McQuay AWS 150A Installation Manual

Operating & Maintenance Manual

Group: Chiller

Part Number: 10000199900

Date: Sept 2010

Supercedes: July 2010

OM 1051-2

Pathfinder™ Air-Cooled Chillers

AWS 150A through AWS 530A (Includes Optional Compressor VFD Models)

50/60 Hertz,

R-134a

Software Version: 2507500205

Table of Contents

INTRODUCTION ........................................................3

OPERATING LIMITS: ...............................................4

CONOMIZER CONTROL

IQUID INJECTION

IQUID LINE SOLENOID VALVE

APACITY OVERRIDES – LIMITS OF OPERATION

........................................... 42

.................................................... 42

............................... 43

...... 43

CONTROLLER FEATURES .....................................4

GENERAL DESCRIPTION........................................5

ONTROL PANEL LAYOUT

OWER PANEL LAYOUT

CONOMIZER COMPONENTS

CONTROLLER DESCRIPTION ...............................9

ARDWARE STRUCTURE

YSTEM ARCHITECTURE

SEQUENCE OF OPERATION ................................11

CONTROLLER OPERATION.................................15

ETPOINTS

UNIT FUNCTIONS....................................................22

ALCULATIONS

NIT AVAILABILITY

NIT MODE SELECTION

NIT CONTROL STATES

NIT STATUS

CE MODE START DELAY

VAPORATOR PUMP CONTROL

OISE REDUCTION

EAVING WATER TEMPERATURE

NIT CAPACITY CONTROL

NIT CAPACITY OVERRIDES

CIRCUIT FUNCTIONS ............................................34

................................................................18

.........................................................22

............................................................24

....................................................25

..........................................5

..............................................6

.......................................7

.............................................9

...........................................10

.................................................22

............................................23

..........................................24

.................................25

(LWT) R

........................................28

.....................................30

ESET

.......26

ALARMS AND EVENTS ......................................... 44

IGNALING ALARMS

LEARING ALARMS/FAULTS

ESCRIPTION OF ALARMS

LARM LISTING

NIT FAULTS

NIT WARNINGS

IRCUIT FAULTS

IRCUIT PROBLEMS

LARM LOGGING

VENT LOG

.............................................................. 55

................................................ 44

.................................... 44

........................................ 45

....................................................... 45

........................................................... 47

...................................................... 48

...................................................... 49

................................................. 54

..................................................... 55

USING THE CONTROLLER.................................. 56

AVIGATING

OPTIONAL REMOTE USER INTERFACE ......... 61

............................................................ 57

OPTIONAL COMPRESSOR VFD.......................... 63

AULTS AND MINOR FAULTS/ALARMS

LEARING

AVIGATING

OPTIONAL POWER FACTOR CORRECTION

CAPACITORS........................................................... 67

START-UP AND SHUTDOWN ............................... 68

EMPORARY SHUTDOWN

XTENDED (SEASONAL) SHUTDOWN

FIELD WIRING DIAGRAM ................................... 71

VFD F

AULTS

.......................................... 63

AULT CODES

......................................... 68

.................... 63

............................ 63

....................... 69

ALCULATIONS

IRCUIT CONTROL LOGIC

IRCUIT STATUS

OMPRESSOR CONTROL

ONDENSER FAN CONTROL

AN CONTROL WITHOUT

AN CONTROL WITH

EXV C

ONTROL

.........................................................34

.........................................35

.......................................................36

............................................37

......................................38

VFD ..................................38

VFD.........................................40

.........................................................40

Modbus

Manufactured in an ISO Certified Facility

SYSTEM MAINTENANCE ..................................... 73

REVENTATIVE MAINTENANCE SCHEDULE

APPENDIX ................................................................ 78

EFINITIONS

............................................................ 78

.............. 77

Unit controllers are LONM

optional LONW

ORKS

ARK

certified with an

communications module

2010 McQuay International. Information covers the McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice.  The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONM from McQuay International; Excel from Microsoft Corp.

2 OM 1051-2

ARK and LONWORKS

from Echelon Corporation; McQuay, MicroTech III, Guardister, and Open Choice

Introduction

This manual provides setup, operating, troubleshooting and maintenance information for the Daiken McQuay Pathfinder chillers.

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

Warnings indicate potentially hazardous situations, which can result in property damage, severe

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment

Software Version:

The unit software and BSP (Board Support Package) versions can be viewed using the keypad/display. From the Main Menu, turn the knob to the right until you reach the About Chiller menu and press Enter (the knob). The software version is displayed as "App Version =". Scroll down in this menu (turn knob to the right), the BSP version will also be displayed ("BSP Version=").

AZARD IDENTIFICATION INFORMATION

DANGER

WARNING

personal injury, or death if not avoided.

CAUTION

damage if not avoided.

• App Version 2507500205 for units with or without the optional compressor VFDs

WARNING

Electric shock hazard: can cause personal injury or equipment damage. This equipment must be properly grounded. Connections to, and service of, the MicroTech III control panel must be performed only by personnel who are knowledgeable in the operation of this equipment .

CAUTION

Static sensitive components. A static discharge while handling electronic circuit boards can cause damage to the components. Discharge any static electrical charge by touching the bare metal inside the control panel before performing any service work. Never unplug any cables, circuit board terminal blocks, or power plugs while power is applied to the panel.

NOTICE

This equipment generates, uses, and can radiate radio frequency energy and, if not

installed and used in accordance with this instruction manual, can cause interference to

radio communications. Operation of this equipment in a residential area can cause

harmful interference, in which case the user will be required to correct the interference at

the user’s own expense. McQuay International Corporation disclaims any liability

resulting from any interference or for the correction thereof.

OM 1051-2 3

Operating Limits:

• Maximum standby ambient temperature, 130°F (55°C)

• Maximum operating ambient temperature is 115°F (46°C), or 125°F (52°C) with the addition

of the optional high ambient package

• Minimum operating ambient temperature (standard), 35°F (2°C)

• Minimum operating ambient temperature (with optional low-ambient control), 0°F (-18°C)

• Leaving chilled water temperature, 39.2°F to 59.0°F (4.0°C to 15.0°C)

• Leaving chilled fluid temperatures with glycol, 24.8°F to 59.0°F (-4.0°C to 15.0°C). Normal

unloading.

• Leaving temperature in ICE mode, 17.6°F to 39.2°F (-8.0°C to 4°C). No unloading.

• Operating Delta-T range, 6°F to 16°F (3.3°C to 8.9°C)

• Maximum operating inlet fluid temperature, 76°F (24°C)

• Maximum non-operating inlet fluid temperature, 100°F (38°C)

Controller Features

Readout of the following temperature and pressure readings:

• Entering and leaving chilled water temperature

• Saturated evaporator refrigerant temperature and pressure

• Saturated condenser temperature and pressure

• Outside air temperature

• Suction and discharge line temperatures − calculated superheat for discharge and suction

lines

• Oil pressure

Automatic control of primary and standby chilled water pumps. The control will start one of the pumps (based on lowest run-hours) when the unit is enabled to run (not necessarily running on a call for cooling) and when the water temperature reaches a point of freeze possibility.

Two levels of security protection against unauthorized changing of setpoints and other control parameters.

Warning and fault diagnostics to inform operators of warning and fault conditions in plain language. All events and alarms are time and date-stamped for identification of when the fault condition occurred.

Twenty-five previous alarms are available.

Remote input signals for chilled water reset, demand limiting, and unit enable.

Test mode allows the service technician to manually control the controllers’ outputs and can be useful for system checkout.

Building Automation System (BAS) communication capability via LonTalk, Modbus, or BACnet standard protocols for all BAS manufacturers-simplified with McQuay’s Open Choices feature.

Pressure transducers for direct reading of system pressures. Preemptive control of low evaporator pressure conditions and high discharge temperature and pressure to take corrective action prior to a fault trip.

4 OM 1051-2

General Description

Switch

The control panel is located on the front of the unit at the compressor end. There are three doors. The control panel is behind to left-hand door. The power panel is behind the middle and right-hand doors.

General Description

The MicroTech III control system consists of a microprocessor-based controller and a number of extension modules, which vary depending on the unit size and conformation. The control system provides the monitoring and control functions required for the controlled, efficient operation of the chiller.

The operator can monitor all critical operating conditions by using the screen located on the main controller. In addition to providing all normal operating controls, the MicroTech III control system will take corrective action if the chiller is operating outside of its normal design conditions. If a fault condition develops, the controller will shut a compressor, or the entire unit, down and activate an alarm output.

The system is password protected and only allows access by authorized personnel. Except that some basic information is viewable and alarms can be cleared without a password. No settings can be changed.

Additional information about the Daikin McQuay Pathfinder Chiller is available in Catalog 600 and IM 997, which can be found on www.mcquay.com.

Control Panel Layout

Figure 1, Control Panel Components, Three-Circuit Unit, w/o VFD

Controller

Fuse

Emergency

Switch

Relay

Control

Circuit

Breaker

Unit On/Off

Circuit #1

Pumpdown

Circuit #2

Pumpdown

Switch

Circuit #3

Pumpdown

Switch

Alarm & Limit Extension Module

MicroTech III Main Controller

Fan Control Extension Modules

Emergency Switch Located on Front Door

OM 1051-2 5

NOTES:

Fan

Circuit Breaker

1 per Fan

Circuit #

Circuit Breaker

1. The Emergency Switch Relay de-energizes all circuit’s control power when activated, causing an

immediate compressor and fan shutdown. The red emergency button switch is located on the front of the control panel door.

2. The control power transformer is located in the power panel adjacent to the control panel.

3. Additional extension (aka expansion) modules are located elsewhere on the chiller.

4. See the VFD section for a description of the panel used with the VFD option as it is considerably

different from the standard panel.

Power Panel Layout

The power panel is at the front of the unit, behind the two doors to the right.

Figure 2, Power Panel, Three-Circuit Units, w/o VFD

Fan Contactors

1 per Fan, Circuit #2

Fan Contactors

1 per Fan, Circuit #3

Compressor #1

Circuit Breaker

Single Point

Disconnect Switch with

Compressor #3

Compressor #2

6 OM 1051-2

Line/120V

Transformer

Incoming Power

Connections

NOTE: See the VFD section of this manual for a description of the power used with the VFD option as it is considerably different from the standard panel.

Economizer Components

The chiller may or may not have economizers depending on design capacity requirements. An economizer is a well-proven device to increase a refrigerant circuit’s capacity and efficiency.

Figure 3, Economizer Components

Brazed-plate

Heat Exchanger

Gas to Comp.

Interstage

Liquid from Condenser

TXV LLSV

Warm liquid from the condenser is fed into the economizer where it is cooled by flashing off liquid also from the condenser. The flash gas is piped to a compressor interstage point. Lowering the liquid refrigerant temperature to the evaporator decreases its enthalpy (heat content) and results in a greater amount of heat absorption from the chilled water.

OM 1051-2 7

Liquid Feed to Economizer

Liquid Feed to Evaporator

Figure 4, Piping Schematic with Economizer Circuit, One Circuit Shown

Figure 5, Piping Schematic without Economizer Circuit, One Circuit Shown

8 OM 1051-2

Controller Description

Hardware Structure

The MicroTech III control system for Pathfinder chillers consists of a main unit controller with a number of extension input/output I/O modules attached depending on the chiller size and configuration.

One of the optional BAS communication modules may be included.

An optional Remote Operator Interface panel may be included, connected with up to nine Pathfinder units.

The MicroTech III controllers used on Pathfinder chillers are not interchangeable with previous MicroTech II controllers.

MicroTech III unit controller

Remote Operator Interface

BACnet/

MSTP

Communication

MODbus LON

BACnet/IP

Extension I/O Modules

OM 1051-2 9

System Architecture

The overall controls architecture uses the following:

• One MicroTech III main controller

• I/O extension modules (sometimes referred to as “controllers”) as needed depending

on the configuration of the unit

• Optional BAS interface as selected

Figure 6, System Architecture

BAS Interface (BACnet, Lon,

Modbus)

MicroTech III Main Controller

Peripheral Bus

I/O Extension

Alarm/Limiting

I/O Extension

Compressor 1

I/O Extension

Compressor 2

I/O Extension

Compressor 3

I/O Extension

Fans Circuit 1

and 2

I/O Extension

EXV 1

I/O Extension

EXV 2

I/O Extension

EXV 3

I/O Extension Fans Circuit 3

I/O Extension

Fans Circuit 3

and 4

I/O Extension Fans Circuit 4

I/O Extension

Compressor 4

I/O Extension

EXV 4

10 OM 1051-2

Sequence of Operation

Figure 7, Unit Sequence of Operation (see Figure 9 for circuit sequence of operation)

Unit power up

Unit in Off state

Is unit enabled?

Yes

Is low ambient lockout

active?

Evaporator pump output on

AWS Chiller Sequence of Operation in Cool Mode

The chiller may be disabled via the unit switch, the remote switch, the keypad enable setting, or the BAS network. In addition, the chiller will be disabled if all

circuits are disabled, or if there is a unit alarm. If the chiller is disabled, the unit status display will reflect this and also show why it is disabled.

If the unit switch is off, the unit status will be Off:Unit Switch. If the chiller is disabled due to network command, the unit status will be Off:BAS Disable. When

Yes

the remote switch is open, the unit status will be Off:Remote Switch. When a unit alarm is active, the unit status will be Off:Unit Alarm. In cases where no circuits are enabled, the unit status will be Off:All Cir Disabled. If the unit is disabled via the Chiller Enable set point, the unit status will be Off:Keypad Disable.

Low ambient lockout will prevent the chiller from starting even if it is otherwise enabled. When this lockout is active, the unit status will be Off:Low OAT Lock.

If the chiller is enabled, then the unit will be in the Auto state and the evaporator water pump output will be activated.

Is flow present?

Yes

Wait for chilled water loop to

recirculate.

Keep pump output on while chiller is enabled and either

running or ready to run.

Is there enough load to

start chiller?

Yes

The chiller will then wait for the flow switch to close, during which time the unit status will be Auto:Wait for flow.

After establishing flow, the chiller will wait some time to allow the chilled water loop to recirculate for an accurate reading of the leaving water temperature. The unit status during this time is Auto:Evap Recirc.

The chiller is now ready to start if enough load is present. If the LWT is not higher than the Active Setpoint plus the Start Up Delta T, the unit status will be Auto:Wait for load.

If the LWT is higher than the Active Setpoint plus the Start Up Delta T, the unit status will be Auto. A circuit can start at this time.

OM 1051-2 11

12 OM 1051-2

OM 1051-2 13

Figure 8, Circuit Sequence of Operation

Unit power up

Circuit is in Off state

Is circuit is enabled to

start?

Yes

Are compressor cycle

timers active?

Is compressor oil sump

ready?

AWS Sequence of Operation - Circuits

When the circuit is in the Off state the EXV is closed, compressor is off, and all fans are off.

The circuit must be enabled before it can run. It may be disabled for several reasons. When the circuit switch is off, the status will be Off:Circuit Switch. If the BAS has disabled the circuit, the status will be Off:BAS Disable. If the circuit

Yes

has an active stop alarm then the status will be Off:Cir Alarm. If the circuit has been disabled via the circuit mode set point, the status will be Off:Cir Mode Disable.

A minimum time must pass between the previous start and stop of a compressor and the next start. If this time has not passed, a cycle timer will be active and the circuit status will be Off:Cycle Timer.

If the compressor is not ready due to refrigerant in the oil, the circuit cannot start. The circuit status will be Off:Refr In Oil.

Yes

Circuit is ready to start

Is circuit commanded to

start?

Yes

Run circuit

Is circuit commanded to

shut down?

Yes

Pumpdown circuit

If the compressor is ready to start when needed, the circuit status will be Off:Ready.

When the circuit begins to run, the compressor will be started and the EXV, fans, and other devices will be controlled as needed. The normal circuit status at this time will be Run.

When the circuit is commanded to shut down, a normal shut down of the circuit will be performed. The circuit status during this time will be Run:Pumpdown. After the shut down is completed, the circuit status will normally be Off:Cycle Timer initially.

14 OM 1051-2

Controller Operation

MicroTech III Inputs/Outputs

I/O for the unit control and for circuits one and two are found on CP1. The chiller may be equipped with two or three compressors.

Analog Inputs

# Description Signal Source Expected Range

AI1 Evaporator Entering Water Temp NTC Thermister (10K@25°C) -50°C – 120°C

AI2 Evaporator Leaving Water Temp NTC Thermister (10K@25°C) -50°C – 120°C

AI3 Evaporator #1 Leaving Water Temp (*) NTC Thermister (10K@25°C) -50°C – 120°C

X1 Evaporator #2 Leaving Water Temp (*) NTC Thermister (10K@25°C) -50°C – 120°C

X2 Outside Ambient Temperature NTC Thermister (10K@25°C) -50°C – 120°C

X4 LWT Reset 4-20 mA Current 1 to 23 mA

*Evaporator #1 LWT and Evaporator #2 LWT will only be used when unit is configured with four circuits

Analog Outputs

# Description Output Signal Range

X5 Fan VFD #1 0-10VDC 0 to 100% (1000 steps resolution)

X6 Fan VFD #2 0-10VDC 0 to 100% (1000 steps resolution)

X7 Fan VFD #3 0-10VDC 0 to 100% (1000 steps resolution)

X8 Fan VFD #4 0-10VDC 0 to 100% (1000 steps resolution)

Digital Inputs

# Description Signal Off Signal On

DI1 Unit PVM Fault No Fault

DI2 Evaporator Flow Switch No Flow Flow

DI3 Double Setpoint/ Mode Switch Cool mode Ice mode

DI4 Remote Switch Remote off Remote on

DI5 Unit Switch Unit off Unit on

DI6 Emergency Stop Unit off/rapid stop Unit on

Digital Outputs

# Description Output OFF Output ON

DO1 Evaporator Water Pump Pump Off Pump On

Alarm Active

DO2 Unit Alarm Alarm not Active

DO3 Circuit #1 Fan Step #1 Fan Off Fan On

DO4 Circuit #1 Fan Step #2 Fan Off Fan On

DO5 Circuit #1 Fan Step #3 Fan Off Fan On

DO6 Circuit #1 Fan Step #4 Fan Off Fan On

DO7 Circuit #2 Fan Step #1 Fan Off Fan On

DO8 Circuit #2 Fan Step #2 Fan Off Fan On

DO9 Circuit #2 Fan Step #3 Fan Off Fan On

DO10 Circuit #2 Fan Step #4 Fan Off Fan On

(Flashing= circuit

alarm)

OM 1051-2 15

Expansion I/O Compressor #1 to #3

Analog Inputs

# Description Signal Source Expected Range

X1 Discharge Temperature NTC Thermister (10K@25°C) -50°C – 125°C X2 Evaporator Pressure Ratiometric 0.5-4.5 Vdc -100 kPa to 700 kPa X3 Oil Pressure Ratiometric 0.5-4.5 Vdc 0 kPa to 3000 kPa X4 Condenser Pressure Ratiometric 0.5-4.5 Vdc 0 kPa to 3000 kPa X7 Motor Temperature See note below

Note: European chillers will have the PTC thermistor in the compressor motor connected to this input. X7 is configured as an NTC 10k input for European chillers.

Analog Outputs

# Description Output Signal Range

Not Needed

Digital Inputs

# Description Signal Off Signal On

X6 Starter Fault Fault No fault X7 Motor Protection See note below DI1 High Pressure Switch Fault No fault

Note: US chillers will use the motor protection board connected to this input. X7 is configured as a digital input for US chillers.

Digital Outputs

Europe Configuration

# Description Output Off Output On

DO1 Start Compressor Compressor Off Compressor On DO2 Economizer Solenoid Closed Solenoid Open DO3 Non-modulating Slide Load/Unload Solenoid Closed Solenoid Open DO4 Liquid Injection Solenoid Closed Solenoid Open DO5 Modulating Slide Load Solenoid Closed Solenoid Open DO6 Modulating Slide Unload Solenoid Closed Solenoid Open

X5 Modulating Slide “turbo” Solenoid Closed Solenoid Open

U.S. Configuration

# Description Output Off Output On

DO1 Start Compressor Compressor Off Compressor On

DO2 Economizer Solenoid Closed Solenoid Open

DO3 Non-modulating Slide Load Solenoid Closed Solenoid Open

DO4 Non-modulating Slide Unload Solenoid Closed Solenoid Open

DO5 Modulating Slide Load Solenoid Closed Solenoid Open

DO6 Modulating Slide Unload Solenoid Closed Solenoid Open

X5 Modulating Slide ‘Turbo’ Solenoid Closed Solenoid Open

X8 Liquid Injection Solenoid Closed Solenoid Open

16 OM 1051-2

I/O EXV Circuit #1 to #3

Analog Inputs

# Description Signal Source Expected Range

X2 Suction Temperature NTC Thermister 10K@25°C) -50°C – 120°C X3 Slide Position LVDT 4 to 20 mA 0% to 100%

Analog Outputs

# Description Output Signal Range

Not Needed

Digital Inputs

# Description Signal Off Signal On

DI1 Low Pressure switch Fault No fault

Digital Outputs

# Description Output Off Output On

DO1 Liquid Line Solenoid Closed Solenoid Open

Stepper Motor Output

# Description

M1+

M1-

M2+

M2-

EXV Stepper Coil 1

EXV Stepper Coil 2

Extension I/O Fan Module Circuit #1 & 2

Digital Inputs

# Description Output Off Output On

DI1 PVM/GFP Circuit #1 Fault No fault

DI2 PVM/GFP Circuit #2 Fault No fault

Digital Outputs

# Description Output Off Output On

DO1 Circuit #1 Fan Step #5 Fan Off Fan On

DO2 Circuit #1 Fan Step #6 Fan Off Fan On

DO3 Circuit #2 Fan Step #5 Fan Off Fan On

DO4 Circuit #2 Fan Step #6 Fan Off Fan On

Extension I/O Fan Module Circuit #3

Digital Outputs

# Description Output Off Output On

DO1 Circuit #3 Fan Step #5 Fan Off Fan On

DO2 Circuit #3 Fan Step #6 Fan Off Fan On

Extension I/O Unit Alarm & Limiting

Analog Inputs

# Description Signal Source Range

X3 Demand Limit 4-20 mA 1 to 23 mA

X4 Unit Current 4-20 mA 1 to 23 mA

Analog Outputs

# Description Output Signal Range

Not Needed

OM 1051-2 17

Digital Inputs

# Description Signal Off Signal On

X1 External Alarm/Event

X2 Current Limit Enable No Limiting Limiting

X5 Circuit Switch #1 Circuit Off Circuit On

X6 Circuit Switch #2 Circuit Off Circuit On

X7 Circuit Switch #3 Circuit Off Circuit On

External Device Failure

External Device OK

Digital Outputs

# Description Output Off Output On

DO1 Evaporator Water Pump #2 Pump Off Pump On

DO2 Open

DO3 Circuit #1 Alarm No Alarm Alarm

DO4 Circuit #2 Alarm No Alarm Alarm

DO5 Circuit #3 Alarm No Alarm Alarm

Setpoints

The following parameters are remembered during power off, are factory set to the Default value, and can be adjusted to any value in the Range column.

Read and write access to these setpoint is determined by the Global HMI (Human Machine Interface) Standard Specification.

Table 1, Setpoint Default and Range

Description Default Range

Unit

Manufacturing Location

Frequency

Voltage

Unit Enable

Unit Status after Power Failure

Not Selected

60 Hz

460 V

Enable

Not Selected, Europe, USA

50, 60

230, 380, 400, 460, 575

Disable, Enable

Enable Disable, Enable

Control source Local Local, Network

Available Modes Cool

Cool LWT 1 Cool LWT 2 Cool LWT 1 with Glycol Cool LWT 2 with Glycol Ice LWT

7.0°C (44.6°F)

-4.0°C (24.8°F)

4.0°C to 15.0°C (39.2°F to 59.0°F)

-4.0°C to 15.0°C (24.8°F to 59.0°F)

Cool, Cool w/Glycol

Cool/Ice w/Glycol, Ice, Test

-8.0°C to 4.0°C (17.6°F to 39.2°F)

Startup Delta T 2.7 deg C (4.9 deg F) 0 to 5.0 deg C (0 to 9.0 deg F) Shut Down Delta T 1.5 deg C (2.7 deg F) 0 to 1.7 deg C (0 to 3.1 deg F) Stage Up Delta T 0.5 deg C (0.9 deg F) 0 to 1.7 deg C (0 to 3.1 deg F) Stage Down Delta T 0.7 deg C (1.3 deg F) 0 to 1.7 deg C (0 to 3.1 deg F)

Max Pulldown

1.7 deg C/min

(3.1 deg F/min)

0.3 to 2.7 deg C/min

(0.5 to 4.9 deg F/min)

Continued next page.

Description Default Range

Nominal Evap Delta T 2 Cir 5.6 deg C (10.1 deg F) 3.3 to 8.9 deg C (5.9 to 16.0 deg F) Nominal Evap Delta T 3 Cir 5.6 deg C (10.1 deg F) 3.3 to 10 deg C (5.9 to 18.0 deg F) Variable Evap Flow No No, Yes

18 OM 1051-2

Evap Recirc Timer 30 sec 0 to 300 seconds

Pump Control #1 Only

#1 Only, #2 Only, Auto,

#1 Primary, #2 Primary LWT Reset Type None None, 4-20mA, OAT Max Reset 5.0 deg C (9.0 deg F) 0 to 10.0 deg C (0 to 18.0 deg F) Start Reset Delta T 5.0 deg C (9.0 deg F) 0 to 10.0 deg C (0 to 18.0 deg F) Max Reset OAT Start Reset OAT

15.5°C (59.9°F)

23.8°C (74.8°F)

10.0°C to 30.0°C (50°F to 86.0 °F)

Soft Load Off Off, On Begin Capacity Limit 40% 20-100% Soft Load Ramp 20 min 1-60 minutes Demand Limit Off Off, On Current @ 20mA 800 A 0 to 2000 A Current limit Setpoint 800 A 0 to 2000 A # of Circuits 2 2, 3 Ice Delay Timer 12 hrs 1-23 hours Clear Ice Timer No No, Yes PVM Multi Point Single Point, Multi Point , None(SSS) Noise Reduction Disabled Disabled, Enabled Noise Reduction Start Time 21:00 18:00 – 23:59 Noise Reduction End Time 6:00 5:00 – 9:59 Noise Reduction Offset 5.0 deg C (9.0 deg F) 0 to 14.0 deg C (0 to 25.2 deg F) Evap LWT Sensor Offset 0 deg C (0 deg F) -5.0 to 5.0 deg C (-9.0 to 9.0 deg F) Evap EWT Sensor Offset 0 deg C (0 deg F) -5.0 to 5.0 deg C (-9.0 to 9.0 deg F) OAT Sensor Offset 0 deg C (0 deg F) -5.0 to 5.0 deg C (-9.0 to 9.0 deg F)

Compressors-Global

Start-start timer 20 min 15-60 minutes Stop-start timer 5 min 3-20 minutes Pumpdown Pressure 100 kPa (14.5 psi) 70 to 280 kPa (10.2 to 40.6 psi) Pumpdown Time Limit 120 sec 0 to 180 sec Light Load Stage Down 40% 26 to 50% High Load Stage Up 80% 50 to 100% Stage Up Time 5 min 0 to 60 min Stage Down Time 3 min 3 to 30 min Stage Delay Clear No No, Yes Soft Load Off Off, On Max # Comps Running 2 2,3 Sequence # Cir 1 1 1-3 Sequence # Cir 2 1 1-3 Sequence # Cir 3 1 1-3 Liquid Injection Activation

85.0°C (185.0°F)

50.0°C to 110.0°C (122.0°C to 230.0°F)

Liq. Line Solenoid Valves No No, Yes Slide Position Sensors Yes No, Yes

Continued next page.

OM 1051-2 19

Description Default Range

Alarm Limits

Low Pressure-Unload 160 kPa (23 psi) 160 kPa to 310 kPa (23 psi to 48 psi) Low Pressure-Hold 180 kPa (26 psi) 180 kPa to 310 kPa (26 psi to 48 psi) Low Press-Unload w/ Glycol 160 kPa (23 psi) 0 kPa to 310 kPa (0 psi to 48 psi) Low Press-Hold w/Glycol 180 kPa (26 psi) 0 kPa to 310 kPa (0 psi to 48 psi) High Oil Press Diff Delay 30 sec 10-180 sec High Oil Press Differential 250 kPa (36 psi) 0 to 415 kPa (0 to 60 psi) High Discharge Temperature 110.0°C (230.0°F) 65.0 to 110.0 °C (149.0 to 230.0°F) High Cond Pressure Delay 5 sec 0 to 30 sec Low Pressure Ratio Delay 90 sec 0 to 180 sec Start Time Limit 60 sec 20 to 180 sec Evap. Water Freeze Evap. Water Freeze w/ Glycol

2.2°C (36.0°F)

1.1°C to 6.0°C (34.0°F to 42.8°F)

-18.0°C to 6.0°C (-0.4°F to 42.8°F)

Evaporator Flow Proof 15 sec 5 to 15 sec Recirculate Timeout 3 min 1 to 10 min Low OAT Lockout Low OAT Lockout/with Fan VFD

12.0°C (53.6°F)

2.0°C to 15.0°C (35.6°F to 59.0°F)

-23.0°C to 15.0°C (-9.4°F to 59.0°F)

The following setpoints exist individually for each circuit:

Description

Default Range

Circuit mode Enable Disable, enable, test

Compressor Size for Non-VFD HSA204

Compressor Size for VFD HSV204

HSA192, HSA204, HSA215 HSA232, HSA241, HSA263

HSV204, HSV215

HSV232, HSV241, HSV263 Economizer (VFD Only) With With, Without Capacity Control Auto Auto, Manual Manual Capacity See Note 1 0 to 100% Clear Cycle Timers No No, Yes EXV control Auto Auto, manual Service Pumpdown No No, Yes Economizer Enable Capacity (VFD Model Only)

40% 40 to 75%

Evap pressure Sensor offset 0 kPa (0 psi) -100 to 100 kPa (-14.5 to 14.5 psi) Cond pressure Sensor offset 0 kPa (0 psi) -100 to 100 kPa (-14.5 to 14.5 psi) Oil pressure Sensor Offset 0 kPa (0 psi) -100 to 100 kPa (-14.5 to 14.5 psi) Suction temp Sensor Offset 0 deg C (0 deg F) -5.0 to 5.0 deg C (-9.0 to 9.0 deg F) Discharge temp offset 0 deg C (0 deg F) -5.0 to 5.0 deg C (-9.0 to 9.0 deg F) Slide sensor mA @ minimum

Slide sensor mA @ maximum

4 mA 4 to 22 mA

20 mA 4 to 22 mA

Fans

Fan VFD enable Enable Disable, Enable Number of fans 5 5 to 12 Saturated Condenser Temp Target Min Saturated Condenser Temp Target Max

32.0°C (89.6°F)

43.0°C (109.4°F)

20.0°C to 50.0°C (68.0°F to

122.0°F)

32.0°C to 50.0°C (89.6°F to

122.0°F)

Continued next page.

20 OM 1051-2

Description Default Range

Fan Stage 0 Up Deadband 2.5 deg C (4.5 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 1 Up Deadband 2.5 deg C (4.5 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 2 Up Deadband 4.0 deg C (7.2 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 3 Up Deadband 5.0 deg C (9.0 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 4 Up Deadband 4.0 deg C (7.2 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 5 to 12 Up Deadband

4.0 deg C (7.2 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F)

Fan Stage 1 Down Deadband 10.0 deg C (18.0 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 2 Down Deadband 4.0 deg C (7.2 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 3 Down Deadband 3.5 deg C (6.3 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 4 Down Deadband 3.0 deg C (5.4 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 5 Down Deadband 2.5 deg C (4.5 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F) Fan Stage 6 to 12 Down Deadband

2.5 deg C (4.5 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F)

Fan VFD Max Speed 100% 90 to 110% Fan VFD Min Speed 25% 20 to 60%

Dynamic Default Values

The fan staging dead bands have different default values based on the VFD enable setpoint. When the VFD enable setpoint is changed, a set of default values for the fan staging dead bands is loaded as follows:

Fan VFD is Enabled

Setpoint

Default

loaded (oF)

Stage 0 On Deadband 4.5 Stage 0 On Deadband 7.2

Stage 1 On Deadband 4.5 Stage 1 On Deadband 9.0

Stage 2 On Deadband 7.2 Stage 2 On Deadband 9.9

Stage 3 On Deadband 9.0 Stage 3 On Deadband 10.8

Stage 4 On Deadband 7.2 Stage 4 On Deadband 11.7

Stage 5 On Deadband 7.2 Stage 5 On Deadband 11.7

Stage 2 Off Deadband 7.2 Stage 2 Off Deadband 18

Stage 3 Off Deadband 6.3 Stage 3 Off Deadband 14.4

Stage 4 Off Deadband 5.4 Stage 4 Off Deadband 9.9

Stage 5 Off Deadband 4.5 Stage 5 Off Deadband 7.2

Stage 6 Off Deadband 4.5 Stage 6 Off Deadband 7.2

The low pressure settings have different default values based on the Manufacturing Location setpoint. When the manufacturing location is configured, the default values for these setting are loaded as shown below:

US Chiller

Setpoint Default loaded

Low Evap Press.Unload 160 kPa (23.2 psi) Low Evap Press. Unload 160 kPa (23.2 psi)

Low Evap Press.-Hold 180 kPa (26.1 psi) Low Evap Pressure-Hold 180 kPa (26.1 psi)

Fan VFD is Disabled

Setpoint

Default

loaded (oF)

European Chiller

Setpoint Default loaded

OM 1051-2 21

Unit Functions

Calculations

EWT Slope

EWT slope is calculated such that the slope represents the change in EWT over a time frame of one minute.

Pulldown Rate

The slope value calculated above will be a negative value as the water temperature is dropping. A pulldown rate is calculated by inverting the slope value and limiting to a minimum value of 0°C/min.

Unit Availability

The unit is available to start if the following conditions are true:

1. Unit switch is closed

2. If unit mode is ice and the ice timer has timed out.

3. No unit alarms exist

4. Emergency stop input is closed

5. At least one circuit is enabled

6. Unit enable setpoint is Enable

7. If remote control is connected and remote unit switch is closed

8. If Control Source = Network, BAS Enable = True

Enabling and disabling the chiller is accomplished using setpoints and inputs to the chiller. The unit switch, remote switch input, and Unit Enable Setpoint all are required to be on for the unit to be enabled when the control source is set to local. The same is true if the control source is set to network, with the additional requirement that the BAS request must be on.

Unit is enabled according to the following table. NOTE: An x indicates that the value is ignored.

Table 2, Enable Combinations

Unit

Switch

Off x x x x Off

x x Off x x Off x x x Off x Off

On Local On On x On

x Network x x Off Off

On Network On On On On

Control

Source

Setpoint

Remote

Switch Input

Unit Enable

Setpoint

BAS

Request

Unit

Enable

All of the methods for disabling the chiller, discussed in this section, will cause a normal shutdown (pumpdown) of any running circuits.

When the controller is powered up, the Unit Enable Setpoint will be initialized to ‘Disable’ if the Unit Enable Init Setpoint is set to ‘Disable’. .

22 OM 1051-2

Unit Mode Selection

The operating mode of the unit is determined by setpoints and inputs to the chiller. The Available Modes Setpoint determines what modes of operation can be used. This setpoint also determines whether the unit is configured for glycol use. The Control Source Setpoint determines where a command to change modes will come from. A digital input switches between cool mode and ice mode if they are available and the control source is set to local. The BAS mode request switches between cool mode and ice mode if they are both available and the control source is set to network. The Available Modes Setpoint must only be changed when the unit switch is off. This is to avoid changing modes of operation inadvertently while the chiller is running.

Unit Mode is set according to the following table.

Table 3, Mode Combinations

Control Source

Setpoint

x x x Cool Cool

x x x Cool w/Glycol Cool Local Off x Cool/Ice w/Glycol Cool Local On x Cool/Ice w/Glycol Ice

Network x Cool Cool/Ice w/Glycol Cool Network x Ice Cool/Ice w/Glycol Ice

x x x Ice w/Glycol Ice

x x x Test Test

Notes

1. “x” Indicates that the value is ignored.

2. If the Available Modes Setpoint is set to an option ‘w/Glycol’, then glycol operation should be enabled for the unit. Glycol operation should only be disabled when the Available Modes Setpoint is set to ‘Cool’.

Mode

Input

BAS

Request

Available Modes

Setpoint

Unit Mode

Glycol Configuration

If the Available Modes Setpoint is set to an option w/Glycol, then glycol operation is enabled for the unit. Glycol operation must be disabled only when the Available Modes Setpoint is set to Cool.

Unit Control States

The unit will always be in one of three states:

• Off – Unit is not enabled to run.

• Auto – Unit is enabled to run.

• Pumpdown – Unit is doing a normal shutdown.

Off. The unit should be in the Off state if any of the following are true:

• A unit alarm is active

• All circuits are unavailable to start (cannot start even after cycle timers have expired)

• The unit mode is ice, all circuits are off, and the ice mode delay is active

• Manufacturing Location is not set

• Either manufacturing location or number of circuits have been changed and controller

has not been rebooted

Auto. The unit should be in the Auto state if all of the following are true:

• Manufacturing location is set and controller has been rebooted

• Unit enabled based on settings and switches

• If unit mode is ice, the ice timer has expired

• No unit alarms are active

• At least one circuit is enabled and available to start

OM 1051-2 23

Pumpdown. The unit should be in Pumpdown until all running compressors finish pumping down if any of the following are true:

• Unit is disabled via settings and/or inputs in section Unit Availability.

• Unit pumpdown alarm is triggered

Unit Status

The displayed unit status is determined by the conditions in the following table:

Table 4, Unit Status

Enum

0 Auto Unit State = Auto

1 Off: Ice Mode Tmr

2 Off: OAT Lockout Unit State = Off and Low OAT Lockout is active 3 Off: All Cir Disabled Unit State = Off and all compressors unavailable 4 Off: Unit Alarm Unit State = Off and Unit Alarm active 5 Off: Keypad Disable Unit State = Off and Unit Enable Setpoint = Disable 6 Off: Remote Sw Unit State = Off and Remote Switch is open

7 Off: BAS Disable

8 Off: Unit Sw Unit State = Off and Unit Switch = Disable 9 Off: Test Mode Unit State = Off and Unit Mode = Test

10 Auto: Noise Reduction Unit State = Auto and Noise Reduction is active

11 Auto: Wait for Load

12 Auto: Evap Recirc Unit State = Auto and Evaporator State = Start

13 Auto: Wait for flow

14 Auto: Pumpdn Unit State = Pumpdown

15 Auto: Max Pulldn

16 Auto: Unit Cap Limit

17 Auto: Current Limit

18 Off. Cfg Chg, Rst Ctlr

19 Off Mfg Loc Not Set Mfg Location is not set

Status Conditions

Unit State = Off, Unit Mode = Ice, and Ice Delay = Active

Unit State = Off, Control Source = Network, and BAS Enable = false

Unit State = Auto, no circuits running, and LWT is less than the active setpoint + startup delta

Unit State = Auto, Evaporator State = Start, and Flow Switch is open

Unit State = Auto, max pulldown rate has been met or exceeded

Unit State = Auto, unit capacity limit has been met or exceeded Unit State = Auto, unit current limit has been met or exceeded Unit configuration setpoint has changed, and reboot of controller is required

Ice Mode Start Delay

Compressor Staging in Ice Mode

The first compressor will start when evaporator LWT is higher than the target plus the Startup Delta T setpoint.

When at least one compressor is running, the other compressors will start only when evaporator LWT is higher than the target plus the Stage Up Delta T setpoint.

All compressors will be staged off when evaporator LWT is less than the target.

Stage Up Delay

A fixed stage up delay of one minute between compressor starts is used in this mode. When at least one compressor is running, the other compressors will start as quickly as possible with respect to the stage up delay. An adjustable start-to-start ice delay timer will limit the frequency with which the chiller may start in Ice mode. The timer starts when the first compressor starts while the unit is in ice mode. While this timer is active, the chiller cannot restart in Ice mode. The time delay is user adjustable.

24 OM 1051-2

The ice delay timer may be manually cleared to force a restart in ice mode. A setpoint specifically for clearing the ice mode delay is available. In addition, cycling the power to the controller will clear the ice delay timer.

Evaporator Pump Control

State

Three evaporator pump control states for control of the evaporator pumps:

• Off - No pump on.

• Start – Pump is on, water loop is being recirculated. Recirc timer runnning

• Run – Pump is on, water loop has been recirculated. Recirc timer has timed out

Off The control state is Off when all of the following are true:

• Unit state is Off

• LWT is higher than the Evap Freeze setpoint or LWT sensor fault is active

• EWT is higher than the Evap Freeze setpoint or EWT sensor fault is active

Start. The control state is Start when any of the following are true:

• The unit state is auto

• LWT is less than the Evap Freeze setpoint and LWT sensor fault isn’t active

• EWT is less than the Evap Freeze setpoint and EWT sensor fault isn’t active

Run. The control state is Run when

• The flow switch input has been closed for a time greater than the Evaporator

Recirculate setpoint.

• The flow switch fault is not active

Pump Selection

The pump output used is determined by the Evap Pump Control setpoint. This setting allows the following configurations:

• #1 only – Pump 1 will always be used

• #2 only – Pump 2 will always be used

• Auto – The primary pump is the one with the least run hours, the other is used as

a backup

• #1 Primary – Pump 1 is used normally, with pump 2 as a backup

• #2 Primary – Pump 2 is used normally, with pump 1 as a backup

Primary/Standby Pump Staging

The standby pump will be on if either of the following are true:

• Pump state is Run and the flow switch is open for Evap Proof Time/2

• Pump start is start and Recirculate timeout has expired.

Auto Control

If auto pump control is selected, the primary/standby logic above is still used. When the evaporator is not in the run state, the run hours of the pumps will be compared. The pump with the least hours will be designated as the primary at this time.

Noise Reduction

Noise Reduction is an operating mode designed to reduce unit sound levels by decreasing compressor and fan operating time. It is used during the night when the cooling load is usually reduced and the ambient temperature is lower.

Noise Reduction always requires the Noise Reduction setpoint to be set to ‘enable’. If it is set to ‘disable’, it will not activate for any reason.

Assuming this functionality is enabled, there are two ways it can become active:

OM 1051-2 25

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