McQuay AWS 170A Installation Manual
Operating & Maintenance Manual
Chiller
Part Number: OMM 1123
Date: July 2012
May 2012
OMM 1123
Group:
Supercedes:
Pathfinder™ Air-Cooled Chillers
AWS 170A/B through AWS 550A/B (Includes Models with Optional VFD)
60 Hertz
R-134a
Software Version: 2507500209 and 2507500210
Rev
© 2012 McQuay International
Table of Contents
ISO Certified Facility
Modbus
INTRODUCTION ........................................................3
OPERATING LIMITS: ...............................................4
ECONOMIZER CONTROL ........................................... 43
LIQUID INJECTION .................................................... 43
LIQUID LINE SOLENOID VALVE ............................... 44
CAPACITY OVERRIDES – LIMITS OF OPERATION ...... 44
CONTROLLER FEATURES .....................................4
GENERAL DESCRIPTION ........................................5
CONTROL PANEL LAYOUT ..........................................5
POWER PANEL LAYOUT ..............................................6
ECONOMIZER COMPONENTS .......................................7
CONTROLLER DESCRIPTION ...............................9
HARDWARE STRUCTURE .............................................9
SYSTEM ARCHITECTURE ........................................... 10
SEQUENCE OF OPERATION ................................ 11
CONTROLLER OPERATION ................................. 15
SETPOINTS ................................................................ 18
UNIT FUNCTIONS.................................................... 22
CALCULATIONS ......................................................... 22
UNIT AVAILABILITY ................................................. 22
UNIT MODE SELECTION ............................................ 23
UNIT CONTROL STATES ............................................ 23
UNIT STATUS ............................................................ 24
ICE MODE START DELAY .......................................... 24
EVAPORATOR PUMP CONTROL ................................. 25
NOISE REDUCTION .................................................... 25
LEAVING WATER TEMPERATURE (LWT) RESET ....... 26
UNIT CAPACITY CONTROL ........................................ 28
UNIT CAPACITY OVERRIDES ..................................... 30
RAPIDRESTORE™ OPTION ........................................ 33
CIRCUIT FUNCTIONS ............................................ 35
CALCULATIONS ......................................................... 35
CIRCUIT CONTROL LOGIC ......................................... 36
CIRCUIT STATUS ....................................................... 37
COMPRESSOR CONTROL ............................................ 38
CONDENSER FAN CONTROL ...................................... 39
FAN CONTROL WITHOUT VFD .................................. 39
FAN CONTROL WITH VFD......................................... 41
EXV CONTROL ......................................................... 41
ALARMS AND EVENTS ......................................... 45
SIGNALING ALARMS ................................................ 45
CLEARING ALARMS/FAULTS .................................... 45
DESCRIPTION OF ALARMS ........................................ 46
ALARM LISTING ....................................................... 46
UNIT FAULTS ........................................................... 48
UNIT WARNINGS ...................................................... 49
CIRCUIT FAULTS ...................................................... 50
CIRCUIT PROBLEMS ................................................. 55
ALARM LOGGING ..................................................... 56
EVENT LOG .............................................................. 57
USING THE CONTROLLER .................................. 58
NAVIGATING ............................................................ 59
OPTIONAL REMOTE USER INTERFACE ......... 63
OPTIONAL COMPRESSOR VFD .......................... 65
FAULTS AND MINOR FAULTS/ALARMS .................... 65
CLEARING VFD FAULTS .......................................... 65
NAVIGATING VFD FAULT CODES ............................ 65
OPTIONAL POW ER FACTOR CORRECTION
CAPACITORS ........................................................... 69
START-UP AND SHUTDOWN ............................... 70
TEMPORARY SHUTDOWN ......................................... 70
EXTENDED (SEASONAL) SHUTDOWN ....................... 71
FIELD WIRING DIAGRAM ................................... 73
SYSTEM MAINTENANCE ..................................... 75
PUMP OPERATION .................................................... 78
PREVENTATIVE MAINTENANCE SCHEDULE .............. 79
APPENDIX ................................................................ 80
DEFINITIONS ............................................................ 80
Unit controllers are LONMARK certified with an
optional
LONWORKS communications module
2012 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; L
Choice and RapidRestore from McQua y Int er nati on al ; Excel from Microsoft Corp.
2 OMM 1123
ONMARK and LONWORKS from Echelon Corporation; Daikin Mc Qua y, MicroTech III, Guardister, and Open
Introduction
!
DANGER
!
WARNING
!
CAUTION
!
WARNING
!
CAUTION
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=").
HAZARD IDENTIFICATION INFORMATION
personal injury, or death if not avoided.
damage if not avoided.
App Version 2507500210 for units with or without optional compressor VFDs or
RapidRestore™. Version 2507500210 has certain operational revisions to the previous version
but the information in this manual is unchanged.
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 .
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.
OMM 1123 3
Operating Limits:
• Maximum standby ambient temperature, 130°F (55°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 superhe at 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 Daikin 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 OMM 1123
General Description
MicroTech III
Fan Control
Controller
Emergency
Control
Unit On/Off
Switch
Circuit #1
Switch
Circuit #2
Circuit #3
Emergency
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
1122, which can be found on
Control Panel Layout
Figure 1, Control Panel Components, Three-Circuit Unit, w/o VFD
www.daikinmcquay.com.
Fuse
Switch
Relay
Circuit
Breaker
Pumpdown
Pumpdown
Switch
Pumpdown
Switch
Alarm & Limit
Extension
Module
Main
Controller
Extension
Modules
Switch
Located on
Front Door
OMM 1123 5
NOTES:
Fan Circuit Breakers
Fan Contactors
1 per Fan, Circuit #1
Line/120V
Single Point
Compressor #1
Compressor #2
Circuit Breaker
Fan Contactors
Fan Contactors
Compressor #3
Circuit Breaker
Incoming Power
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
Circuit Breaker
Disconnect Switch with
1 per Fan, Circuit #2
1 per Fan, Circuit #3
Transformer
NOTE: See the VFD section of this manual for a descript ion of the power used with the VFD option
as it is considerably different from the standard panel.
Connections
6 OMM 1123
Brazed-plate
Gas to Comp.
Liquid from
Liquid Feed
Liquid Feed
TXV LLSV
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
Heat Exchanger
Interstage
Condenser
OMM 1123 7
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.
to
Economizer
to
Evaporator
Figure 4, Piping Schematic with Economizer Circuit, One Circuit Shown
Figure 5, Piping Schematic without Economizer Circuit, One Circuit Shown
8 OMM 1123
Controller Description
Communication
BACnet/IP
MSTP
MODbus
LON
Remote Operator Interface
Hardware Structure
The Micr oTech 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.
BACnet/
MicroTech III unit controller
Extension I/O Modules
OMM 1123 9
I/O Extension
Compressor 1
I/O Extension
Compressor 2
I/O Extension
Compressor 3
I/O Extension
Compressor 4
I/O Extension
EXV 1
I/O Extension
EXV 2
I/O Extension
EXV 3
I/O Extension
EXV 4
I/O Extension
Fans Circuit 1
and 2
I/O Extension
Fans Circuit 3
I/O Extension
Fans Circuit 4
I/O Extension
Fans Circuit 3
and 4
I/O Extension
Alarm/Limiting
BAS Interface
(BACnet, Lon,
Modbus)
MicroTech III Main Controller
Peripheral Bus
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 int erface as selec ted
Figure 6, System Architecture
10 OMM 1123
Sequence of Operation
Is unit enabled?
Is flow present?
Evaporator pump output on
Wait for chilled water loop to
recirculate.
Yes
Yes
No
Unit power up
Unit in Off state
No
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
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.
If the chiller is enabled, then the unit will be in the Auto state and the evaporator
water pump output will be activated.
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 will then wait for the flow switch to close, during which time the unit
status will be Auto:Wait for flow.
Is low ambient lockout
active?
Yes
No
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.
Is there enough load to
start chiller?
No
Keep pump output on while
chiller is enabled and either
running or ready to run.
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.
Yes
AWS Chiller Sequence of Operation in Cool Mode
Figure 7, Unit Sequence of Operation (see Figure 9 for circuit sequence of operation)
OMM 1123 11
Start first circuit.
Yes
The first circuit to start is generally the available circuit with the least number of
starts.
This circuit will go through its start sequence at this point.
Is more capacity
needed to satisfy load?
Has the stage up time
delay expired?
Yes
No
Load/unload as needed to
satisfy load.
No
The first circuit will be loaded and unloaded as needed in an attempt to satisfy the
load by controlling LWT to the Active Setpoint.
A minimum time must pass between the starting of circuits. The time remaining
can be viewed on the HMI if the minimum password level is active.
If a single circuit is not enough to satisfy the load, additional circuits will need to be
started. An additional circuit will be started when all running compressors are
loaded to a specific capacity and the LWT is higher than the Active Setpoint plus
the Stage Up Delta T.
Start next circuit.
Yes
The second circuit will go through its start sequence at this point.
Note that a third circuit can be started if available. The two preceding conditions
must again be satisfied after starting the second circuit before starting the third
circuit.
Load/unload as needed to
satisfy load.
Can less circuits handle
the load?
No
As the load drops off, the circuits will unload accordingly. If the LWT drops below
the Active Setpoint minus the Stage Down Delta T, one circuit will shut off. If all
running circuits are unloaded below a minimum value, this can also result in one
circuit shutting off.
A minimum time must pass between the shutting down of circuits. The time
remaining can be viewed on the HMI if the minimum password level is active.
All running circuits will now be loaded/unloaded as needed to satisfy the load.
When possible, they will load balance so that running circuits are providing nearly
equal capacity.
Yes
Shut down one circuit.
The next circuit to shut off is generally the one with the most run hours.
12 OMM 1123
Load/unload as needed to
satisfy load.
Is load satisfied?
No
Shut down last circuit.
Yes
When only one circuit is running, the load may drop off to the point where even
minimum unit capacity is too much. The load has been satisfied when the LWT
drops below the Active Setpoint minus the Shutdown Delta T. At this time the only
running circuit can shut down.
The remaining running circuit(s) will be loaded/unloaded as needed to satisfy the
load.
The last circuit running now shuts down.
The unit should be ready to start again when the LWT gets high enough. Until that
time, unit status will be Auto:Wait for load.
OMM 1123 13
Figure 8, Circuit Sequence of Operation
Is circuit commanded to
start?
Is circuit commanded to
shut down?
Pumpdown circuit
Yes
Yes
No
Unit power up
Circuit is in Off state
No
Run circuit
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.
When the circuit is in the Off state the EXV is closed, compressor is off, and all fans
are off.
Is circuit is enabled to
start?
Yes
No
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
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.
Is compressor oil sump
ready?
Yes
No
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.
Circuit is ready to start
If the compressor is ready to start when needed, the circuit status will be
Off:Ready.
Are compressor cycle
timers active?
No
Yes
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.
AWS Sequence of Operation - Circuits
14 OMM 1123
Controller Operation
alarm)
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 Rem o te 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
OMM 1123 15
Expansion I/O Compressor #1 to #3
#
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
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
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 Solenoi d Closed Solenoid Open
X5 Modulating Slide ‘Turbo’ Solenoid Closed Solenoid Open
X8 Liquid Injection Solenoid Closed Solenoid Open
16 OMM 1123
I/O EXV Circuit #1 to #3
X3
Slide Position
LVDT 4 to 20 mA
0% to 100%
#
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 Inputs
# Description Signal Source Expected Range
X2 Suction Temperature NTC Therm i s ter 10K@25°C) -50°C – 120°C
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+
M1M2+
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
OMM 1123 17
Analog Outputs
# Description Output Signal Range
Not Needed
Digital Inputs
Failure
Description
Default
Range
Unit
Manufacturing Location
Not Selected, Europe, USA
Frequency
50, 60
Voltage
230, 380, 400, 460, 575
Unit Enable
Disable, Enable
Unit Status after Power
Control source
Local
Local, Network
Cool, Cool w/Glycol
Cool LWT 1
7.0°C (44.6°F)
4.0°C to 15.0°C (39.2°F to 59.0°F)
Cool LWT 2
7.0°C (44.6°F)
4.0°C to 15.0°C (39.2°F to 59.0°F)
Cool LWT 1 with Glycol
7.0°C (44.6°F)
-4.0°C to 15.0°C (24.8°F to 59.0°F)
Cool LWT 2 with Glycol
7.0°C (44.6°F)
-4.0°C to 15.0°C (24.8°F to 59.0°F)
Ice LWT
-4.0°C (24.8°F)
-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)
1.7 deg C/min
0.3 to 2.7 deg C/min
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
Evap Recirc Timer
30 sec
0 to 300 seconds
# 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
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 Al arm Alarm
DO5 Circuit #3 Alarm No Al arm 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
Not Selected
60 Hz
460 V
Enable
Failure
Enable Disable, Enable
Available Modes Cool
Cool/Ice w/Glycol, Ice, Test
Max Pulldown
Continued next page
18 OMM 1123
(3.1 deg F/min)
(0.5 to 4.9 deg F/min)
.Description
Default
Range
Pump Control #1 Only
#1 Only, #2 Only, Auto,
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
10.0°C to 30.0°C (50°F to 86.0 °F)
Start Reset OAT
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)
Max Power Failure time
15 sec
15-180 sec
RapidRestore™
Disable
Enable, Disable (special software req’d)
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
80.0°C to 100.0°C (176.0°C to 212.0°F)
Liq. Line Solenoid Valves
No
No, Yes
Slide Position Sensors
Yes
No, Yes
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)
15.5°C (59.9°F)
23.8°C (74.8°F)
#1 Primary, #2 Primary
OMM 1123 19
85.0°C (185.0°F)
Continued next page.
Description
Default
Range
Alarm Limits
High Discharge Temperature
110.0°C (230.0°F)
65.0 to 110.0 °C (149.0 to 230.0°F)
Low discharge superheat
High Cond Pressure Delay
5 sec
0 to 30 sec
Low Pressure Ratio Delay
90 sec
0 to 180 sec
Start Time Lim it
60 sec
20 to 180 sec
Evap. Water Freeze
1.1°C to 6.0°C (34.0°F to 42.8°F)
Evap. Water Freeze w/ Glycol
2.2°C (36.0°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
12.0°C (53.6°F)
2.0°C to 15.0°C (35.6°F to 59.0°F)
Low OAT Lockout/with
Fan VFD
Description
Circuit mode
Enable
Disable, enable, test
HSA192, HSA204, HSA215
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)
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
Fans
Fan VFD enable
Enable
Disable, Enable
Number of fans 5 5 to 12
Saturated Condenser Temp
122.0°F)
Saturated Condenser Temp
32.0°C to 50.0°C (89.6°F to
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)
12°C (21.6°F) 10.0-15.0°C (18-27°F)
2.2°C (36.0°F)
12.0°C (53.6°F)
The following setpoints exist individually for each circuit:
Default Range
Compressor Size for Non-VFD HSA204
Compressor Size for VFD HSV204
40% 40 to 75%
-23.0°C to 15.0°C (-9.4°F to 59.0°F)
HSA232, HSA241, HSA263
Target Min
Target Max
Continued next page.
20 OMM 1123
4 mA 4 to 22 mA
20 mA 4 to 22 mA
32.0°C (89.6°F)
20.0°C to 50.0°C (68.0°F to
43.0°C (109.4°F)
122.0°F)
Description
Default
Range
Fan Stage 5 to 12
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
Fan VFD Max Speed
100%
90 to 110%
Fan VFD Min Speed
25%
20 to 60%
Fan VFD is Enabled
Fan VFD is Disabled
Default
loaded (oF)
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
Up Deadband
4.0 deg C (7.2 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F)
2.5 deg C (4.5 deg F) 1.0 to 10.0 deg C (1.8 to 18 deg F)
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:
Setpoint
Setpoint
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:
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)
OMM 1123 21
US Chiller
Setpoint Default loaded
European Chiller
Setpoint Default loaded
Unit Functions
Control
Setpoint
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
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 followi ng conditio ns are tru e:
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 rem ote 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
Source
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 initializ ed to ‘D isa b le ’ if
the Unit Enable Init Setpoint is set to ‘Disable’.
.
22 OMM 1123
Unit Mode Selection
Control Source
Setpoint
Mode
Input
BAS
Request
Available Modes
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
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 acco rd in g to the fol lo win g tab le.
Table 3, Mode Combinations
Notes
1. “x” Indicates that the value is ignored.
2. If the A vailable 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’.
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 (canno t start ev en after cycle tim er s 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
OMM 1123 23
Pumpdown. The unit should be in Pumpdown until all running compressors finish
Enum
Status
Conditions
0
Auto
Unit State = Auto
Active
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
Unit State = Off, Control Source = Network, and BAS
Enable = false
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
Unit State = Auto, no circuits running, and LWT is
less than the active setpoint + startup delta
12
Auto: Evap Recirc
Unit State = Auto and Evaporator State = Start
Unit State = Auto, Evaporator State = Start, and Flow
Switch is open
14
Auto: Pumpdn
Unit State = Pumpdown
Unit State = Auto, max pulldown rate has been met or
exceeded
exceeded
Unit State = Auto, unit current limit has been met or
exceeded
Unit configuration setpoint has changed, and reboot
of controller is required
19
Off Mfg Loc Not Set
Mfg Location is not set
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 Sta tu s
1 Off: Ice Mode Tmr
7 Off: BAS Disable
11 Auto: Wait for Load
13 Auto: Wait for flow
15 Auto: Max Pulldn
16 Auto: Unit Cap Limit
17 Auto: Current Limit
18 Off. Cfg Chg, Rst Ctlr
Unit State = Off, Unit Mode = Ice, and Ice Delay =
Unit State = Auto, unit capacity limit has been met or
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 targ et.
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 OMM 1123
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:
OMM 1123 25
• If the unit mode is cool, and the unit controller clock time is between the Noise
Control Source
Setpoint
Mode
Input
BAS
Request
Available Modes
Setpoint
OFF
X
Cool Setpoint 1
ON X Cool Setpoint 2
Network
X X BAS Cool Setpoint
OFF
X
Cool Setpoint 1
ON X Cool Setpoint 2
Network
X X BAS Cool Setpoint
OFF
x
Cool Setpoint 1
ON x Ice Setpoint
x
COOL
BAS Cool Setpoint
x
ICE
BAS Ice Setpoint
Local
x
x
Ice Setpoint
Network
x x BAS Ice Setpoint
Start Reset Delta T
LWT set Point+Max Reset
(54)
LWT Set Point
(44)
Return Reset
0
Max Reset
(10)
Evap Delta T (oF)
Active
LWT
(
o
F)
Reduction start time and end time
• Control Source setpoint is set to network, and the BAS command is ‘enable’
When Noise Reduction is active, the Maximum Reset is applied to the cool LWT
setpoint. However, if any reset type is selected, that reset will continue to be used rather
than the Maximum Reset. Also, the saturated conde ns er targ et for each circu it wil l be
offset by the Noise Reduction Condenser Target Offset.
Leaving Water Temperature (LWT) Reset
LWT Target
The LWT Target varies based on settings and inputs and is selected as follows:
Table 5, Leaving Water Temperature Targets
Base LWT Target
Local
Local
Local
Network
COOL
COOL w/Glycol
COOL/ICE w/Glycol
ICE w/Glycol
Leaving Water Temperature (LWT) Reset
The base LWT target may be reset if the unit is in Cool mode and it is configured for a
reset. The type of reset to be used is determined by the LWT Reset Type setpoint.
When the active reset increases, the Active LWT Target is changed at a rate of
0.2 degrees
is changed all at once.
After resets are applied, the LWT target can never exceed a value of 60°F.
Reset Type – None
The Active Leaving Water variable is set equal to the current LWT setpoint.
F every 10 seconds. When the active reset decreases, the Active LWT Target
26 OMM 1123
Reset Type – Return Chilled Wa ter
The Active Leaving Water variable is adjusted by the return water temperature.
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