HEATCRAFT H-IM-LLC Lead Lag Control System Instruction Manual

HEATCRAFT H-IM-LLC Lead Lag Control System

Specifications

• Product Name : Lead Lag Control System
• Model : H-IM-LLC
• Part Number : 25092501
• Controller : CAREL pCO5+ small Controller, CAREL c.pCO mini Controller, CAREL pCOXS Controller

Product Usage Instructions

Installation

1. Installation and maintenance should only be performed by qualified personnel familiar with this equipment.
2. Ensure all field wiring complies with equipment requirements and relevant codes.
3. Disconnect all power sources before servicing the units.

Inspection
Responsibility should be assigned to a reliable individual at the job site to receive materials. Carefully check each shipment against the bill of lading and report any shortages or damages to the delivering carrier.

Check Out and Start Up
Follow the provided sequence of operation to check out and start up the system.

User Interface
The system features different controllers including CAREL pCO5+ small Controller, CAREL c.pCO mini Controller, and CAREL pCOXS Controller each with specific setup procedures and menus for control settings.

Electrical Connections
Refer to the respective wiring diagrams for each controller type to make proper electrical connections.

In-Warranty Return Material Procedure
If any parts need to be returned within warranty, follow the In-Warranty Return Material Procedure outlined in the manual.

FAQ

• Q: Who should perform installation and maintenance of the Lead Lag Control System?
  

  • A: Installation and maintenance should only be carried out by qualified personnel familiar with this type of equipment.

• Q: What should be done before servicing the units?
  

  • A: All power sources should be disconnected before any service work is performed on the units.

• Q: How should damages or shortages in shipments be handled?
  

  • A: Damages or shortages should be reported to the delivering carrier, and damaged material should not be returned to the manufacturer without prior approval.

Installation and Operations Manual

H-IM-LLC
April 2024
Part No. 25092501

Lead Lag Control System

Installation and Operations Manual

General Safety Information

1. Installation and maintenance to be performed only by qualified personnel who are familiar with this type of equipment
2. Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes.
3. Make sure all power sources are disconnected before any service work is done on units.

Inspection
Responsibility should be assigned to a dependable individual at the job site to receive material. Each shipment should be carefully checked against the bill of lading. The shipping receipt should not be signed until all items listed on the bill of lading have been accounted. Check carefully for concealed damage. Any shortage or damages should be reported to the delivering carrier.

Warranty Statement

Seller warrants to its direct purchasers that products, including Service Parts, manufactured by SELLER shall be
of a merchantable quality, free of defects in material or workmanship, under normal use and service for a period of one (1) year from date of original installation, or eighteen (18) months from date of shipment by SELLER, whichever first occurs. Any product covered by this order found to Seller’s satisfaction to be defective upon examination at Seller’s factory will at SELLER’s option, be repaired or replaced and returned to Buyer via lowest common carrier, or SELLER may at its option grant Buyer a credit for the purchase price of the defective article. Upon return of a defective product to SELLER’s plant, freight prepaid, by Buyer, correction of such defect by repair or replacement, and return freight via lowest common carrier, shall constitute full performance by SELLER of its obligations hereunder.

SELLER shall have no liability for expenses incurred for repairs made by Buyer except by prior, written authorization. Every claim on account of breach of warranty shall be made to SELLER in writing within the warranty period specified above – otherwise such claim shall be deemed waived. Seller shall have no warranty obligation whatsoever if its products have been subjected to alteration, misuse, negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to SELLER’s or manufacturer’s recommendations, or if the serial number has been altered, defaced, or removed.

Seller makes no express warranties except as noted above. All implied warranties are limited to the duration of the Express Warranty. Liability for incidental and consequential damages is excluded. The forgoing is in lieu of all other warranties, express or implied, notwithstanding the provisions of the uniform commercial code, the Magnuson-Moss Warranty – Federal Trade Commission Improvement Act, or any other statutory or common law, federal or state.

Damaged material becomes the delivering carrier’s responsibility, and should not be returned to the manufacturer unless prior approval is given to do so. When uncrating, care should be taken to prevent damage. Heavy equipment should be left on its shipping base until it has been moved to the final location. Check the serial tag information with invoice. Report any discrepancies to your Heatcraft Refrigeration Products Sales Representative.

SELLER makes no warranty, express or implied, of fitness for any particular purpose, or of any nature whatsoever, with respect to products manufactures or sold by seller hereunder, except as specifically set forth above and on the face hereof. It is expressly understood and agreed that SELLER shall not be liable to buyer, or any customer of buyer, for direct or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or misuse by buyer or third parties of
said products. To the extent said products may be considered “consumer products,” As defined in Sec. 101 of the Magnuson-Moss Warranty – Federal Trade Commission Improvement Act, SELLER makes no warranty of any kind, express or implied, to “consumers,” except as specifically set forth above and on the face hereof.

The following conditions should be adhered to when installing this unit to maintain the manufacturers warranty:

• The power supply to the unit must meet the following conditions
  • Single phase must be within +10% or – 5% of nameplate ratings.
  • Phase imbalance cannot exceed 2%.
• All control and safety switch circuits must be properly connected according to the wiring diagram.
• The factory installed wiring must not be changed without written factory approval.
• All equipment is installed in accordance with local, state and national electrical code specified minimum clearances.

Lead Lag Control System

INTRODUCTION

The Lead Lag thermostat control system provides thermostat and auto-rotation functionality for 2 to 4 refrigeration systems in order to provide equal system run times. The number of temperature inputs utilized can be from 1 to 4. The control temperature can use a single sensor input or multiple sensors can be configured to control by average, maximum or minimum temperature.

The standard operation of the control system is to use all the systems it controls to maintain the box temperature desired. The control system does this by monitoring the rate of change of the box temperature and turning on or off systems based on the rate of change towards the desired temperature. At any given moment all systems or no systems may be running depending on the current box temperature and load. Algorithms are built in to stage the systems on so as to keep even run time between the systems. Staging time of the systems and system safeties are also configurable as described later in this manual.

Control Box
The standard ETL certified control box is NEMA 4 rated. The lead-lag control system image below is for reference only. The actual unit could built with the pCOXS, pCO5+ small, or c.pCO mini controller from CAREL.

Lead Lag Control System Placement
The Lead Lag control package is designed to be wall mounted outside the area being controlled. The control enclosure features four mounting tabs to be used to securely mount the enclosure to the wall. Mounting hardware and method should be sufficient to hold the weight of the enclosure. In areas requiring water resistance, care should be taken dur-ing mounting and installation to maintain the enclosures NEMA 4 rating. Locations selected should meet the following requirements:

1. Ambient temperature should be between 15° F and 140° F.
2. Relative humidity should be below 90% and be non-condensing.
3. Location should not have objectionable vibrations.

Check Out and Start Up
After the installation has been completed, the following points should be covered before the system is placed in operation

Prior to Applying Power

1. Confirm incoming power supply matches the unit’s specifications.

2. Confirm system wiring matches electrical wiring diagram.

3. Check all electrical connections. Ensure they are all tight.
   After Applying Power

4. Set temperature and alarm set points.

5. Confirm control system parameter settings.

Sequence of Operation

On power-up, the control system will begin to modulate the relay outputs in order to meet the space temperature set point. The first system that is available will turn on based on previous run time in conjunction with the minimum com-pressor off and stage delay timers. Once the stage delay timer has been satisfied, the next system with the lowest run time will be turned on if the temperature and the rate of change (slope) set points are not satisfied. Once the space temperature has been satisfied, the control system will stage the systems off based on the control scheme being utilized (output run time or first in-first out), and the stage delay timer. Once cycled off, a system will remain off until the mini-mum off cycle time set point has been satisfied.

For Lead-lag Control System Built with CAREL pCO5+ small Controller

Thermostat connections are normally open and are connected through the NO1, NO2, NO3, and NO4 for system 1 through 4 respectively. Terminal NO1, NO2, and NO3 share the C1 common while terminal NO4 uses C4 for common.

Sensors are connected to the U terminals as shown in the diagram below using U1, U2, U3, U4 and GND.
The alarm output is connected through the normally open contact NO5 and C4. The alarm contact is closed (energized) upon the application of power and opens (de-energizes) when there are alarms present or during a loss of power.

Wiring Diagram for pCO5+ small Controller

For Lead-lag Control System Built with CAREL c.pCO mini Controller

Thermostat connections are normally open and are connected through the NO1, NO2, NO3, and NO4 for system 1 through 4 respectively. Terminal NO1 and NO2 share the C1/2 common while terminal NO3 and NO4 uses C3/4/5 terminal for common.

Sensors are connected to the U terminals as shown in the diagram below using U1, U2, U3, U4 and GND.
The alarm output is connected through the J12 isolated relay (NO6, NC6 and C6). The alarm relay is energized when there are alarms present.

Wiring Diagram for c.pCO mini Controller

Electrical Connections

For Lead-lag Control System Built with CAREL pCOXS Controller
(For reference only, pCOXS controller was discontinued.)

Thermostat connections are normally open and are connected through the NO1, NO2, NO3, N04 and C1, C4. Sensors are connected to the B terminals as shown in the diagram below using B1, B2, B3, B4 and GND. The alarm output is connected through NO5, NC5, and C5.

Wiring Diagram for pCOXS Controller

Warnings

• Electrical connections must only be completed by a qualified electrician.
• A power supply other than the type specified may seriously damage the system.
• Separate as much as possible the sensor wiring from wiring carrying inductive loads and power wiring to avoid possible electromagnetic disturbance. Never lay power wiring and sensor wiring in the  same conduits. Do not install the sensor wiring in the immediate vicinity of power devices (contactors, circuit breakers or similar).
• Reduce the path of sensor wiring as much as possible and avoid spiral baths that enclose power devices.
• Avoid direct contact with internal electronic components.
• Connection errors (and connections other than those indicated in this manual) may involve danger to the users and may cause faults on the instruments and components connected.

User Interface

The user interface shows the system status as well as allows for changes to the system parameters.

CAREL pCOXS Controller User Interface

Setup for CAREL pCOXS and pCO5+ small Controller

Main Status
Press the Escape Esc button to return to the Main Status Screen at any time.

Cntrl Temp: is the current space temperature reading. This temperature shows the actual or calculated temperature based on the configuration selected.
Set Pnt : is the desired space temperature.

System: Shows the overall status of the control system and the status of each system. In the example above, refrigeration system 1 is on and system 2, 3 & 4 are off (1 0 0 0).

Sensor Status

To enter the sensor status screen, press the down button with the cursor in the top left corner of the display.

This page displays the temperature sensor’s current readings along with the average temperature.
If a sensor is not connected no value will display here. Temperature sensor is 27.28 kOhm at 32°F.

Output Closure Time

To enter the output closure time screen, press the down button with the cursor in the top left corner of the display from the sensor status page.

• This page displays the total time that each relay output has been energized (closed).
• You can reset all the times by hitting the Enter button and changing “Reset: No” to “Reset: Yes”.
• This operation cannot be undone and will reset all four times.

Set Points (Page 1)

Press the Program Prg button to enter the main Set Points screen.
To change a parameter, press the Enter button to navigate to the desired parameter.

• Once at the desired parameter, press the up or down buttons to change the value of the parameter.
• Press Enter again to save the change.
• Control Set : This is the desired space temperature set point. Control Set set point range: -99.9°F to 99.9°F in 0.1°F increments.

System: This will turn on or off the overall functionality of the control system.
All systems will turn off and will not turn on until the control system has been turned on again.
Cntrl Value : This is the actual space temperature value and cannot be changed.

Set Points (Page 2)

To enter page two of the set point screen, press the down button with the cursor in the top left corner of the display.

• Slope: The rate of change of the space temperature in degrees per minute that is deemed sufficient without needing to turn on another stage of cooling. Slope set point range: -10.0°F to 10.0°F in 0.1°F increments.
• Slope Value : This is the current slope value in real time and cannot be changed.

The slope is used to keep additional stages from coming on if the space temperature is pulling down at a fast rate. When the space temperature is increasing the slope value will be a positive number and when the space temperature is decreasing the slope value will be a negative number.

Set Points (Page 3)

To enter page three of the set point screen, press the down button with the cursor in the top left corner of the display.

• Hi Alarm : This is the high temperature alarm set point. Hi Alarm set point range: -99.9°F to 99.9°F in 0.1°F increments.
• Low Alarm : This is the low temperature alarm set point. Low Alarm set point range: -99.9°F to 99.9°F in 0.1°F increments.
• Alarm Delay: This is the time delay before the control system will alarm due to a high or low temperature alarm. Alarm Delay set point range: 0 minutes to 999 minutes in 1 minute increments.

In addition to the high and low box temperature alarm, the control system will also alarm in the event there are either no temperature sensors connected or if all the sensors connected have failed. This alarm is immediate and is not affected by the alarm delay.

Control Setup

To enter the control setup screen press the Prg and the Esc at the same time.

• Cntrl Sensor : This setting selects which sensor or calculation to use in the box temperature measurement. The choices are T1, T2, T3, T4, Average, Maximum, and Minimum. The average setting automatically calculates the average temperature based on the number of sensor(s) connected and their current measurements.
• Temperature Units : °F or °C.

Sensor Settings

Press the Down button to page through each sensor settings.

• Ch: Input Sensor Channel
• NTC : Sensor Type
• Offs : Sensor offset calibration and actual value

Control Deadband (Page 1)

• Direction: Direct or Reverse Acting. Refrigeration should always be direct acting.
• Num Stages : The number of refrigeration systems attached to controller (2 – 4).
• Control: Applies to the method of energizing the stages of cooling. OUTPUT TIME or FIFO.

OUTPUT TIME chooses the next output to energize based on which output has the least amount of time

energized (times can be seen on the output closure time screen).  It chooses the next output to de-energize based on which output has the most amount of time energized.

FIFO chooses the next output to energize and de-energize based on a First In First Out (FIFO) algorithm.

The first output that was energized will be the first output to be de- energized.

Control Deadband (Page 2)

• Diff + : The number of degrees above set point to enable a call for a cooling stage.
• Diff – : The number of degrees below set point to disable a call for a cooling stage. The Deadband differentials can be set from 0 to 10°F in 0.1°F increments.

Stage Delay Timers

• Stage Up : The minimum delay before the control system can energize an output. Stage Up set point range: 0 seconds to 32000 seconds in 1 second increments.
• Stage Down : The minimum delay before the control system can de-energize an output. Stage Down set point range: 0 seconds to 32000 seconds in 1 second increments.

Compressor Timers

• Min Off: The minimum stage off time for each output. Min Off set point range: 0 seconds to 999 seconds in 1 second increments.
• Min On: The minimum stage on time for each output. Min On set point range: 0 seconds to 999 seconds in 1 second increments.
• 2 Starts Same: The minimum time between the same output being energized twice. 2 Starts same set point range: 0 seconds to 999 seconds in 1 second increments.

2 Starts Diff: The minimum time between two different outputs being energized. 2 Starts Diff set point range: 0 seconds to 999 seconds in 1 second increments.

Default Settings

Setup for CAREL c.pCO mini Controller

Keypad Description

Main Status
Press the Escape Esc button to return to the Main Status Screen at any time.

• Control Temp : is the current space temperature reading. This temperature shows the actual control point based on the sensor configuration selected.
• Set Point: is the desired space temperature
• System: shows the overall status of the control system and the status of each system.

In this example, the controller is ON. The four digits to the right of ON are relay status (A value of 1 means the relay is on and a value of 0 means the relay is off). If it was to read “System: ON 1 1 0 0”, then the refrigeration relays 1 and 2 are on and relays 3 and 4 are off.

The system ON/OFF values and setpoints can be changed from this screen.
To change a parameter value, press the Enter to navigate to the desired parameter.
Once at the desired parameter, press Up or Down to change the value.
Press Enter again to save the change.

• Set Point Range : -99.9°F to 99.9°F in 0.1°F increments.
• System: This will turn on or off the overall functionality of the control system. All relay outputs will turn off until the control system has been turned on again.

Sensor Status

To enter the sensor status screen, press the Down with the cursor in the top left corner of the display.

This page displays the temperature sensor’s current readings along with the average temperature. If a sensor is not connected, the display shows a default value of at 32°F, at 27.28kOhm.

Output Closure Time

To enter the output closure time screen, press the Down button with the cursor in the top left corner of the display from the sensor status page.

• This page displays the total time that each relay output has been energized (closed).
• You can reset all the times by hitting the Enter button and changing “Reset:No” to “Reset:Yes”.
• This operation cannot be undone and will reset all four times.

Main Menu

• Press the Program Prg to enter the Main Menu screens.
• If not yet logged in, The LOGIN screen will appear.
• The Default End User Password is 0001.
• The Default Service Password is 0002.
• Press the Up and Down to change the digit and the Enter to move to next digit.
• After the 4-digit code is entered it will go to the Main Menu screen.

There are seven sub-menus, A through G. Pressing Up and Down to move the highlight bar and then press Enter to select the sub-menu.

Main Menu

• A. Set Points
• B. Control Setup
• C. Timers
• D. Unit Config
• E. Alarm Logs
• F. Settings
• G. Logout

Set Points Menu

With “A. Set Points” highlighted, press Enter to enter the Set Points sub- menus. Press Enter again to scroll through editable parameters. Use the Up and Down to change the parameter value.

• Slope : The rate of change of space temperature in degrees per minute deemed sufficient without needing to turn on another stage of cooling. Adjustment of slope set point range: -10.0°F to 10.0°F in 0.1°F increments.
• Slope Value : This is the calculated current slope value in real time and cannot be changed.

The slope is used to keep additional stages from coming on if the space temperature is pulling down at a fast rate.
When the space temperature is increasing the slope value will be a positive number and when the space temperature is decreasing the slope value will be a negative number.

• Hi Alarm : This is the high temperature alarm set point. The set point range: -99.9°F to 99.9°F in 0.1°F increments.
• Low Alarm : This is the low temperature alarm set point. The set point range: -99.9°F to 99.9°F in 0.1°F increments.
• Alarm Delay: This is the time delay before the control system will offer an alarm output based upon meeting the set point for alarms. The set point range: 0 minutes to 999 minutes in 1-minute increments.

In addition to the high and low box temperature alarm, the control system will alarm upon loss of a calculated control point. This alarm is immediate and is not affected by the alarm delay.

Control Setup Menu

To enter the Control Setup screen, press Escape Esc to get back to MAIN MENU. Press the Down to highlight “B. Control Setup” and then press the Enter.

The available sub-menus are,

• Control Setup
• SIO Config
• Control DeadBand

Control Sensor: This setting selects which sensor or calculation to use in the box temperature measurement. The choices are T1, T2, T3, T4, Average, Maximum, and Minimum. The average setting automatically calculates the average temperature based on the number of sensor(s) connected and their current measurements.

Temperature Units : °F (Temperature unit can be changed in the Units of Measure menu.)

Sensor Settings Sub-menu

In the Control Setup Menu, press the Down to get to the screen for each sensor settings.

• Uai: Sensor address (pre-configured from factory, should not modify in the field)
• Type: Sensor type (pre-configured from factory, should not modify in the field)
• HW Value : Sensor reading
• Offset: Sensor offset calibration
• Status: The current status of the sensor

Control Deadband Sub-menu

In the Control Setup Menu, press the Down to get to the screen for Control Deadband settings.

• Direction: Direct or Reverse Acting. Refrigeration should always be direct acting.
• Num Stages : The number of refrigeration systems attached to controller (2 – 4).
• Control: Applies to the method of energizing the stages of cooling, OUTPUT TIME or FIFO.

OUTPUT TIME chooses the next output to energize based on which output has the least amount of runtime energized (times can be seen on the output closure time screen). It chooses the next output to de-energize based on which output has the most amount of time energized.

FIFO chooses the next output to energize and de-energize based on a First In First Out (FIFO) algorithm. The first output energized will be the first output de-energized.
Press Down to get to the second page of the Control Deadband menu.

• Diff + : The number of degrees above set point to enable a cooling stage.
• Diff – : The number of degrees below set point to disable a cooling stage.

Deadband differential can be set from 0 to 10°F in 0.1°F increments.

Timers Menu

Press Escape Esc back to MAIN MENU and select “C. Timers.” Press Enter Button to get to the Stage Delay Timers menu.

The available sub-menus are,

• Stage Delay Timers

• Compressor Timers

• Stage Up: The minimum delay before the control system can energize additional output. Stage Up set point range: 0 seconds to 32,000 seconds in 1 second increments.

• Stage Down : The minimum delay before the control system can de-energize an output. Stage Down set point range: 0 seconds to 32,000 seconds in 1 second increments.

Press Up or Down to get to the Compressor Timers sub-menu

• Min OFF: The minimum stage off time for each output. Min Off set point range: 0 seconds to 999 seconds in 1 second increments.
• Min ON : The minimum stage on time for each output. Min On set point range: 0 seconds to 999 seconds in 1 second increments.
• 2 Starts Same : The minimum time between the same out-put being energized twice. 2 Starts same set point range: 0 seconds to 999 seconds in 1 second increments.
• 2 Starts Diff: The minimum time between two different outputs being energized. 2 Starts Diff set point range: 0 seconds to 999 seconds in 1 second increments.

Controller Default Settings

Unit Config Menu

WARNING: This menu is for configuring the hardware of the controller. It is pre-configured from the factory for the lead-lag controller. DO NOT modify the parameters in this menu in the field.

Alarm Logs Menu
Press Escape Esc back to MAIN MENU and use Down Button to scroll to “E. Unit Config”. Press Enter to get to the sub-menus.
Use Up and Down to scroll through the alarm records.

Settings Menu
Press Escape Esc back to MAIN MENU and use Down Button to scroll to “F. Settings”. Press Enter to get to the sub-menus.

The available sub-menus are,

• Date/Time
• Language
• Communications
• Pwd Change
• Initialization
• UoM
• Import/Export

WARNING: The Communications, Initialization and Import/Export sub-menus are not supported for the lead-lag controller. DO NOT modify the settings in these sub-menus in the field.

To change parameters in the sub-menu, use the Up and Down keys to scroll to the sub-menu and press Enter to select the sub-menu. Press Enter again to scroll through the editable parameters. Use Up and Down keys to change the parameter value.
To change the Unit of Measure, scroll to sub-menu “UoM” and press the Enter. Press Enter again to get to the editable parameter.

Logout Menu
To logout of the programming mode, press Escape Esc back to MAIN MENU and press Down to scroll to “G. Logout”. Press Enter twice to logout of the programming mode.

In-Warranty Return Material Procedure

Material may not be returned except by permission of authorized factory service personnel of Heatcraft Refrigeration Products in Stone Mountain, Georgia. A “Return Goods” tag will be sent to be included with the returned material. Enter the required information on the tag in order to expedite handling at our factories and prompt issuance of credits. All parts shall be returned to the factory designated on the “Return Goods” tag, transportation charges prepaid.
The return of a part does not constitute an order for replacement. Therefore, a purchase order must be entered through your nearest Heatcraft Refrigeration Products representative. The order should include part number, model number and serial number of the unit involved.
Following our careful inspection of the returned par and if it is determined that the failure is due to faulty material or workmanship, credit will be issued on customer’s purchase order.

Parts by InterLink™
When writing to the factory for service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

InterLink™ Lead Lag Control System Parts List

NOTE: Build with CAREL pCO5+ small controller.

This guide is designed to provide only general information. If you need advice about a particular product application or installation, you should consult your Heatcraft representative. The applicable specification sheets, data sheets, handbooks, and instructions for Heatcraft products should be consulted for information about that product, including, without limitation, information regarding the design, installation, maintenance, care, warnings relating to, and proper uses of each product.

INFORMATION CONTAINED WITHIN THIS GUIDE, IS PROVIDED “AS IS,” WITH ALL FAULTS, WITH NO REPRESENTATIONS OR WARRANTIES OF ANY KIND BEING MADE, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. HEATCRAFT SPECIFICALLY DISCLAIM ALL LIABILITY FOR ERRORS OR OMISSIONS IN, OR THE USE, MISUSE OR MISINTERPRETATION OF, ANY INFORMATION CONTAINED IN THIS GUIDE. HEATCRAFT DOES NOT WARRANT THE ACCURACY, COMPLETENESS OR TIMELINESS OF THE INFORMATION CONTAINED IN THIS GUIDE.

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