McQuay ALR C Installation Manual

Page 1
Installation and Operating Manual
Leaving Water Controller, AS-UNT33n-1
Applied to ALR C/D/E and WHR D/E
IOM UNT33n
Group: Chiller Date: May 2000 Supersedes: IM 552
© 1996 McQuay International
Page 2
Table of Contents
Introduction........................................................................................3
Specifications.....................................................................................4
Installation..........................................................................................5
Dimensional Data................................................................................6
Electrical Data.....................................................................................7
Operation...........................................................................................9
Additional Features............................................................................11
Settings And Adjustments.................................................................. 12
System Checkout and Troubleshooting .............................................. 13
Zone Terminal User's Guide.............................................................. 16
Zone Terminal Glossary.................................................................... 21
"McQuay" is a registered trademarks of McQuay International
"Illustrations and information cover McQuay International products at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice"
1996 McQuay International
Page 3
Introduction
This controller is the standard controller on ALR "C", "D" or “E” vintage and WHR "D" or "E" vintage packaged chillers where control of leaving water temperature is desired. On these units with the controller factory installed, the control is pre-set and calibrated and should not need any adjustment other than the control setpoint.
For further information on the AS-UNT33n-1 Microprocessor based leaving water controller and accessories contact McQuay International for specification sheets for each individual control.
The controller and sensor covered in this Installation and Operating Manual is also available as a substitute replacement for earlier ALR and WHR units.
General Description
The AS-UNT33n-1 Microprocessor-based Leaving Water Control is designed to control multiple capacity steps of cooling from a single sensor.
The AS-UNT33n-1 operation is based on an adjustable Setpoint and Control Band as shown in the OPERATION section of this document. If the leaving chilled water temperature begins to rise to the desired Setpoint plus Control Band/2 (upper limit) , Cooling Stage 1 brings on the first stage of cooling. Additional stages of cooling will follow as long as the leaving water temperature remains above the upper limit of the Control Band. As the leaving water temperature begins to drop to Setpoint minus Control Band/2 (lower limit), cooling stages will begin to de-energize.
There will be no energizing or de-energizing of cooling stages as long as the leaving water temperature is between the upper and lower limits of the Control Band.
As a rule, anytime the leaving water temperature is above the upper limit of the Control Band, stages will be energized, and anytime the leaving water temperature falls below the lower limit of the Control Band, stages will be de-energized.
At the initial start of the unit a time delay will occur. There is a 60 second Interstage On Delay between stages. Each stage incorporates minimum on and off timers with a maximum cycle rate of six cycles per hour.
CAUTION-Offering this control device is not intended to imply that rapid cycling of compressors is condoned. If an application produces rapid cycling, the control and/or the application must be reviewed and altered to prevent compressor failure.
Table 1, Standard Control Characteristics
DESCRIPTION
AS-UNT-33n-1
Setpoint Range
Control Band Range
Interstage On Delay Between Stages 60 seconds Minimum Off Time (each stage) 5 minutes Minimum On Time (each stage) 60 seconds
Soft Start During Start-up
10°F to 60°F (-12°C to +15°C) Adjustable 0°F to 10°F (0°C to 6°C) Adjustable
50% command over 5 minutes
SETTING
Table 2, Controller Specific Characteristics
CONTROLLER
DESCRIPTION
AS-UNT330-1 4 or 6 Honeywell AS-UNT332-1 8 Honeywell AS-UNT334-1 4 or 6 Johnson Controls AS-UNT336-1 8 Johnson Controls
NUMBER OF
STAGES
LEAVING WATER
SENSOR
Page 4
Specifications
Electrical Ratings:
Input voltage and frequency (terminals 24 VAC–COMMON) 20 to 30 VAC at 50/60 Hz (50 Hz requires download.) Power Consumption: 25 VA at 24 VAC and 50/60 Hz Input Signal: Honeywell sensor—positive temperature coefficient of 4.8 ohms/Degree F; resistance of 3484 ohms at 77°F. Johnson Controls sensor—positive temperature
Number of Stages Selection:
Refer to Table 5, Figure 1 for stage selection
Temperature Ranges:
Ambient: -40°F to +150°F.
Humidity Rating:
5 to 90% RH non-condensing.
Leaving Water Sensor:
The Honeywell C7173Al017, Honeywell C7170A1010, or Johnson Controls TE-6300-300 senses Leaving Water Temperature on control
terminals AI3 and AI3 COM. coefficient of 3 ohms/Degree F; resistance of 1000 ohms at 70°F. .
Table 3, Contact Rating
CONTACT VOLTAGE (V) INRUSH (VA) RUNNING (VA)
N.O. 24 240 60 N.C. 24 75 30 N.O. 120/240 750 75 N.C. 120/240 240 40
Table 4, Accessories
Model No. Johnson TE-6313P-1 070312301 1 Outdoor Air Sensor Used for reset of Leaving Water Setpoint.
Johnson TE-6300-300 070312401 1 Immersion Sensor (30 ft. cord) Senses Leaving or Return Water Temperature. Sensor Well 047441506 1 Immersion Well Used with TE-6300-300. Johnson TE-6410S­2000 Johnson AS-ZTU330­1 Honeywell C7173A1017 Honeywell C7170A1010 Honeywell 121371A 048442403 1 Copper Immersion Well Used with C7173A1017 or C7170A1010. Honeywell 121371E 048442404 1 Stainless Steel Immersion Well Used with C7173A1017 or C7170A1010. Johnson AS-KIT100-0 1 Resistor Test Kit Used for field diagnostics.
McQuay
Part No.
070312801
070312701 1 Zone Terminal
048442405 1 Immersion Sensor (30 ft. cord) Sensing of Leaving Water Temperature.
048442402 1 Immersion Sensor (10 ft. cord) Sensing of Leaving Water Temperature.
Quantit
y
depends on
# of zones
Description Application
Zone Temperature Sensor Used for zone temperature reset.
Used for monitoring and local control of designated points.
Page 5
Installation
AS-UNT330-1
STANDARDS COMPLIANCE
The UNT Controller complies with the following standards: * CSA C22.2 No. 205* UL 916 * IEEE 472 * IEEE 446 * VDE 0871 Class B * IEEE 587 Category A * IEEE 518 * FCC Part 15, Subpart A, Cl. J * NEMA ICS 2, Part 2-230 All wiring must comply with local codes and ordinances:
1. Disconnect power before making connections to avoid electrical shock or equipment damage.
2. Check ratings given in the specification and on the product to make sure the controller fits the application.
3. Choose a location for the AS-UNT33n-1 controller that is not exposed to the weather and where controls, connections, and the zone bus phone jack are accessible.
4. Mount the controller with three No. 8 screws through the mounting holes in the base. (See Figure 2.)
5. Install immersion well and sensor bulb in the Leaving Chilled Water piping as instructed by the installation manual for the unit being controlled.
6. Connect 24 VAC to terminals marked 24 VAC and COM. CAUTION: Never spark the 24 V power leads to check for power.
CAUTION: Do not run low-voltage wiring in the same conduit as line-voltage wiring (30 VAC or above) or wiring that switches power to highly inductive loads (such as contactors, coils, motors, or generators).
7. Wire the compressor and capacity controls steps to the individual controller relay terminals as shown in the unit wiring diagram.
8. Adjust SW1 and SW2 on AI2 for the appropriate number of cooling stages. The AS-UNT330-1/AS-UNT334-1 is factory set for 6 stages by Johnson Controls. The AS-UNT332-1/AS-UNT336-1 is factory set for 8 stages.
Table 5, Dipswitch Settings
Dipswitch Settings
Factory
Set
Stage
Select
Factory Set
AS-UNT33n-1 AI 1 AI 2 AI 3 AI 4 AI 5 AI 6
AS-UNT330-1 SW2 10 V AS-UNT334-1 2 V
4 stage
SW1 T (set by others) V AS-UNT330-1 SW2 10 V AS-UNT334-1 2 V
6 Stage
SW1 T
(Factory Set) V AS-UNT332-1 SW2 10 V AS-UNT336-1 2 V
8 Stage
SW1 T
(Factory Set) V
Figure 1, Analog Input Switches
C D V 5 1 +
A N A LO G I N PU TS
B IN A R Y IN
COM
PW R
I N
2 4V
B IN A R Y CO M
A C
BIN ARY INA NAL OGIN PUTS
BINA RY OUT PUT S
ANAL O G I N PU TS
1 2 3 4 5 6 1 2 3 4
A N A L OG I N P U TS
CO MM ON
B IN A RY OU TP U T 1 2 3 4 5 6 7 8
2 4V A C TO L OA D S
Page 6
Dimensional Data
Figure 2, Dimensional Data
These relays are for the 7th and 8th stages.
COOL 8
COOL 7
7.78
8.95
SW2 SW1
ANALOG INPUTS BINARY IN
1.245.80
C B
A C B A
BINARY OUTPUTS
McQuay
RECIPROCATING CHI LLER CONTROL
SETPOIN T
RESET
CON TROL BAND
COOL 6
COOL 5
COOL 4
COOL 3
COOL 2
COOL 1
C B A C B A
C B A C B A
C B A C B
A
8.95
9.23
0.89
14.90
= mounting holes
5.16
2.23
0.74
2.17
2.77
0.25
Page 7
Electrical Data
Sensor for Outdoor, Return Water, or Zone Temperature Reset options are connected to AI-1 and AI-CM.
Figure 3, Wiring Diagram
Note: See Additional Features on page 11 for explanation.
DEMAND LIMIT*
(1)
(2)
0-10 VDC
LEAVING
WATER SENSOR
SHUTDOWN*
COMP LEAD/LAG*
ICE MODE*
FLOW INTERLOCK
Indicates
*
optional feature.
24VAC
(+)
AI CM
25
26
528
529
(-)
AI CM AI CM AI CM AI CM
AI CM
+15VDC
24VAC 24VAC
24VAC 24VAC
24 C OM Z
VAC B U S
P5 P6
AI1 AI2 AI3
AI4 AI5
AI6
+15VDC
BI1 BI2
BI3 BI4
ANALOG INPUTS BINARY IN
DS
REF N 2 N 2
18
28
512/518
519
- +
P4
(1) (2) Field connections must be made between TB3-18 and BI-4 for unit to operate.
NNotes:
1. Sensor for Outdoor, Return Water, or Zone Temperature Reset options are connected to Al-1 and Al-CM.
2. Field connections must be made between TB3-18 and Bl-4 for unit to operate.
3. If a time clock is desired, it should be installed between 24 VAC and Bl1. The time clock switch should be installed as follows: Open to Run and Close to Stop.
Figure 4, Stage Relay Configuration
M cQuay
C ONT ROL BA ND
S ET PO I NT
RE SET
RECIPROCATING CHILLER CONT ROL
COO L 6
COO L 5
COO L 4
COO L 3
COO L 2
COO L 1
C
B
A
C B
A
C
B
A
C
B A
C
B A
C
B A
C
B
A
Stage Relays
COM
NC
NO
Note: Refer to Unit Wiring
Diagram for Stage Wiring.
Page 8
Table 6, Wiring Location Cross Reference
Lead #
512 TB3-18 to TB3-29 (4,6,8 Stages) Not Needed (See Note 1 and 2) 518 TB3-29 to "TR" " TB3-18 to 24 VAC 519 "TR" " Common 522 Ground " Not Needed 524 "7" " Not Needed (See Note 3) 525 TB3-23 to TB3-24 " Not Needed 526 "6" " Not Needed (See Note 3) 527 "P" to "P1" " Not Needed or Zone Terminal Adjust
528 "T" "
529 "T1" "
400 OHM Resister "7" to "8" 4 Stages 600 OHM Resister "7" to "8" 6 Stages See Table 5 800 OHM Resister "7" to "8" 8 Stages
523 Ground 8 Stages Not Needed 535 "1" " Not Needed 536 "2" " Not Needed 537 "3" " Not Needed 538 "4" " Not Needed 539 "5" " Not Needed
Note 1: To install Flow Switch Contacts, connect between TB3-18 and UNT BI-4. Note 2: To install Time Clock Contacts, connect between TB3-18 and UNT BI-1. Note 3: The options are as follows. (Option A is standard; options B, C, and D require field download. See "Features Requiring
Configuration and/or Field Adjustment" section for more information): A. The standard is Demand Limit Input. 0-10VDC signal is required. Connect leads to AI-1 and AI-CM on the
controller.
B. Johnson Controls Outdoor Air Sensor if Outdoor Air Reset is used. C. Johnson Controls Zone Temperature Sensor if Zone Temperature Reset is used. D. Johnson Controls Return Water Sensor if Return Water Reset is used.
Honeywell (H/W)
W7100G
Stages
AI-3 (JCI or H/W Leaving Water Sensor. See
Johnson Controls (JCI)
AS-UNT33n-1
appropriate sensor section)
AI-CM (JCI or H/W Leaving Water Sensor.
See appropriate sensor section)
Page 9
Operation
AS-UNT33n-1
LEAVING
WATER
CONTROL
COOLER
ZONE
TEMPERATURE
OR
OUTDOOR AIR
RESET
(optional)
PUMP
RETURN
WATER SENSOR
(optional)
LEAVING
WATER
SENSOR
COOLING LOAD
RETURN
WATER
LEAVING
WATER
Chiller System
Figure 5, Chiller System
Chiller systems are used to provide cold water for comfort cooling or process applications. Control of the compressor operation to supply that chilled water may be initiated by sensing return water temperature or leaving water temperature. If precise control of leaving water temperature is desired a AS­UNT33n-1 controller is recommended.
LEAVING WATER TEMPERATURE CONTROL OPERATION
Leaving water temperature will be controlled to the actual leaving water setpoint. The actual leaving water setpoint will be a function of what mode of operation the controller is in and if a reset option is used. The Control Band potentiometer located on the front of the controller is used to determine the Actual Leaving Dead Band and Prop Band.
Actual Leaving Dead Band: Control Band (AI6)/2.
Actual Leaving Prop Band: Dead Band * Number of Stages.
Example:
Control Band = 4 Deg F Number of Stages = 6 Dead Band = 4/2 = 2 Deg F Prop Band = 2 * 6 = 12 Deg F
As the leaving water temperature rises above the actual leaving water setpoint, but within the leaving dead band, there will be no increase in the Compressor Command. As the leaving water temperature continues to rise above the Dead Band and into the Prop Band, the Compressor Command will be increased. When Leaving Integration Gain is used, a Proportional Plus Integral command will be calculated. As the Compressor Command increases, stages of cooling capacity will be energized. Minimum on, off, interstage times, and cycles per hour attributes will control the stages.
As the leaving water temperature decreases towards the actual leaving water setpoint, the Compressor Command will be decreased. Upon reentering the Dead Band, the current Compressor Command will be maintained. If the Leaving Water Temperature falls below the Actual Leaving Water Setpoint (using the same Dead Band), the Compressor Command will again start to decrease.
Figure 6, Leaving Water Control Algorithm Operation
57
PB
47
45
43
LWSP
DB
DB
Control Band
Page 10
The "Control Band" is the non-staging area of the control. Anytime the Leaving Water Temperature is outside of the Control Band limits, staging will occur. Anytime the Leaving Water Temperature is within the Control Band limits, no staging occurs. As shown in Figure 6, with a 45°F Setpoint and a 4°F Control Band setting, stages of cooling energize when the Leaving Water is 47°F or higher. Stages de-energize when the Leaving Water is 43°F or lower (4°F difference). All stages will remain in their current state between 43°F and 47°F.
AS-UNT33n-1 LED OPERATION
The AS-UNT33n-1 has one LED for each staged output. The LED on the AS-UNT33n-1 will light simultaneously as that stage relay energizes. If the LED is not lit, the stage is not energized. When a stage relay energizes, the normally closed contacts open, and the normally open contacts close.
JOHNSON CONTROLS LEAVING WATER SENSOR
Note: Johnson Controls or Honeywell Leaving Water Sensors may be used with the AS-UNT33n-1. Refer to Table 4, page 4. A description of the Honeywell sensor follows the description of the Johnson Controls sensor. Accuracy can be determined by measuring sensor resistance and making a comparison to the temperature and resistance chart. The thin-film nickel sensor has a reference resistance of 1000 ohms at 70°F (21°C) and a change in resistance of approximately 3 ohms/ °F (5 ohms/°C). See Table 7 for resistance values at selected temperatures.
Table 7, Johnson Controls Leaving Water Sensor, TE-6300-300
Temperature Resistance (Ohms) Temperature Resistance (Ohms)
°° F °° C Nickel °° F °° C Nickel
0 -18 803 70 21 1000 10 -12 830 80 27 1030 20 -7 858 90 32 1060 30 -1 885 100 38 1090 40 4 914 110 43 1121 50 10 942 120 49 1152 60 16 971
HONEYWELL LEAVING WATER SENSOR
The C7173A and C7170A are sensors for use in applications requiring a broad temperature sensing range. Unlike thermistors, the C7173A and C7170A have a positive temperature coefficient (PTC); resistance increases as the temperature increases. As shown in Table 8, the resistance curve increases by 4.8 ohms per degree F temperature rise [8.6 ohms/C].
Resistance in the sensor wiring positively offsets the temperature sensed by 1 degree F every 4.8 ohms [8.6 ohms/C] of resistance. Use short wire lengths or larger gauge wire when longer lengths are necessary.
With an accurate thermometer (+/-l°F [.5°C]), measure the fluid temperature at the sensor location, allowing time for the thermometer to stabilize before reading. Use an ohmmeter to measure the resistance across the sensor wires. Then verify sensor accuracy with the temperature/resistance values in Table 8.
Table 8, Honeywell Temperature/Resistance Table for C7173A, Leaving Water Sensor
TEMP
°° F
23 3224.8 32 3268.0 41 3311.2 50 3354.4 59 3397.6 68 3440.8 77 3484.0 86 3527.2 24 3229.6 33 3272.8 42 3316.0 51 3359.2 60 3402.4 69 3445.6 78 3488.8 87 3532.0 25 3234.4 34 3277.6 43 3320.8 52 3364.0 61 3407.2 70 3450.4 79 3493.6 88 3536.8 26 3239.2 35 3282.4 44 3325.6 53 3368.8 62 3412.0 71 3455.2 80 3498.4 89 3541.6 27 3244.0 36 3287.2 45 3330.4 54 3373.6 63 3416.8 72 3460.0 81 3503.2 90 3546.4 28 3248.8 37 3292.0 46 3335.2 55 3378.4 64 3421.6 73 3464.8 82 3508.0 91 3551.2 29 3253.6 38 3296.8 47 3340.0 56 3383.2 65 3426.4 74 3469.3 83 3512.8 92 3556.0 30 3258.4 39 3301.6 48 3344.8 57 3388.0 66 3431.2 75 3474.4 84 3517.6 93 3560.8 31 3263.2 40 3306.4 49 3349.6 58 3392.8 67 3436.0 76 3479.2 85 3522.4 94 3565.6
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
TEMP
°° F
OHMS
Page 11
Additional Features
The following features are also included with the controller algorithm operation. Where there is a point number specified after the feature name (e.g., AI3), a sensor or contact closure input is required.
LEAVING WATER LOW LIMIT
If the Leaving Water sensor reads a reliable value below an adjustable Leaving Water Low Limit (LWLL) for more than 3 seconds, the compressor command will be forced to 0% immediately. Once the Leaving Water Temperature rises above the LWLL by a LWLL Differential (LWLLD), a normal control sequence will be initiated. Default values are 15°F for the LWLL and 5°F for the LWLLD. Leaving Water Low Limit will effect compressor commands only.
The default value for the Leaving Low Limit and Differential is adjustable through the Zone Terminal, HVAC PRO Software, or Johnson Controls Facility Management System.
DEMAND LIMIT INPUT - ANALOG INPUT (AI1)
Demand Limit Input will effect the control strategy as follows. This AI will inversely limit the Compressor Command for external demand limiting control strategies. As the input goes from 0 - 10 VDC, the Compressor Command will be proportionally limited from 100% to 0%. For example, if the Demand Limit Input is 5 VDC, the Compressor Command cannot exceed 50%, if 8 VDC is present, the maximum Compressor Commands will be 20% and so on. The Demand Limiting function can operate when the control is in the Occupied mode only. Demand Limiting will not occur while in the Ice Mode.
CAUTION: For the Demand Limit Input feature, use only 0-10 VDC input. COOLING DIAGNOSTICS
The Leaving Water Temperature sensor will be used to determine a drop in Leaving Water Temperature over time whenever a stage is energized. When a stage is energized, if the Leaving Water Temperature does not drop by 1°F in five minutes, this is considered a Cooling "Stage Failure." This failure point can be monitored with the use of a Zone Terminal or Johnson Controls Facility Management System. Once a Failure has occurred for a particular stage, the alarm can only be cleared by producing the change in temperature over time or by cycling power.
SHUTDOWN MODE (BI-1)
When shutdown mode is enabled, all stages will be de-energized.
COMPRESSOR LEAD/LAG CONTROL (BI2)
If Lead/Lag Control is desired, a BI (Binary Input) point can be configured to initiate the mode of operation. When BI2 is open, circuit 1 is the lead. When BI2 is closed, circuit 2 is the lead. The lead circuit will not change unless all stages are off.
ICE MODE (BI3)
When Ice Mode is enabled, the controller will control Leaving Water Temperature to Ice Mode Setpoint (default is 23°F). This mode can be enabled or disabled through a BI (Binary Input) hardware point.
When Ice Mode is enabled, the current Leaving Water Temperature will be compared to the Ice Mode Setpoint. If it is above the Setpoint, the Compressor Command will be forced to 100%. When the Leaving Water Temperature drops below the Ice Mode Setpoint, the Compressor Command will be forced to 0%. These are the only two levels of Compressor Command during Ice Mode. Once the Compressor Command has fallen to 0% or the Ice Mode is de-activated, the control will return to the Chiller On or Shutdown Mode. The control will not cycle to maintain an Ice Mode Setpoint. Whatever triggered Ice Mode must be released before Ice Mode can be triggered again.
The default value for the Ice Mode Setpoint is adjustable through the Zone Terminal, HVAC PRO Software, or Johnson Controls Facility Management System.
Page 12
FLOW INTERLOCK INPUT (BI4)
After a transition from Shutdown Mode or Restart Delay the controller will wait 10 seconds for a verification of Pump Status. If Pump Status is verified during this time, normal control will occur. If Pump Status is not verified, a "Pump Failure" point will be initiated.
If Pump Status had previously been verified, and then is lost for a period of three seconds, the Compressor Commands will be forced to zero. If Pump Status is lost for a period of 10 seconds (Pump Status Delay Timer), the Pump Failure Alarm will be initiated. Once Pump Status is again verified, normal control will occur and the Alarm will be cleared.
Settings and Adjustments
SETPOINT KNOB
HVAC Applications-Typical Setpoints for HVAC applications range from 42°F to 50°F [5°C to 10°C]. These Setpoints may change due to many factors, including desired space temperature, required/desired humidity conditions, etc.
CONTROL BAND KNOB
Set for the desired Control Band in accordance with the following formula. Increasing the Control Band slows down the response of the AS-UNT33n-1, and increases the temperature deviation. Lowering the Control Band speeds up the response of the AS-UNT33n-1, while decreasing the temperature deviation from Setpoint.
The Control Band Setpoint should be as narrow as possible without causing hunting or rapid cycling. If instability, hunting or rapid cycling occurs, widen the Control Band Setpoint. McQuay International recommends the following formula for calculating the minimum Control Band Setpoint:
Temperature drop across vessel (T) at full load/number of stages + .5°F. Example: 10°FT/4 stages of cooling +.5°F = 3°F Control Band.
RESET KNOB
This adjustment adds to the Leaving Water Setpoint, when the control is factory downloaded to incorporate an Outdoor Air, Zone Temperature, or Return Water Reset function. The standard application does not include reset; therefore, this Setpoint is disregarded in the algorithm.
Page 13
System Checkout and Troubleshooting
LWR
B
LWSPOALLOAHLOAR
B
(OALL=OAHL-OARB
)
Equipment needed:
1. Digital Voltmeter 2. Resistor Harness (AS-KIT100-0) included with controller
Table 9, Troubleshooting
Step Action Verification
1 Disconnect power to AS-UNT33n-1. 2 Disconnect compressor and unloader line voltage power. Check for 0 VAC at compressor and unloader contactors or
3 Remove Fast-On for Control Band input from AI6 and
connect resistors as shown.
relays.
AI CM
AI6
+15VDC
4
Set Setpoint knob on AS-UNT33n-1 to 10oF (-12oC). 5 Turn 24 VAC power on to the AS-UNT33n-1. Check for 24 VAC power at AS-UNT33n-1 6 After approximately 70 seconds, all stages will be
7 8 All stages should now be turned off quickly in a
9 Remove power from AS-UNT33n-1 terminals. Check for 0 VAC at compressor and unloader contactors or
10 Reconnect all wiring as originally installed. 11 Reconnect AS-UNT33n-1 power supply, close
energized quickly in an ascending order.
Move Setpoint to 60oF (16oC).
descending order.
compressor disconnects and place Setpoints as desired.
All LED's should be ON. The number of stage LED's illuminated
should correspond to the control model number. If there is a
discrepancy, the stage selection DIP switch (AI2) should be
checked for proper settings. Refer to page 2, Figure 1, Table 5.
All LED's should be OFF.
relays.
System is now operational.
FEATURES REQUIRING FACTORY CONFIGURATION AND/OR FIELD ADJUSTMENT
RESET OPTIONS
One of the following three reset options can be selected: Outdoor Air Reset, Zone Temperature Reset, and Return Water Reset. The reset options described below operate on identical strategies. The main differences are Setpoints and sensor locations.
Leaving Water Setpoint and Leaving Water Reset Band are adjusted using the Setpoint adjustment knobs on the front of the AS-UNT33n-1.
Outdoor Air, Zone Temperature, and Return Water High Limits and their respective Reset Bands are values that can be adjusted by use of a Zone Terminal, HVAC PRO Software, or Johnson Controls Facility Management System.
Ramping Strategy
Figure 7, Outdoor Air Reset
Page 14
This ramping strategy applies to all three reset options. When a reset function is used, a Ramping of
sensor
sensor
sensor
sensor
sensor
sensor
sensor
sensor
sensor
Nine sensors wired in
a series/parallel
arrangement for large
areas.
AI1
AI1 COM
the Compressor Command is also used. Two adjustable variables setup the ramp as needed. These are Ramp Output and Ramp Time.
The Ramp is used to meter the Proportional Command into the Sequencer when conditions don't require a quick startup of all stages. For example, if the Outdoor Air Temperature (OAT) is at Outdoor Air Low Limit (OALL), with OALL being equal to Outdoor Air High Limit minus Outdoor Air Reset Band (OAHL - OARB), the stages do not need to be energized as quickly as they do if the OAT is at the Outdoor Air High Limit (OAHL). When the OAT is at OAHL, the Proportional Command is fed to the Sequencer at the same rate as it is calculated. But if the OAT drops below the OAHL, the Proportional Command is ramped to the Sequencer. This allows for a slower startup of stages.
OUTDOOR AIR RESET
When this option is chosen, an Outdoor Air Temperature (OAT) sensor (AI1) is required. Four variables are used to setup the reset ramp that calculates the Actual Leaving Water Setpoint.
These are: Leaving Water Setpoint (AI4), Leaving Reset Band (AI5), Outdoor Air High Limit (OAHL), and Outdoor Air Reset Band (OARB).
As the OAT increases above the Outdoor Air Low Limit (OALL), the Actual Leaving Water Setpoint is decreased from its Leaving High Limit (Leaving Water Setpoint plus Leaving Reset Band) to the Leaving Water Setpoint. When OAT reaches the OAHL, the Actual Leaving Water Setpoint equals the Leaving Water Setpoint (AI4). If the OAT sensor is missing or unreliable, no reset occurs and the Actual Leaving Water Setpoint equals the Leaving Water Setpoint. If the Leaving Water Sensor (AI3) becomes unreliable, the compressor command is forced to 0%.
Outdoor Temperature Lockout: If an Outdoor Air Temperature sensor is installed and reliable, the shutdown mode is initiated whenever it senses, for more than five minutes, an input below the adjustable Outdoor Temperature Lockout (OTL) Setpoint (45°F).
The default value for this Setpoint is adjustable through the Zone Terminal, HVAC PRO Software, or Johnson Controls Facility Management System.
ZONE TEMPERATURE RESET
When this option is chosen, a Zone Temperature must be made available to the controller. There are two ways to do this. The first is through an adjustable Analog Data Float (ADF) point. With the use of a Johnson Controls Facility Management System, a Zone Temperature or average of multiple Zone Temperatures can be shared with the controller through the ADF point. The second is through a Zone Temperature Sensor connected directly to the controller. Regardless of which method is used, the control strategy is the same.
Four variables are used to setup the reset ramp that calculates the Actual Leaving
Figure 8, Average Zone Temp. Using TE-6410S-2000 Sensors
Water Setpoint. These are: Leaving Water Setpoint (AI4), Leaving Reset Band (AI5), Zone Temperature High Limit (ZTHL), and Zone Temperature Reset Band (ZTRB).
As the Zone Temperature increases above the Zone Temperature Low Limit (ZTLL), the controller decreases the Actual Leaving Water Setpoint from its Leaving High Limit (Leaving Water Setpoint plus Leaving Reset Band) to the Leaving Water Setpoint. When the Zone Temperature reaches the ZTHL, the Actual Leaving Water Setpoint equals the Leaving Water Setpoint (AI4).
Page 15
Figure 9, Zone Temperature Reset
(RWLL=RWHL-RWRB
)
If the Zone Temperature sensor is missing or unreliable, or if there is an unreliable Zone Temperature value at the Analog Data Float (ADF) point, no reset occurs and the Actual Leaving
LWRB
Water Setpoint equals the Leaving Water Setpoint. If the Leaving Water Sensor (AI3) becomes unreliable, the compressor command is forced to 0%.
(ZTLL=ZTHL -Z TRB)
LWSP
ZTLL ZTHL
ZTRB
RETURN WATER RESET
When this option is chosen, a Return Water Temperature (RWT) sensor (AI1) is required. Four variables are used to setup the reset ramp that calculates the Actual Leaving Water Setpoint. These are: Leaving Water Setpoint (AI4), Leaving Reset Band (AI5), Return Water High Limit (RWHL), and Return Water Reset Band (RWRB).
As the RWT increases above the Return Water Low Limit (RWLL), the
Figure 10, Return Water Reset
controller decreases the Actual Leaving Water Setpoint from its Leaving High Limit (Leaving Water Setpoint plus Leaving Reset Band) to the Leaving Water Setpoint. When RWT reaches
LWRB
the RWHL, the Actual Leaving Water Setpoint equals the Leaving Water Setpoint (AI4). If the RWT sensor is missing or unreliable, no reset occurs and the Actual Leaving Water Setpoint equals the Leaving Water Setpoint. If
LWSP
RWLL RWHL
RWRB
the Leaving Water Sensor (AI3) becomes unreliable, the compressor command is forced to 0%. When Return Water Reset is chosen, a Fail Smart Logic option is also available. This option works as
follows. If the Leaving Water Sensor (AI3) becomes unreliable, the controller switches from Leaving Water control to Return Water control. Actual Return Water Setpoint equals Leaving Water Setpoint (AI4) plus an adjustable Leaving Water Setpoint Offset. This value takes into account the temperature differential between Leaving and Return water temperatures, which is typically about 10°F. If both the Leaving and Return water sensors are unreliable, the compressor is forced to 0%.
Page 16
Zone Terminal User's Guide
This user's guide contains step-by­step instructions for using the Zone Terminal (AS-ZTU330-1) on a McQuay Reciprocating Chiller (AS­UNT33n-1).
This guide assumes you are familiar with the McQuay Reciprocating Chiller. This guide contains examples of the Zone Terminal (ZT) screen that is standard with the ZT accessory to the McQuay Reciprocating Chiller.
USER'S GUIDE ORGANIZATION
Three major sections describe how to use the Zone Terminal.
Introduction and Overview:
Explains in general terms the features and operating modes of the Zone Terminal.
Getting Started: Includes an explanation of the Keys, Displays, and Symbols on the Zone Terminal. Also includes an explanation of the Zone Terminal labels and how to install them. In addition, this section instructs the user about handling Alarm Status and connecting the Zone Terminal.
Making ZT Adjustments: Includes specific instructions for making set point adjustments with the Zone Terminal.
OVERVIEW OF THE ZONE TERMINAL
The Zone Terminal (ZT) is a hand-held or wall-mounted device that monitors and adjusts your McQuay Reciprocating Chiller information.
A standard telephone-style jack connects the ZT to the McQuay Reciprocating Chiller controller directly or through the TE-6410S-2000 Zone Temperature Sensor.
Features
The ZT provides:
Portability
Simultaneous monitoring of three different settings or values
Easy operation with only seven buttons
Flashing numbers to show which items are ZT adjustable
Flashing symbols to notify you of alarm conditions
Capabilities
With the ZT, you can:
Quickly identify a chiller alarm and its location
Monitor and adjust up to 18 different settings
To familiarize yourself with the ZT, refer to Figure 12.
Page 17
Figure 11, Zone Terminal Template (See Glossary for Definitions)
Disp lay Item List Warning Signal
Displa y Button
1
2
3
Mode Selector
Button M ode Selector Panel
Displa y Indicator Do t
Lvg Water Temp
Demand L imit Lvg Reset Band Lvg Cntrl Band
Lvg Dead Band Lvg Prop Band
Lv g Setp oint
Lvg Low L imit
Low Limit Di ff
Fa ilsoft Set pt
Comp Com mand Ice Mode S etpt Cool Diag Time Cool Diag Temp
Oper at ing Mode Indicat or
MONITOR ADJUST TIME SCHEDULE
PASSWORD
ENTER
McQuay Chiller with Demand Limit ON OFF INSERT 12
R amp Ou tput
Ramp Time
Up/Down Arrow Keys
Door
Disp lay A rea 1 1
Disp lay Ar ea 2 1
Disp lay Ar ea 3 1
On/Off Status
Chiller Off Cht 2 Lead Stage 1 Fail Stage 1 Stage 2
Fail Stage 2
Stage 3
Fail Stage 3 Stage 4
Fail Stage 4 Stage 5 Fail Stage 5
Stage 6 Fail Stage 6 Stage 7 Fail Stage 7 Stage 8 Fail Stage 8
ALARM
Alarm Light
OPERATING MODES
Two operating modes are included: Monitor and Adjust.
Monitor Mode
As soon as the ZT is connected, it completes a self-check, and starts up in the Monitor Mode. Monitor Mode lets you view up to three of chiller settings/sensed values at a time.
To allow you to monitor your system, a clear plastic Insert (factory made and installed) relates the ZT’s output to your McQuay Reciprocating Chiller system.
You can simultaneously monitor the chiller in three ways:
Monitor up to three settings/sensed values. A maximum of six items are accessible in each of the three
displays.
Read the symbols to the right of the display numbers to learn the on/off status of various inputs, outputs,
or modes (| = On status; m = Off status). This provides continuous monitoring of 18 different statuses (on/off).
Monitor alarm status–a flashing red alarm light and any flashing symbol ( |, m, s) visually notifies you
when your chiller has an alarm condition.
Adjust Mode
In Adjust Mode, the ZT displays information in each of the three numerical displays. Typically, the displays are set up so that the relationship between the values can be viewed simultaneously. For example:
Page 18
Table 10, Displays, Symbols, Keys, and Buttons
DISPLAYS, SYMBOLS, KEYS,
DESCRIPTION
BUTTONS
Display Button 1, 2, 3
Enter Key
Flashing Numbers
Flashing
ss , mm , ( | )
Mode Selector Button
On/Off Status Symbols( | ) for On/a circle ( mm ) for Off
Red Alarm Light
Up ( ↑↑) or Down (↓↓) Arrow Keys
ll
Select the value you want to monitor or adjust.
Use to commit your changes. Adjustments are not processed unless you press Enter.
Appear in Display 1, 2, or 3 to indicate numbers you can adjust. Numbers that do not flash are monitor only numbers.
Shows an item is in alarm. Press this button to select Operating
Modes: Monitor, Adjust, Password, Time Scheduling. A green Mode Indicator light moves through the modes.
Observe On/Off conditions of a point in the HVAC controller with these symbols. A bar (| ) for On, a circle (m) for Off. These are always monitor only items. If the symbol flashes, item is in alarm.
Flashes anytime a problem exists regardless of which Operating Mode you have entered.
Use these keys to adjust a flashing number.
Appears in the displays, and corresponds to the item you are monitoring or adjusting.
Display 1 = Lvg Water Temp Display 2 = Lvg Setpoint Display 3 = Comp Command This operating mode allows you to adjust
any flashing setpoints. Setpoints adjusted by the ZT remain in effect until you change them
GETTING STARTED
DISPLAYS, SYMBOLS, KEYS, AND BUTTONS
The Zone Terminal simultaneously displays three set points or sensed values. In addition, flashing symbols indicate when items are in a state of alarm. The keys, buttons, displays, and symbols are explained below.
Figure 12, Installing the Insert
Note: The insert is normally factory­installed. These steps are required only if the insert is not already installed.
To use the ZT, you'll need the plastic label which is included with your ZT.
Insert
The clear plastic Insert is a custom-made label unique to your chiller. Use this Insert when monitoring or adjusting specific items of your system:
1. With the ZT on a flat surface, press the white tab with your index finger (Fig. 12).
2. Pull the front cover of the ZT away from the back and slide the Insert into position.
3. Press the ZT together. With the Insert in place and the ZT connected, the l in the top position of each display lines up with the first word.
Page 19
CONNECTING THE ZONE TERMINAL
You can wall-mount the ZT, or use it as a portable tool for convenient access to any chiller information.
Figure 13, Connecting ZT to a Reciprocating Chiller Controller Using 6 to 8 Pin Cable
6 Pin Connection
ALARM STATUS
The ZT indicates an alarm as follows (see Figure 12):
McQuay Reciprocating Controller Connection
A standard telephone-style jack connects the ZT to a McQuay Chiller Controller directly or through a TE­6410S-2000 sensor.
AS-UNT3 30-1
+15VD C
CO M MO N
B I N A R Y I NA N A L OG I NP U TS
BI N A R Y COM
BIN ARY INA NALOG INPUTS
1 2 3 4 5 6 1 2 3 4
A N A LOG I N P UT S
Connection
8 Pin
BINARY OUTPUT
CO M
1 2 3 4 5 6 7 8
TO
ZONE
P W R
STAT
I N
24 V
24 V A C TO L OA D S
A C
BIN ARY OUTPUTS
Connect ZT
here.
1 2 3 4 5 6 7 8
OFF
Figure 14, Connecting ZT to a TE-6410S-2000 (METASTAT) Sensor Using Coiled 6 to 6 Pin Cable
The warning signal (s) flashes to the
right of the Display Indicator dot ( l ) if the system operating values are in alarm.
The On/Off Status bar ( | ) or circle
(m) flashes when an On/Off status is in alarm.
The red alarm light to the right of the
Mode Selector Panel flashes when any of the above items are in alarm.
Alarms cannot be cleared with the ZT. The problem must be corrected by maintenance or repair of the affected item.
Connect ZT
here.
Open cover.
Page 20
MAKING ZONE TERMINAL ADJUSTMENTS
Adjusting Control Settings
You can adjust only a flashing number with the ZT. If the number does not flash, that item is a monitor only item. Adjust Control Settings in Display 1, 2, or 3 as follows:
1. Press the Mode Selector Button until the green Mode Indicator Light moves next to the word Adjust.
2. Press either Display Button 1, 2, or 3 to locate adjustable items, which are indicated by flashing numbers. If you continue pressing the display buttons, the dot ( l ) in each display changes positions and the
corresponding number appears.
3. Press the Up ( - ) or Down ( ¯ ) Arrow key until you reach the number you want to enter. If you hold down the Up ( - ) or Down ( ¯ ) Arrow keys, you can speed through the numbers more quickly.
Press Enter. After you press Enter, the numbers stop flashing for a few seconds. This pause tells you the ZT has processed your adjustment.
4. Press any of the Display Buttons to make other adjustments, and repeat Steps 2 and 3.
Note: Some adjustable set points have high and low limits beyond which you cannot adjust them. Adjustable Points
The following McQuay Reciprocating Chiller points are adjustable by the Zone Terminal.
Table 11, Adjustable points
FULL POINT NAME TEMPLATE NAME
Leaving Low Limit Lvg Low Limit
Low Limit Differential Low Limit Diff
Ice Mode Setpoint Ice Mode Setpt
Failsoft Setpoint Failsoft Setpt
Cool Diagnostic Time Cool Diag Time
Cool Diagnostic Temperature Cool Diag Temp
Note: Refer to the Glossary (next section) for definitions
Page 21
Zone Terminal Glossary
Chiller Off
A "|" indicates the chiller is in Shutdown Mode.
Ckt 2 Lead
A "|" indicates circuit 2 is lead circuit.
Comp Command
The Compressor Command is the percent of Chiller capacity that is required.
Cool Diag Time/Temp
When a compressor stage is started, the controller must sense the Leaving Water Temperature change (Cool Diag Temp) within a time span (Cool Diag Time) or a Full Stage Alarm will occur.
Demand Limit
The percentage by which the maximum Compressor Command of 100% is reduced.
Failsoft Setpt
If the adjustable Leaving Water Setpoint setting ion the face of the controller fails, the failsoft setpoint is the value the Leaving Water Setpoint defaults to.
Fail Stage n
A "|" indicates a possible fault condition exists.
Ice Mode Setpt
The Leaving Water Temperature at which Ice Mode operation is concluded.
Low Limit Diff
The amount the Leaving Water Temperature has to increase above the Leaving Water Low Limit to allow compressors to restart.
Lvg Cntrl Band
The Leaving Water Control Band is centered around the Leaving Water Setpoint. When the Leaving Water Temperature is within the Leaving Water Control Band, stages will not be energized or de-energized.
Lvg Dead Band
The Leaving Water Dead Band is one half of the Leaving Water Control Band.
Lvg Low Limit
When Leaving Water reaches the Leaving Water Low Limit, the Compressor Command will be forced to 0%.
Lvg Prop Band
The Leaving Water Proportional Band is the Leaving Water Dead Band multiplied by the number of stages.
Lvg Reset Band
When reset functions are used, the Leaving Water Reset Band is the amount the Leaving Water Setpoint is automatically increased. The Leaving Water Reset Band adjustment can be found on the face of the controller.
Lvg Setpoint
The Leaving Water Temperature setting by which the controller will control to. The Leaving Water Setpoint adjustment can be found on the face of the controller.
Lvg Water Temp
The temperature of the leaving water from a McQuay Reciprocating Chiller.
Ramp Output/Time
Ramp Output and Time are used to determine softstart. They define the percentage rate of increase for the Compressor Command.
Stage n
A "|" indicates stage is energized.
Page 22
Page 23
Page 24
P.O. Box 2510, Staunton, Virginia 24402 USA (800) 432-1342 www.mcquay.com
Loading...