Copeland Digital Controller XR02CH FW 1.1

1. GENERAL WARNINGS

1.1 PLEASE READ BEFORE USING THIS MANUAL

• This manual is part of the product and should be kept near the instrument for easy and quick reference.
• The instrument shall not be used for purposes different from those described hereunder. It cannot be used as a safety device.
• Check the application limits before proceeding.
• Copeland Controls Srl reserves the right to change the composition of its products, even without notice, ensuring the same and unchanged functionality.

1.2 SAFETY PRECAUTIONS

• Check the supply voltage is correct before connecting the instrument.
• Do not expose to water or moisture: use the controller only within the operating limits avoiding sudden temperature changes with high atmospheric humidity to prevent formation of condensation.
• Warning: disconnect all electrical connections before any kind of maintenance.
• Fit the probe where it is not accessible by the End User. The instrument must not be opened.
• In case of failure or faulty operation send the instrument back to the distributor or to "Copeland Controls Srl" (see address) with a detailed description of the fault.
• Consider the maximum current which can be applied to each relay (see Technical Data).
• Ensure that the wires for probes, loads and the power supply are separated and far enough from each other, without crossing or intertwining.
• In case of applications in industrial environments, the use of mains filters (our mod. FT1) in parallel with inductive loads could be useful.

2. GENERAL DESCRIPTION

The XR02CH, format 32x74x60mm, is a microprocessor-based controller, suitable for applications on medium or low temperature ventilated refrigerating units. It has 1 relay output to control the compressor. The device has an NTC probe input for temperature control. A configurable free-of-voltage digital input is present with various functionalities. The HOT KEY output allows to connect the unit, by means of the external module XJ485-CX, to a network line ModBUS-RTU compatible such as the monitoring units of X-WEB family. It allows to program the controller by means of the HOT KEY programming keyboard. The instrument is fully configurable through special parameters that can be easily programmed through the keyboard.

3. REGULATION

3.1 TYPE OF REGULATION

The regulation is performed according to the temperature measured by probe. The XR01CX is provided with the CH programmable parameter which enables the user to set the regulation both for heating or cooling applications:

• CH=CL: cooling applications
• CH=Ht: heating applications

3.2 COOLING APPLICATION

The regulation is performed according to the temperature measured by the thermostat probe with a positive differential from the set point: if the temperature increases and reaches set point plus differential the compressor is activated and then turned off when the temperature reaches the set point value again.

A visual representation of this process shows temperature on the Y-axis and time on the X-axis. The compressor is OFF until the temperature reaches SET + HY, then it turns ON. It remains ON until the temperature drops back to SET, at which point it turns OFF.

3.3 HEATING APPLICATION

The regulation is performed according to the temperature measured by the thermostat probe with a negative differential from the set point: if the temperature decreases and reaches set point minus differential, the heating output is activated and then turned off when the temperature reaches the set point value again.

A visual representation of this process shows temperature on the Y-axis and time on the X-axis. The heating output is OFF until the temperature drops to SET - HY, then it turns ON. It remains ON until the temperature rises back to SET, at which point it turns OFF.

4. DEFROST

Defrost is controlled by parameters:

• id: interval between two consecutive defrost cycles
• Md: maximum defrost duration
• dF: visualization during any defrost

5. FRONT PANEL COMMANDS

The front panel features a display and several keys for control and programming.

SET Key

To display target set point, in programming mode it selects a parameter or confirms an operation.

DEF Key

(DEF) To start a manual defrost.

UP Key

(UP) In programming mode it browses the parameter codes or increases the displayed value.

DOWN Key

(DOWN) In programming mode it browses the parameter codes or decreases the displayed value.

ON/OFF Key

To put the controller in "OFF" or "ON" mode.

KEYS COMBINATION

• UP + DOWN: To lock or unlock the keyboard.
• SET + UP: To enter in programming mode.
• SET + DOWN: To return to room temperature display.
• UP + DOWN: To reset parameter.

LED Indicators

5.1 HOW TO SEE THE SET POINT

1. Push and immediately release the SET key, the set point will be showed.
2. Push and immediately release the SET key or wait about 5s to return to normal visualization.

5.2 HOW TO CHANGE THE SETPOINT

1. Push the SET key for more than 2 seconds to change the Set point value.
2. The value of the set point will be displayed and starts blinking.
3. To change the Set value push the UP or DOWN arrows within 10s.
4. To memorize the new set point value push the SET key again or wait 15s.

5.3 HOW TO START A MANUAL DEFROST

Push the DEF key for more than 2 seconds and a manual defrost will start, the pre-condition is evaporator probe temp lower than dE.

5.4 HOW TO CHANGE A PARAMETER VALUE

1. Enter the Programming mode by pressing the SET+UP keys for 3s.
2. Select the required parameter.
3. Press the "SET" key to display its value (set value starts to blink).
4. Use UP or DOWN to change its value.
5. Press "SET" to store the new value and move to the following parameter.

To exit: Press SET+UP or wait 15s without pressing a key.

NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire. Please restart the controller after changing the parameters.

5.5 HOW TO RESET TO THE FACTORY PARAMETER VALUE

In the first 60s after controller power-on, it allows the user to reset to the factory parameters through key combination with steps below:

1. Start pressing DEF key and hold for 5s.
2. Then release just DEF but keep the UP key pressed for another 5s. Then parameter reset is successful by controller re-start automatically.

NOTE:

• The Parameters Factory Reset function is available only after Fr=Y has been configured.
• The Parameters Factory Reset function shall be accessible in the first 60 seconds from the device power-on. The default configuration will initiate the loading, during this time all regulation will be interrupted, relays will be powered off, and the controller is reset.

5.6 HIDDEN MENU

The hidden menu includes all the parameters of the instrument.

HOW TO ENTER THE HIDDEN MENU

1. Enter the Programming mode by pressing the SET+UP keys for 3s (Set value starts to blink).
2. Released the keys, then push again the SET+UP keys for more than 7s. The L2 label will be displayed immediately followed by the Hy parameter.

NOW YOU ARE IN THE HIDDEN MENU.

1. Select the required parameter.
2. Press the "SET" key to display its value.
3. Use UP or DOWN to change its value.
4. Press "SET" to store the new value and move to the following parameter.

To exit: Press SET+UP or wait 15s without pressing a key.

NOTE1: if there aren't any parameter in L1, after 3s the "nP" message is displayed. Keep the keys pushed till the L2 message is displayed.

NOTE2: the set value is stored even when the procedure is exited by waiting the time-out to expire.

HOW TO MOVE A PARAMETER FROM THE HIDDEN MENU TO THE FIRST LEVEL AND VICE VERSA.

Each parameter present in the HIDDEN MENU can be removed or put into "THE FIRST LEVEL" (user level) by pressing SET+UP. In HIDDEN MENU when a parameter is present in First Level the decimal point is on.

5.7 TO LOCK THE KEYBOARD

1. Keep pressed for more than 3s the UP and DOWN keys.
2. The "OF" message will be displayed and the keyboard will be locked. If a key is pressed more than 3s the "OF" message will be displayed.

5.8 TO UNLOCK THE KEYBOARD

Keep pressed together for more than 3s the UP and DOWN keys till the "on" message will be displayed.

5.9 THE ON/OFF FUNCTION

With "b3 = oF", by keeping pushed the DOWN key, the instrument is switched off. The "OF" message is displayed. In this configuration, the regulation is disabled.

To switch the instrument on, push again the DOWN key.

WARNING: Loads connected to the normally closed contacts of the relays are always supplied and under voltage, even if the instrument is in stand by mode.

6. PARAMETERS

REGULATION

• Hy Differential: (0.1°C ÷ 25°C / 1°F ÷ 45°F) Intervention differential for set point. Compressor Cut IN is SET POINT + differential (Hy). Compressor Cut OUT is when the temperature reaches the set point.
• LS Minimum SET POINT: (-55°C+SET/-67°F÷SET): Sets the minimum value for the set point.
• US Maximum SET POINT: (SET+99°C/SET+99°F). Set the maximum value for set point.
• od Outputs activation delay at start up: (0÷99min) This function is enabled at the initial start up of the instrument and inhibits any output activation for the period of time set in the parameter.
• AC Anti-short cycle delay: (0÷50 min) minimum interval between the compressor stop and the following restart.
• Cy Compressor ON time with faulty probe: (0÷99 min) time during which the compressor is active in case of faulty thermostat probe. With Cy=0 compressor is always OFF.
• Cn Compressor OFF time with faulty probe: (0÷99 min) time during which the compressor is OFF in case of faulty thermostat probe. With Cn=0 compressor is always active.
• CH Type of action: (CL; Ht) CL=cooling; Ht=heating.

DISPLAY

• CF Measurement unit: (°C ÷ °F) °C =Celsius; °F =Fahrenheit. WARNING: When the measurement unit is changed the SET point and the values of the parameters Hy, LS, US, OE, 01, AU, AL have to be checked and modified if necessary.
• rE Resolution (only for °C):(dE ÷ in) dE= decimal between -9.9 and 9.9°C; in= integer.
• dy Display delay: (0÷15 min.) when the temperature increases, the display is updated of 1 °C/1°F after this time.

PROBES

• PC Type of probe: nt = NTC; Pt = PTC.
• ot First probe calibration: (-9.9 ÷ 9.9°C / -17°F ÷ 17°F) allows to adjust possible offset of the first probe.
• F5 Filter probe enabling: set the field of action of the internal measurement filter. Nu=not used; AL=the filter will always works on all probes; do=the filter will only works on all probes for 30 sec after opening of the door.
• F6 Filter coefficient: define the coefficient for the Probe Filter. The lower the F6 value, the higher is the Probe Filter action (1 ÷ 99).

DEFROST

• id Interval between defrost cycles: (0÷99 minutes) Determines the time interval between the beginning of two defrost cycles.
• Md Maximum length for defrost: (0÷99 min. with 0 no defrost) when P2=n, (not evaporator probe: timed defrost) it sets the defrost duration, when P2 = y (defrost end based on temperature) it sets the maximum length for defrost.
• dF Display during defrost: (rt / it / SP / dE) rt= real temperature; it start defrost temperature; SP= SET-POINT; dE= label dF.
• tA Max display delay after defrost (0-99min).

ALARMS

• AU Maximum temperature alarm: (AL ÷ 99°C/99°F) when this temperature is reached the alarm is enabled, after the "Ad" delay time.
• AL Minimum temperature alarm: (-55÷AU°C / -67÷AU°F) when this temperature is reached the alarm is enabled, after the "Ad" delay time.
• AH Alarm hysteresis [0.1 to 25°C; 1 to 45°F].
• Ad Temperature alarm delay: (0÷99 min) time interval between the detection of an alarm condition and alarm signalling.
• dA Exclusion of temperature alarm at startup: (0÷99 min) time interval between the detection of the temperature alarm condition after instrument power on and alarm signalling.
• OA Open door alarm delay: 0 to 99 min.

DIGITAL INPUT

• iP Digital input polarity: (oP ÷ cL) oP= activated by closing the contact; cL= activated by opening the contact.
• iF Digital input configuration: (nU / do / EA / bA / dF / Fn / Hc / Au) nU= not used; do door switch function; EA= external alarm: "EA" message is displayed; bA= serious alarm "CA" message is displayed; dF= defrost activation; Fn=not used; Au =not used.
• di Digital input delay: (0÷99 min) with iF=EA or bA delay between the detection of the external alarm condition and its signalling. With iF=do it represents the delay to activate the door open alarm.
• dC Compressor status when open door: (no / Fn / cP / Fc): no; Fn = normal; Cp, FC =Compressor OFF.
• rd Regulation with door open: (n ÷ y) n = no regulation if door is opened; Y= when di is elapsed regulation restarts even if door open alarm is present.

SERIAL OUTPUT

• Sr Serial address (1 to 10).
• bd Baudrate 96(0); 19(1); 38(2); 57(3).
• PA Parity; Communication no(0); od(1); ev(2).

OTHER

• Fr Parameter factory reset: (n ÷ y) n= disable to reset to factory parameters; y= able to reset to factory parameters.
• rL Firmware release: (readable only).
• Sv Sub-versioning: reading only.
• Pt Parameter code table.

7. DIGITAL INPUTS

The free voltage digital input is programmable in different configurations by the "iF" parameter.

7.1 NOT USED (IF=NU)

The digital input is not used.

7.2 DOOR SWITCH (IF=DO)

It signals the door status and the corresponding relay output status through the "dc" parameter: no, Fn = normal (any change); CP, FC = Compressor OFF. Since the door is opened, after the delay time set through parameter "di", the door alarm is enabled, the display shows the message "dA" and the regulation restarts if rd = y. The alarm stops as soon as the external digital input is disabled again. With the door open, the high and low temperature alarms are disabled.

7.3 EXTERNAL ALARM (IF=EA)

As soon as the digital input is activated the unit will wait for "di" time delay before signalling the "EA" alarm message. The outputs status don't change. The alarm stops just after the digital input is de-activated.

7.4 SERIOUS ALARM (IF=BA)

When the digital input is activated, the unit will wait for "di" delay before signalling the "CA" alarm message. The relay outputs are switched OFF. The alarm will stop as soon as the digital input is de-activated.

7.5 START DEFROST (IF=DF)

It starts a defrost if there are the right conditions. After the defrost is finished, the normal regulation will restart only if the digital input is disabled otherwise the instrument will wait until the "Md" safety time is expired.

7.6 TURN ON THE AUXILIARY RELAY (IF=AU)

It starts a turn on the auxiliary relay if there are the right conditions.

8. TTL SERIAL LINE – for monitoring systems

The TTL serial line, available through the HOT KEY connector, allows by means of the external TTL/RS485 converter, XJ485-CX, to connect the instrument to a monitoring system ModBUS-RTU compatible.

9. INSTALLATION AND MOUNTING

Instrument XR02CH shall be mounted on a vertical panel, in a 29x71 mm hole, and fixed using the special bracket supplied. The temperature range allowed for correct operation is 0÷60 °C. Avoid places subject to strong vibrations, corrosive gases, excessive dirt or humidity. The same recommendations apply to probes. Let air circulate by the cooling holes.

10. ELECTRICAL CONNECTIONS

The instrument is provided with a screw terminal block to connect cables with a cross section up to 2,5 mm². Before connecting cables make sure the power supply complies with the instrument's requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay.

10.1 PROBES

The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid infiltration. It is recommended to place the thermostat probe away from air streams to correctly measure the average room temperature.

11. HOW TO USE THE HOTKEY

11.1 HOW TO PROGRAM THE HOT KEY FROM THE INSTRUMENT (UPLOAD)

1. Program one controller with the front keypad.
2. When the controller is ON, insert the "Hot key" and push the UP key; the "up" message appears followed by a flashing "En".
3. Push "SET" key and the "En" will stop flashing.
4. Turn OFF the instrument, remove the "Hot Key", then turn it ON again.

NOTE: the "Er" message is displayed for failed programming. In this case push again the UP key if you want to restart the upload again or remove the "Hot key" to abort the operation.

11.2 HOW TO PROGRAM AN INSTRUMENT USING HOT KEY (DOWNLOAD)

1. Turn OFF the instrument.
2. Insert a programmed "Hot Key" into the 5 PIN receptacle and then turn the Controller ON.
3. Automatically the parameter list of the "Hot Key" is downloaded into the Controller memory, successfully followed by the "En" label.
4. After 10 seconds the instrument will restart working with the new parameters.
5. Remove the "Hot Key".

NOTE: the "Er" message is displayed for failed programming. Check the Hotkey connection, check the data into Hotkey and repeat the action above.

12. ALARM SIGNALLING

12.1 ALARM RECOVERY

Probe alarm "P1" starts some seconds after the fault in the related probe; they automatically stop some seconds after the probe restarts normal operation. Check connections before replacing the probe.

Temperature alarms "HA" and "LA" automatically stop as soon as the temperature returns to normal values.

Alarms "EA" and "CA" (with iF=bL) recover as soon as the digital input is disabled.

13. WIRINGS

13.1 XR02CH-20A OR 8A - 110VAC OR 230VAC

A diagram shows the wiring for the XR02CH controller. It indicates terminals for Hot Key - TTL, Digital Input, Power Line Supply, and Outputs (01). Terminal 8-9 are for the compressor relay with absolute ratings of 20(8)A. Terminals 6-7 are for the power supply.

14. DEFAULT SETTING VALUES

This section provides a table of default setting values for various parameters:

15. TECHNICAL DATA

Copeland Controls S.r.l. Z.I. Via dell'Industria, 27-32016 Alpago (BL) ITALY Tel. +39 0437 9833 r.a. - copeland.com - dixell@copeland.com