Carel UltraCella User Manual
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Carel UltraCella User Manual

Electronic control for cold rooms
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UltraCella
Electronic control for Cold Rooms
User manual
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
H i g h
E f f i c i e n c y
S o l u t i o n s

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  • Page 1 UltraCella Electronic control for Cold Rooms User manual NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT! H i g h E f f i c i e n c y S o l u t i o n s...
  • Page 3 The technical data in the manual can undergo modifi cations without forewarning. NO POWER & SIGNAL The liability of CAREL in relation to its products is specifi ed in the CAREL general CABLES contract conditions, available on the website www.carel.com and/or by specifi c TOGETHER agreements with customers;...

  • Page 5: Table Of Contents

    10.1 Electrical wiring 3PH EVAPORATOR Module ..........66 5. OUTPUTS CONFIGURATION AND PROTECTIONS 42 10.2 Electrical wiring 3PH FULL Module ............72 Analogue output ....................42 11. SOFTWARE RELEASE Digital Outputs ......................42 11.1 Software release table ..................79 UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 7: Introduction

    1. INTRODUCTION Ultracella is a family of products consisting of a control system for the The accessory modules allow: • basic functions of a cold room to which can be added further modules for the installation of the electronic expansion valve, using the module accessory functionalities (e.g.

  • Page 8: Expansion Modules

    UltraCella Service Terminal (cod. PGDEWB0FZ0) Power module (cod. WM00P000*N) The UltraCella control can be connected to an external terminal, without Expansion module that contains the circuit breaker switch and 3 Hp relay having to open the unit, for easy commissioning and programming of for compressor control.

  • Page 9: Installation

    1.b: Make 4 holes (Ø 4,5 mm) according to the drilling template and insert the dowels (mm) 2.a: Remove the frames, loosen the screws (1) and open the panel 2.b: Remove the frames UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 10: Structure

    Models with single digit display cod. WB000S* Keyboard Display Wall mounting holes Locking screws Connector for UltraCella Service (*) Green LED (*) Red LED (*) USB Port (*) (*) Visible after removing the bottom frame Fig. 2.c UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 11: Wiring Diagram

    Fig. 2.d 2.3 Wiring diagram CAREL NTC, PT1000 CAREL NTC, PT1000 CAREL NTC, PT1000 analog output (0 to 10 Vdc) CAREL NTC, analog input 0 to 10 Vdc analog 0 to 5Vdc input (4 to 20 mA) Door switch B1…B5 Analogue inputs 1…5...

  • Page 12: Expansion Modules Assembly

    WM00ENNI00 WM00ENSI00 Fig. 2.f Fig. 2.h Overall drilling template (mm) If UltraCella and expansion modules have to be mounted at the same time, use the overall drilling template. Ø 4,5 mm Fig. 2.g Mounting 1: Use a hole saw to drill the panel in correspondence with the predrilled 2: Remove the faceplates.
  • Page 13 3: Raise the cover or remove the faceplates and unscrew the screws to 4: Put the module close to UltraCella control and insert the coupling remove the panel and open the module. clamps supplied as standard. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 14: Ultra Evd Module

    EVD Evo driver commissioning by UltraCella Connect UltraCella to EVD module by serial cable in according with following wiring diagram e refer to below parameters table about EVD Evo driver commissioning. If its’ connected by serial cable, driver parameters can be displayed only (not modifi able) by local EVD Evo display.

  • Page 15: Ultra Power Module

    CAREL NTC, PT1000 CAREL NTC, PT1000 CAREL NTC, PT1000 230 V~ analog output (0 to 10 Vdc) CAREL NTC, analog input 0 to 10 Vdc 49 50 51 52 53 54 B5 analog input 0 to 5 Vdc 5 VREF...

  • Page 16: Ultra 3Ph Module Evaporator

    • Drill side surface of expansion module where it’s necessary and fi t cable glands to connect: power supply cables, serial cable, probes Connect three-phase expansion to UltraCella by shielded serial cable and power cables for loads AWG 22 Close frontal by screwing the 6 screws...

  • Page 17: Ultra 3Ph Module Full

    Connect three-phase expansion to UltraCella by shielded serial cable AWG 22 Fig. 2.q CAREL NTC, PT1000...

  • Page 18: Installation

    • use cable ends that are suitable for the terminals. Loosen every screw UltraCella can be connected to both PlantVisor and PlantWatch via BMS and fi t the cable end, next tighten the screws and gently pull the cables port (RS485 Carel protocol).

  • Page 19: Upload/Download Parameters (Usb Memory Key)

    Note: the fi gure refers to the screens on models with single row display, P/Ns WB000S*. In models with two rows, P/Ns WB000D*, as well as the message indicated, during navigation the display shows the scrolling message "recipes in USB device” on the second row. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 20: User Interface

    11 keys (depending on the model), which, pressed individually or together, allow to perform all of the controller programming operations. The accessory UltraCella Service terminal, accessory terminal, allows the commissioning of the control system via a guided procedure (Wizard) and also programming the parameters with a contextual help that explains the various functions.

  • Page 21: Keyboard

    • Value setting s, allow access to the multifunction menu • Value increase/ decrease UP/DOWN Tab. 3.c (*) Set H1/H5=2. If parameters are not set, if AUX1/AUX2 key are pressed, they blink for 5 seconds. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 22: Programming

    DOWN to pass to the next category: CtL. Repeat steps from 4) to 8) to access the category and change other parameters; press one or more times Prg to exit the parameters modifi cation procedure and return to standard display visualization.  UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 23 UP, select tct parameter and set it from 0 to 1 or from 1 to 0 to perform the data/ time change; select again parameter tcE and set it to 0; press one or more times Prg to save the date/ time and return to standard display. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 24: Procedures

     The control can work with 10 sets of parameters, pre-set in the factory by Carel, but modifi able to suit your requirements, indicated with r01 r10 (recipe 1 ... recipe 10); In order to select the current parameters set (control in OFF): from parameters modifi...
  • Page 25 Note: The Figures refer to the screens on models with single row display, P/Ns WB000S*. In models with two rows, P/Ns WB000D*, the message “On” and “Off ” appear on the second row of the display. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 26: Multifunction Menu

    1 s the control returns to standard display and the press Set to display the alarm date and time; compressor icon appears, to show the activation of the function. press Prg until you return to standard display. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 27 P/Ns WB000S*. In models with two rows, P/Ns WB000D*, as well as the message indicated, during navigation the display shows the scrolling message “Probe1 status” on the second row “.   UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 28 Starting from software release 1.5, the last 64 alarms activated and saved Preliminary operations: on UltraCella can be downloaded to a USB fl ash drive, in order from the remove the lower frame and insert the USB memory key; most recent to the oldest, in csv format. When the 64th alarm is saved, the set the control to OFF.
  • Page 29 7 = SA Second temperature to be How to download the fi le with temperatures recorded by UltraCella: recorded selection remove the bottom frame and insert the USB fl ash drive. The red and 0 = no log green LEDs next to the fl...

  • Page 30: Message Language Selection

    Starting from software release 1.5, the UltraCella software can also be The only messages that change according to the selected language are updated from the LED interface, as well as from the UltraCella Service those shown on the UltraCella Service terminal screens (PGDEWB0FZ0.

  • Page 31: Commissioning

    After wiring the electrical connections and the power supply (see installation chapter), the operations required for commissioning the UltraCella with single row display UltraCella control system depend on the type of interface used. Refer to some parameters such as: Set-point and diff erential;...

  • Page 32: Double Digit Display Models Cod. Wb000D* Commissioning

    2. Press Prg for 2 sec: the second row of the display will show “PASS” (password required). 4. Press Set; the second row of 3. Press UP/DOWN to enter the the display will scroll the name of password: 22. the fi rst category of parameters: Probes. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 33: Commissioning With Ultracella Service Terminal

    2. To enter programming mode: Press Prg and enter the password: 1234 Fig. 4.c Parameters Categ. 1/2 If the UltraCella controller has never been confi gured, as soon as the 1-Probes terminal is connected, the wizard is shown automatically. The Wizard...
  • Page 34 4.6.2 Probes confi guration The UltraCella controls have a maximum of 5 analog inputs, of which 3 can be confi gured as temperature probes (NTC probes, NTC high temperature probes, PT1000), the fourth as temperature probe or input 0 ... 10 V, the fi fth can be confi gured as input 4 ... 20 mA.
  • Page 35 UNIT 3 14 = Continuous cycle activation Defrost Activation: passage of the contact from opened to closed; Deactivation: passage of the contact from closed to opened. dP(1) dP(2) dP(3) d5(2) d5(3) Fig. 4.m UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 36 4.6.6 Type of defrost Compressor on Compressor off UltraCella allows you to manage the following types of defrost, depending before door opening before door opening on parameter d0: open open 0. electric heater defrost by temperature; Door Door 1. hot gas defrost by temperature;...

  • Page 37: Light Management

    Door_sw single characteristic, selectable through /t1 parameter. On models with two rows, P/Ns WB000D*, and on the UltraCella Service terminal, it is possible to show two diff erent characteristics, the fi rst selectable through /t1 parameter, and the second through /t2 parameter.

  • Page 38: Ultra Evd Module Commissioning

    Confi guring the EVD EVO driver from UltraCella Par. Description Max U.M. Connect UltraCella to the EVD module via serial, as shown in the wiring Terminal keys block confi guration diagram in Figure 2.k, and refer to the following parameter table for 0 = all keys enabled.

  • Page 39: Ultra 3Ph Evaporator Module Commissioning

    Main regulation type In UltraCella, access to parameter category “3PH” centralized cabinet cold room self contained cabinetcold room Make sure that fi rst two parameters are set as follows (Carel default perturbated cabinet cold room setting): subcritical co2 cabinet/cold room •...

  • Page 40: Ultra 3Ph Full Module Commissioning

    UltraCella. Make sure that fi rst two parameters are set as follows (Carel default In the table below details of where probes and loads can be connected.
  • Page 41 0 = disable 1 = enable 4.11.2 Function Ultra 3PH Full Module has to be combined with UltraCella controls (P/ Ns WB000S% or WB000D%). Module has inside high power actuators to handle directly three-phase loads of the condensing and evaporator units, but logic and regulation algorithms are inside UltraCella.

  • Page 42: Outputs Configuration And Protections

    fi rst and the second compressor (or between the fi rst and the second step of the compressor). Step1 Step2 Power_ON Fig. 5.a Step1 Step 1 compressor Step2 Step 2 compressor Time UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 43: Control

    UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 44: Autostart In Pump Down

    Notes: • at compressor autostart, the safety times c1 and c2, not c3 are respected; • the message “AtS” is reset automatically on the next correct pump down cycle. Fig. 6.e Fig. 6.f UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 45: Continuous Cycle

    Defrost 1…8: minute min. UltraCella allows you to manage the following types of defrost, depending 1. electric heater defrost (d0 = 0, 2): operating cycle. on parameter d0: The operating cycle refers to default values of the parameters F2 and F3.
  • Page 46 If the dl time is exceeded without performing any defrost, the defrost is automatically activated. The counter remains active even if the controller is off . Fig. 6.k Note: the defrost output (DEF) is used for command of the hot gas valve V_def. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 47: Evaporator Fans

    In this case, the fans are powered by the mains, while the • dd is used to force the stop of the compressor and the evaporator fan control signal is provided by UltraCella by analogue output Y1 0…10 Vdc. after a defrost cycle in order to facilitate the evaporator dripping; •...

  • Page 48: Condenser Fans

    On the other hand, if fans operates for too long time at a reduced speed, ice can form on the blades. To avoid this, at interval of F10 minutes, fans are forced to maximum speed for “peak time” defi ned by F8 Fig. 6.p UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 49: Duty Setting

    Fig. 6.s B2 and B3 Evap. 1 and 2 B2 acts on the evap. 1 and B3 act on evap. 2 Tab. 6.b UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 50 (NOTE: REQ1: Sv > St + rd/2; REQ2: Sv > St + rd) Example 1 Example 3 REQ2 REQ2 Fig. 6.u Fig. 6.w Example 2 Example 4 REQ2 REQ2 Fig. 6.v Fig. 6.x REQ1 request 1 REQ2 request 2 time compressor 1 compressor 2 UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 51: Humidity Management

    UltraCella can interact with CAREL humidifi cation systems, managing the humidity level in combination with cooling control. The humidity must be read from UltraCella, confi guring an analogue input (B4 or B5) as a 0 to 10 V or 4 to 20 mA input for humidity probes.
  • Page 52 10 = B4 11 = B5 6.15.3 AUX1 / AUX2 auxiliary output confi guration and basic humidity control logic To activate the humidifi er connected to UltraCella, confi gure one of the auxiliary outputs AUX1 or AUX2 for humidity control. Par. Description Max U.M.

  • Page 53: Parameters Table

    Operating mode direct with defrost direct without defrost Humidity setpoint 90.0 100.0 Humidity diff erential 20.0 (*): can be viewed only on UltraCella Sevice Terminal or on the controller with double row display. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 54 Enable defrost Do not select Start defrost Aux1 activation Do not select Do not select Remote ON/OFF Continuous cycle activation Do not select Stop compressor on external alarm Low pressure (LP) alarm delay UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 55 Terminal keys block confi guration 0 = all keys enabled par. H6 FUNCTION Set point modifi cation Defrost AUX1 output Multifunction menu (HACCP) AUX2 output On/Off management Light management BMS protocol selection 0= Carel 1= Modbus UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 56 14 Danfoss ets 12.5 - 25b Alco ex6 15 Danfoss ets 50b Alco ex7 16 Danfoss ets 100b Alco ex8 330hz carel recommended 17 Danfoss ets 250 Alco ex8 500hz alco specifi cation 18 Danfoss ets 400 Sporlan sei 0.5-11 19 two Carel exv connected together Sporlan ser 1.5-20...
  • Page 57 Date/time of third last HF alarm: day Date/time of third last HF alarm: hour hour Date/time of third last HF alarm: minute Number of HF alarms Reset HACCP alarms (1 = reset) Tab. 7.a UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 58: Signals And Alarms

    4. On the display the message “IA” appears and at the same time the bell  icon blinks and the buzzer activates. If more errors occur, they will appear in sequence on the display. UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 59: Evd Evo Alarms

    8.5 EVD EVO alarms If an Ultra EVD module, P/N WM00E%, is connected by Fieldbus, UltraCella will be able to signal the following alarms, which only depend on the  status of the EVD EVO controller fi tted on the module.
  • Page 60 Probe S4 fault or set point exceeded ON ON automatic Battery discharged or faulty or electrical connection ON ON automatic interrupted Operating and/or parameter EEPROM error ON ON automatic Valve not closed completely ON ON automatic UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 61: Alarm Parameters

    0 = compressor always off ; 100 = compressor always on; Par. Description Max U.M. Enabling HACCP 0/1=No/Yes A1=1 HACCP alarm delay ALARM Fig. 8.a ALARM Low temperature alarm High temperature alarm Adjustment probe Fig. 8.b UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 62: High Condenser Temperature Alarm

    fi gure below. Description High condenser temperature alarm °C/°F threshold High condenser temperature alarm delay Ac+10 Fig. 8.d Time High condenser temperature alarm delay Condenser probe High condenser temperature alarm threshold High condenser temperature alarm UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 63: Technical Specifications

    When installing, keep the supply and loads connections away from the cables of the probes, digital inputs, and monitoring device. Probe Type NTC std. CAREL: 10 kΩ at 25°C, range from -50°C to 90°C; measuring error: 1°C in range from -50°C to +50°C; 3°C in range from +50°C to +90°C NTC HT: 50 kΩ...

  • Page 64: Evd Modules Technical Characteristics

    Tab. 9.e * Rating with cosφ=0,5; With diff erent power factor, to calculate the rating consider the formula: I = P / (400 * √3 * cosφ) where P is the power in W UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 65: 3Ph Full Modules Technical Characteristics

    Tab. 9.g * Rating with cosφ=0,5; With diff erent power factor, to calculate the rating consider the formula: I = P / (400 * √3 * cosφ) where P is the power in W UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 66: Electrical Wiring 3Ph Modules

    10. ELECTRICAL WIRING 3PH MODULES 10.1 Electrical wiring 3PH EVAPORATOR Module 10.1.1 Power circuit WHITE GRAY BROWN CYAN WHITE GRAY BROWN CYAN Fig. 10.a UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 67 10.1.2 Power circuit WHITE CYAN 0(O1) 230(O1) 0(I) 0(O2) 24(O2) Fig. 10.b UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 68 10.1.3 Auxiliary circuit ORANGE ORANGE ORANGE ORANGE Fig. 10.c UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 69 10.1.4 Auxiliary circuit Fig. 10.d UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 70 10.1.5 Auxiliary circuit Fig. 10.e UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 71 Defrost probe NTC aux evaporator 0…10V for evaporator fans (signal) 0…10V for evaporator fans (GND) Condensing unit enabling / Solenoid valve RS485 - Fieldbus RS485 + Fieldbus - connection to UltraCella RS485 GND Ground terminals Tab. 10.a UltraCella +0300083EN - rel. 1.5 - 07.02.2015...

  • Page 72: Electrical Wiring 3Ph Full Module

    10.2 Electrical wiring 3PH FULL Module 10.2.1 Power circuit WHITE WHITE GRAY GRAY BROWN BROWN WHITE GRAY BROWN CYAN WHITE GRAY BROWN CYAN Fig. 10.g UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 73 10.2.2 Power circuit WHITE CYAN 0(O1) 230(O1) 0(I) 0(O2) 24(O2) Fig. 10.h UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 74 10.2.3 Auxiliary circuit ORANGE ORANGE Fig. 10.i UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 75 10.2.4 Auxiliary circuit Fig. 10.j UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 76 10.2.5 Auxiliary circuit Fig. 10.k UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 77 10.2.6 Connection for Pump Down or thermostat working Connection for operation pump down Connection for operation with thermostat Fig. 10.l 10.2.7 Terminal units terminal block terminal block Fig. 10.m UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 78 High/low Pressure switch Safe thermostat evaporator fans Normally closed. If active (open), evaporator fans are off and it’s not notifi ed in UltraCella Clicson evaporator fans Normally closed. If active (open), evaporator fans are off and it’s not notifi ed in UltraCella...

  • Page 79: Software Release

    Basic cold room management: compressor, defrost, evaporator fans, light, UltraCella single digit display 2xAUX relays Single digit display management Commissioning UltraCella through both built-in LED display and pGD1 UltraCella Service Commissioning through wizard on pGD1 Upload/Download parameters via USB key...
  • Page 80 Notes UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 81 Notes UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 82 Notes UltraCella +0300083EN - rel. 1.5 - 07.02.2015...
  • Page 84 Agenzia / Agency: CAREL INDUSTRIES S.p.A. Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 e-mail: carel@carel.com - www.carel.com...

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