messages. Advanced error codes cannot be prioritized individually.

I/O Busmodules

Usage of the inputs and outputs of the I/O-Busmodules

• In order to read in analog and digital signals and output control signals, the VPR 5340 uses I/O modules that are connected to the VPR 5340 by a dedicated data bus.
• The following I/O bus module types can be integrated into the system:
• BMO 30xx (digital signal inputs), BMR 3001 (switching outputs), BMA 32XX (analog inputs and outputs).

Overview of possible uses per I/O type:

BMO 3011 / BMO 3031

• Bus module with 24 digital signal inputs

The digital inputs of the BMO modules can be used as follows:

• Fault messages per unit: Oil pressure, hot gas, suction pressure, motor protection, high pressure.

• Per Compound (V1, V2, V3) Pressure limiter/safety pressure limiter (DBK/SDBK),

  • Frost protection switch, lack of refrigerant,
  • Suction pressure switch, high pressure fault, load limit 1-3,
  • Fast backrun, compound lock, condenser speed limiter.,
  • Demand for 2. setpoint, KLO demand,
  • Cascade precooling, CO2 safety shutdown,
  • Demand for 2. superheat setpoint

• System signals like: Emergency stop, phase failure/asymmetry, night operation.
  Freely usable message inputs

  • Gas cooler signals Lock, setpoint offset, and limitation.

BMR 3001
Bus module with 12 relay switching outputs as changeover contacts. The switching outputs of the BMR modules can be used as follows:

• Collective fault messages
• Compressor stages for compound V1, V2, V3, condenser stages for compound V1, V2, V3 For brine systems: condenser stages of the brine circuits, brine pumps per compound. Pre-cooling heat exchanger with cascade control, safety shutdown with CO2.
• Timer channels,
• For each compound: bridging relay for a frequency converter, warning for suction pipe monitor.

BMA 3251 / BMA 3206

• Bus modules with 2 analog outputs each as 4-20 mA / 0-10V, 6 temperature sensor inputs (BMA 3206) or 1 temperature sensor input and 5 signal transmitter inputs 4-20 mA (BMA 3251).
• The analog outputs of the BMA modules can be used as follows:
• PI controller for compressor control, P or PI controller for condenser control,
• PI controller for gas cooler control

The temperature inputs of the BMA modules can be used as follows:

• Control, frost protection, and limitation for brine systems. Condenser control,
• Additional temperature signals for display and logging.

The 4-20 mA inputs of the BMA modules can be used as follows:

• Suction pressure, condensation pressure per compound, media pressure in brine systems, Room humidity,
• Additional pressure signals for display and logging.

Service functions

The VPR5340 system holds and maintains various data that does not need to be changed by the operating personnel during normal operation. However, in the event of service, the functions listed below can be triggered. To prevent accidental or unauthorized execution of these functions, they are provided with their own activation codes.

The data deleted as part of the service functions cannot be restored!

• Clearing the operating hours counters of all machines (compressors, condenser fans, pumps)
• Clearing the historical error memory
• Clearing the data recording memory
• Clearing the configuration and resetting to factory settings

On the Configuration page, select the  Service button. Switch to Service 2 by the > button.

• Deleting operating Hours Meters: Set the value of ‘Delete runtimes of compressors and condensers’ to 45. The runtimes are reset to 0 and the value jumps back to 0.
• Deleting Errors-memory: Set the value of ‘Error History List’ to ‘Delete List’. To do this, user 10 must be logged in! The error history is deleted and the value returns to ‘Idle’.
• Deleting Recorded-data-memory: Set the value of ‘init/Delete recorded data’ to -2. To do this, user 10 must be logged in! The recorded data memory is initialized and the value returns to 0.

Resetting to Factory Defaults
On the Configuration page, select the Configs button. Now tap on the Load default values button. A security query will appear that offers 3 options:

• Yes, with network configuration resets all parameters to default values, including the network settings.
• Yes, without network configuration resets all parameters to default values, the network settings are retained.
• Abort quits the function, nothing is changed.

CAUTION: If the settings have not been previously saved either internally, on a USB stick or on an SD card, they cannot be restored after executing the function!

Home-Screen

• The home screen provides an initial overview of the status of the compound systems.
• It is displayed after system startup and after a long period of no operator action, after returning from dimmed mode.
• Depending on the configuration of the system, the information for one, two or three networks is displayed with the status of each machine, the currently measured actual values and the status of each stage controller.

By scrolling to the right or left using the corresponding arrow buttons, the overview pages of the connected controllers, hereinafter referred to as subcontrollers, follow one after the other.

Subcontrollers on the network (Subcontrollers overview)

• Brief overview of all subcontrollers configured on the Line 1 and Line data buses.
• The subcontrollers on Line 1 are shown in the top half, the subcontrollers on Line 2 in the bottom half.
• The symbol for each sub-controller shows the address on the data bus from 0…63, as well as the status of the controller:

Subcontrollers, grouped by Compound assign-ment V1, V2, V3,

• On three similar pages, you will find all configured subcontrollers, grouped according to their assignment to one of the compounds V1, V2 or V3.
• The status, the line and address, the label text, and the current actual value are displayed for each subcontroller.

Not assigned Subcontrollers
All subcontrollers without a compound assignment are displayed on this page.

Detailed Subcontroller display
On all of these overview pages, selecting a controller symbol opens the detailed view of the respective subcontroller.

Contact data of service company

• The   icon is in the top left  corner of the home screen.
• The page with contact details is accessible via this.
• The address of a service company can be stored here.
• There are 6 lines of 40 characters each available.

Overview of screens

On this page you will find the structure of the individual screen pages in an enlarged view.

Detail image: Screen pages of the configuration and service parameters

Error codes

On the following pages you will find a list of all possible error messages with their error codes. Certain error messages, such as warnings from subcontrollers, have extended error codes that specify the respective error in more detail. These extended error codes are also included in the list. They cannot be prioritized individually.

FAQ

• Q: Where can I find detailed information about parameters and control functions?
  • A: Detailed information about parameters and control functions is provided in a separate documentation. For further inquiries, you can contact the manufacturer.
• Q: How can I obtain the VPR-Configuration tool VPR53Plan?
  • A: You can request the VPR-Configuration tool from the manufacturer or download it directly from their website at www.elreha.de under the Software section.

Wenn der Fehler Nr.46 “NOT-AUS” ansteht, werden die mit ‘*’ markierten Fehlermeldungen unterdrückt
This device complies with the requirements of EU directives 2014/30/EC and 2014/35/EC as well as the applicable standards. The declaration of conformity is deposited at the following address:

NOTICE
This manual has been set up with care and the best knowledge. We reserve the right to change this manual for any reason, including but not limited to technical updates. Please make sure your device complies with the model described herein.

ELREHA Elektronische Regelungen GmbH

• Schwetzinger Str. 103 | 68766 Hockenheim Germany
• Phone: +49 6205 2009-0 |
• E-Mail : sales@elreha.de

References

• Elektronische Regelungen GmbH – The Experts in Electronic Control Systems

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