DHR_Modular_Chiller_O&M_-_2_of_2.pdf

VME Heat Pump Start-Up Data Log

START-UP DATE: _____________________ SHIP DATE: ____________________ JOB NUMBER: _________________________ JOB NAME: _______________________________________________________________________________________________ ADDRESS: ________________________________________________________________________________________________ MULTISTACK REPRESENTATIVE: ______________________________________________________________________________ MODEL NUMBER: __________________________________________________________________________________________

MODULE SERIAL NUMBERS

1. __________________________________ 2. _________________________________

3. __________________________________ 4. _________________________________

5. __________________________________ 6. _________________________________

7. __________________________________ 8. _________________________________ PCO3 Program Version ________________________________________________________

WATER SIDE AND INSTALLATION CHECKLIST CIRCLE CORRECT RESPONSE

1. Chiller mounted on rails and isolators? YES NO

2. Any visible damage? YES NO If yes, detail: __________________________________________________________________

3. Any obvious oil and/or refrigerant leaks? YES NO If yes, detail: __________________________________________________________________

4. All pipe work independently supported from chiller? YES NO

5. Sensor pockets installed: HEAT LOAD: IN ____ OUT ____ SOURCE SINK: IN ____ OUT ____

COOL LOAD: IN ____ OUT ____

6. FLOW or differential switches installed: HEAT LOAD: _____ COOL LOAD: _____ SOURCE /SINK _____

7. Operation of flow or differential switches with reduction of 50% P ________

8. SOURCE/SINK 3-way by-pass valve? YES NO If yes - Temperature set point: ______ °F

9. System strainers installed? SOURCE/SINK YES NO TYPE (Y, Basket, etc.):__________

HEAT LOAD YES NO COOL LOAD YES NO

ELECTRICAL AND CONTROLS CHECKLIST CIRCLE CORRECT RESPONSE

1. All electrical connections tight and correct? YES NO

2. Power wiring sufficient to carry F.L.A? YES NO

3. Voltage levels:

Phases 1 + 2 2 + 3 1 + G 2 + G 3 + G

Voltage

4. Total AMP draw at 100% capacity: ____ AMPS YES NO

5. Program system variable to site connections, program date & time? YES NO

6. Verify demand for cooling? Heat? YES NO

7. Check sensors through microprocessor display? YES NO

8. Check interlock operation: Stop HEAT LOAD water pump? YES NO Stop COOL LOAD water pump? YES NO Stop SOURCE/SINK water pump? YES NO

9. Leave system in full operation? YES NO

10. Notify contractor of any problems? YES NO

Start-up Service Technician Owner or Contractor Acceptance Specification 236422 - Page 79 of 159

Cooling Mode Readings

Cooling Setpoints

UP SET LO SET VSP LOAD LIMIT T. DIFF LOAD P DROP S/S P DROP

Max number of cooling modules: ______

Cooling Mode Readings

Module Circuit

Current Temperature Head Pressure

Suction PressureA B C ELW LLW ESW LSW SH Suct.

A

B

A

B

A

B

A

B

A

B

A

B

Specification 236422 - Page 80 of 159

Heating Mode Readings

Heating Setpoints

UP SET LO SET VSP LOAD LIMIT T. DIFF HEAT DELAY HIGH ESW TEMP # MODULES

Max number of heat modules: _____

Heating Mode Readings

Module Circuit

Current Temperature Head Pressure

Suction PressureA B C ELW LLW ESW LSW SH Suct.

A

B

A

B

A

B

A

B

A

B

A

B

Specification 236422 - Page 81 of 159

Specification 236422 - Page 82 of 159

1064 Maple Avenue Sparta, WI • P 608-366-2400 • F 608-366-2450 www.multistack.com

F153IM0710Specification 236422 - Page 83 of 159

Dedicated HEAT RECOVERY pCO3 CONTROLLER

USER MANUAL

CONTROLLER FOR “MS10-85X LCHW CONTROL”

WATER-COOLED CHILLER WITH VARIABLE FLOW

for Version – MSHR103.07.STD LCHW CONTROL

Specification 236422 - Page 84 of 159

MSHR_102.08

Introduction

The Multistack Heat Recovery Chiller- is a modular water-cooled chiller composed of 2 circuits and is controlled by a master controller, to provide chilled or heated liquid to an external circuit. Each module contains 2 scroll compressors in 2 refrigerant circuits, stainless steel-brazed plate heat exchangers, and other related control components. Each chiller system is operated by a microprocessor based controller that monitors the status of each refrigerant circuit and provides a signal to operate the compressors as required. The system monitors based on selection either the ENTERING chilled or condenser water temperature (ECHWT / ECWT) or the LEAVING chilled or condenser water temperature (LCHWT / LCWT) to determine the need for cooling to the external circuit.

Module Board

Each module has a module board, which sends information to the master controller regarding the temperatures, pressures, and activity of the module and is equipped with a semi graphical LCD with backlight and six button keypad. The feedback from the module board reports the status of each module back to the Master Controller.

The module board performs safety checks and alerts the master controller when something is wrong. Loss of communication with the master controller results in the shutting down of the module when in Auto mode. The screen at the module board will display information regarding that module and the compressor installed on that module. The module board communicates this information and it is also passed to the Master Controller over the pLAN connection. Information like Mode, ECHW, LCHW, ECW, LCW, Suction Temp, High Pressure, Low Pressure, etc. from the compressor is available through this connection.

Master Controller

The master controller is equipped with a semi-graphical LCD with backlight and a six button keypad. These buttons aid the operator in setting SYSTEM VARIABLES, checking fault conditions, monitoring the status of the chiller system, and monitoring the status of individual modules. The master controller is also the interface to field supplied hardwire remote connections such as Remote Start/Stop, flow switch inputs, customer alarm outputs, CHILLED OR CONDENSER WATER RESET or LOAD LIMIT RESET signals. There is also an optional communication link for connecting to a Building Automation System (BAS). This connection will allow the BAS to remote monitor and control the chiller system. See BAS Interface on page 21

PCO3 Module Board MASTER CONTROLLER

Specification 236422 - Page 85 of 159

Esc

Prg

Controller Keys

The UP arrow button is used to go back to the previous category on the screen or to increase the value of a digit in a numeric variable field.

The DOWN arrow button is used to advance to the next category on the screen or to decrease the value of a digit in a numeric variable field.

The ENTER button is used to make a selection from any of the menu screens in the program. It is also used to enter and exit edit mode while in the SYSTEM VARIABLES screens.

The ALARM button is the menu for current system or module faults. When the backlight is red, it indicates that a fault has occurred.

The PROGRAM button goes to the MAIN MENU from any screen in the program.

The ESCAPE button goes to the previous screen or the status screen, if you are at the top of the MAIN

MENU.

Controller Setup

The Master Control and Module Boards’ address are set electronically by simultaneously pressing and holding the ALARM and UP buttons while cycling power on. After a few seconds a screen configuration will appear, to modify the address use the UP and DOWN buttons, and then press ENTER to confirm.

The following are the addressing parameters for setting up a Multistack Chiller network:

Chiller / Heater Modules – 1 thru 8 Master Controller – 30 Remote LCD Display – 32

In setting up the network, the master controller must have an address of 30. The Chiller modules would start with module 1 and proceed numerically through module 8.

Manual/Off/Auto Switch

Each Chiller module has a Manual/Off/Auto switch. In manual mode, the loading of the compressor is done by the module board. The control is independent of the other modules and is based on the LCHW of that module. When auto mode is selected, the staging of the compressors is handled by the master controller. The master controller will determine how many compressors need to be on in order to satisfy the load requirements. Control of the compressors is based on the system LCHW when in auto mode. Disabled mode (off) selection disables the module and the compressor is not allowed to run.

Specification 236422 - Page 86 of 159

Main Menu

The MAIN MENU displays the options the user can access in the program. Press the Prg button to get to the MAIN MENU and then use the UP and DOWN arrow buttons to scroll through the menu. The ENTER button allows displaying of the sub-menu that the greater than sign (>) is located beside. The MAIN MENU contains ON/OFF CONTROL, STATUS, SYSTEM VARIABLES, FAULT REVIEW, LOAD PROFILE, and SECURITY.

On/Off Control Screen Upon power up, the initial screen will go through a 12 second delay before giving control to the user. The ON/OFF CONTROL screen will be the next screen displayed when the timer expires. This screen allows the user to command the chiller on or off. The display will read ‘CHILLER OFF, PUSH ENTER TO START’.

Pushing the ENTER button, will display a message of ’30 SECONDS TO START!’ and will change to ‘CHILLER ON, PUSH ENTER TO STOP’. After the 30 second delay, the first compressor will turn on, if needed, and the display will change to the status screen. The last line of the ON/OFF control screen shows critical system faults such as WAITING FOR CHW FLOW, REMOTE SRART/STOP, and POWER PHASE

MONITOR.

System Variables

Once power is connected to the master controller, the SYSTEM VARIABLES can be accessed. These variables determine how the chiller system will run and are assigned default values.

Use the UP or DOWN arrow buttons to locate the SYSTEM VARIABLES in the MAIN MENU. The greater than sign (>) is the cursor indicator. Press the ENTER button to enter the SYSTEM VARIABLES MENU. Chiller Setup, Customer Resets, Temp Readings, Time and Date, BAS Interface, and Factory Setup are located in the SYSTEM VARIABLES MENU. Press the ENTER button again to enter one of the sub-menus. To change the value of a variable, press the ENTER button. A blinking block cursor will appear in that system variables’ value field indicating that the program is in edit mode. Use the UP or DOWN arrow buttons to change the value of the variable. To save the new setting, press the ENTER button, pressing the Esc button will not save the change. The cursor will move back to the upper left corner of the screen indicating that the program is no longer in edit mode. An asterisk (*) next to the variables indicates that the SYSTEM VARIABLES are locked and cannot be adjusted. For assistance on unlocking the SYSTEM VARIABLES, see SECURITY on page 17

LCHW / LCW Control logic

This manual describes using LCHW / LCW control through the master control. To use LCHW LCW control the application must be variable flow with power actuated butterfly valves on the Multistack modules. If variable valves are not used Entering CHW / CW control should be used. When LCHW / LCW control is enabled the controller looks at the system leaving water temp sensor on the evaporator or condenser side.

Terms:

Ideal Temp: Upper Setpoint minus No Load Point x the present load / total load. This value is then added to the No Load Point to give you the Ideal Temperature.

No Load (Zero) Point: The temperature at which the last compressor should shut off and demand = zero.

Control Temp: The desired leaving chilled / condenser water temperature

Specification 236422 - Page 87 of 159

If the LCHW Temperature is greater than the Lower Setpoint plus offset and the Cooling Control Temp is greater than the Cooling Ideal Temp + 2.6 deg then a compressor will turn on and the next compressor will come on at TDIFF.

If the LCHW Temperature is greater than the Lower Setpoint plus offset and the Cooling Control Temp is greater than the Cooling Ideal Temp + Cooling Offset then a compressor will turn on and the next compressor will come on at 2 x TDIFF.

If LCHW TEMP is less than or equal to the LOWER SETPOINT minus 0.5 °F then a compressor will turn off.

If the LCHW TEMP is less than the LOWER SETPOINT minus LCHW OFFSET, then a compressor will turn off and the next will follow at TDIFF if needed

If COOLING CONTROL TEMP is less than the COOLING IDEAL TEMP minus COOLING OFFSET then a compressor will turn off and the next will follow every 5 seconds as needed

If at any time the actual ECHW TEMP equals the COOLING ZERO LOAD (no load point or point when all compressors are off), the TDIFF TIMER will go to zero.

If at any time the COOLING CONTROL TEMP is less than or equal to the COOLING ZERO LOAD, a compressor will turn off. The TDIFF TIMER will then go to 5 seconds.

If at any time the COOLING CONTROL TEMP is less than or equal to the COOLING ZERO LOAD minus1.0 °F all compressors will turn off. This would be EMERGENCY TURN OFF

Low Temp warning: If any individual module’s LCHW temperature drops to the LCHW LOW TEMP cutout (i.e. 34.0 °F with no glycol) + 2.0 °F then only ONE compressor in that module is allowed to run until the module leaving water temperature is above LCHW LOW TEMP cutout plus 6.0 °F and the minimum off timer for the compressor expires. The compressor with the highest run hours should be the compressor that is disabled.

Chiller Setup (System Variables)

The following is a list of SYSTEM VARIABLES for the modules in Heating Mode.

HEATING MODE SETUP

Select Control to “ENTERING” OR “LEAVING”

For “Leaving” Control Only

1. LCW SETPOINT: The desired Leaving Condenser Water Control Temperature

2. LCW OFFSET: Number of degree’s minus Lower Setpoint before the first compressor turns on

3. LCW STAGE OFF: Number of seconds between staging off of compressor

4. LCW WARNING: Alarm point if when the LCW Temp reaches this degree

For “Entering Control” Only

5. UPPER SETPOINT: The designed leaving condenser water temperature (LCW as displayed by the master control System Sensor) at full load. The temperature drop across this chiller is based on flow rate. If

Specification 236422 - Page 88 of 159 the design temperature drop (∆T) is 10°F across the condenr, then the UPPER SETPOINT should be 10°F above the LOWER SETPOINT. In LCHW control the Upper Setpoint is not the point of temperature control

6. LOWER SETPOINT: The desired entering condenser water temperature (ECW as displayed by the master control System Sensor).

7. VSP SETPOINT: A percentage used to determine the control setpoint. Leaving the VSP at 100% would keep the control setpoint at the value of the UPPER SETPOINT. Lowering the VSP would incorporate a condenser water reset scheme allowing the control setpoint to change depending on the ECW Temperature.

As the ECW Temperature approaches the UPPER SETPOINT value the control setpoint will reset according to the VSP percentage. See Graph on page 9 for explanation.

COOLING MODE SETUP

Select Control to “ENTERING” OR “LEAVING”

For “Leaving” Control Only

8. LCHW SETPOINT: The desired Leaving Chilled Water Control Temperature

9. LCHW OFFSET: Number of degree’s PLUS Lower Setpoint before the first compressor turns on

10. LCHW STAGE OFF: Number of seconds between staging off of compressor

For “Entering Control” Only

11. UPPER SETPOINT: The designed entering chilled water temperature (ECHW – System sensor) at full load. The temperature drop across this chiller is based on flow rate. If the design temperature drop (∆T) is 10°F across the chiller, then the UPPER SETPOINT should be 10°F above the LOWER SETPOINT.

12. LOWER SETPOINT: The desired leaving chilled water temperature (LCHW – System sensor). The LOWER SETPOINT would be the setpoint the chiller is controlling to if the VSP is set to 0%.

13. VSP SETPOINT: A percentage used to determine the control setpoint. Leaving the VSP at 0% would keep the control setpoint at the value of the LOWER SETPOINT. Raising the VSP would incorporate a chilled water reset scheme allowing the control setpoint to change depending on the ECHW Temperature.

As the ECHW Temperature approaches the LOWER SETPOINT value the control setpoint will reset according to the VSP percentage. See Graph on page 9 for explanation

MODE OF OPERATION

14. AUTO: In COOLING MODE if the ECW rises above the no load point (default 120 deg F) of the HEATING MODE the controls will do an auto changeover to HEATING MODE. This will cause all of the compressors to turn off and start a 30 second countdown to re-start. The control will now display HEATING MODE info.

In HEATING MODE if the ECHW drops below the no load point (default 50 deg F) of the COOLIING MODE the controls will do an auto changeover to cooling MODE. This will cause all of the compressors to turn off and start a 30 second countdown to re-start. The control will now display

COOLING MODE info.

In The case that the ECW is above the no load point of the HEATING MODE, and the ECHW is below the no load point of the COOLING MODE, everything should be OFF and the controller should be in the COOLING MODE.

Specification 236422 - Page 89 of 159

14. COOLING OVERRIDE: Runs chiller based on CHW setpoints only. If CW settings are exceeded the chiller will trip out

15. HEATING OVERRIDE: Runs chiller based on CW setpoints only. If CHW settings are exceeded the chiller will trip out

16. OPTIMIZED COOLING: if controlling to heating, HEATING DEMAND LIMITED will be displayed along with OPTIMIZED COOLING. The CW Valve will control to a new setting in the variable flow called CW HP CONTROL compared to LCW of that module, if the Module LCW Sensor is present.

Range 70.0 ‐ 140.0°F 75.0°F

If the Module LCW Sensor is not present, the CW HP CONTRL will be converted to a pressure and passed to the module as cond pres setpt to compare to the Max HP of the 2 circuits

17. OPTIMIZED HEATING: Control to the lighter of the 2 loads. If controlling to cooling, COOLING DEMAND LIMITED will be displayed along with OPTIMIZED HEATING. The CHW Valve will control to a constant 65.0°F compared to the LCHW Temperature of that module.

FOR BOTH CONTROL MODES

16 T-DIFF (Time Difference): Represents the minimum time in seconds between staging of compressors. This time should be set to half of the loop time. The loop time is the time it takes for the water to make one pass through the entire CHW loop of the building or load circuit. When the temperature of the ECHW approaches the ideal temperature, T-DIFF goes to 2 X T-DIFF. When unloading compressors, T-DIFF goes to T-DIFF/2.

17 LOAD LIMIT: A percentage used to limit the maximum system load. If this variable is set to 75% on a 4 compressor chiller, then only 3 of the 4 compressors would be available to run at any given time.

18 FAIL INDIC (Failure Indicator): A percentage value which provides for an output signal to the Customer Alarm Relay whenever compressors of the indicated value have failed. A 0% setting will give an output signal after any failure within the system.

19 LEAD COMPRESSOR: Determines which compressor is the first on. The first compressor off is the compressor that has run the longest in that particular cycle.

20 NUM OF COMPRESSORS: This is the number of the chillers compressors that are in the system.

21 SEQUENCING: Determines the order in which the compressors will turn on or off. In most applications “ODD / EVEN” is the preferred method.

STANDARD – The compressors turn on in numerical order starting with the lead compressor.

ODD/EVEN – A scheme developed to bring one compressor in each module on before the second compressor in any module is allowed to run. If the LEAD COMPRESSOR ends in -2 (M1-2, M2-2, etc), then all even compressors would start before the odd compressors. If the LEAD COMPRESSOR ends in -1 (M1-1, M2-1, etc), then all add compressors would start before the even compressor.

22 INDEXING: INDEXING can either be ON or OFF. If ON, the lead compressor advances by one every 24 hours at midnight. If OFF, the LEAD COMPRESSOR stays the same unless it is changed manually.

Specification 236422 - Page 90 of 159

23 HP CUTOUT: The point where a high pressure fault occurs based on the high pressure reading returned from the compressor. This value is measured in psig. Note: Each module also has a mechanical high pressure switch with a manual reset. (585 psig)

24 FLUSH TIME: The time in hours at when the Multiflush valve is cycled.

25 FLUSH DURATION: The time in seconds that the Multiflush valve is energized.

26 CAPACITY CONTROL: This is found in the Factory Setup Menu.

STANDARD: for capacity control to change modes until the opposite mode reaches the “No Load” point.

SOFT: Capacity control will change anytime based on the demand values. This should only cause 1 compressor stage to shut off rather than the whole machine when switch from heat to cool or vice versa. A mode switch should not allowed to occur until one full stage off timer expires after a compressor shut off.

Standard Application LCHW Control

Program Version Format MSHR.103.07

System Variable Ranges & Default Settings

The following table defines all of the SYSTEM VARIABLE ranges and default values for the standard program.

System Variable Range Default Value

LCW SETPOINT 60-140 120

LCW OFFSET .5 - 10 2

LCW STAGE OFF 5-90 sec 30 sec

LCW WARNING 70 - 190 130

LCW TDIFF 15 – 360 sec 90 sec

LCHW SETPOINT 38-80 45

LCHW OFFSET .5 - 10 3

LCHW TDIFF 15-360 90 sec MODE OF OPERATON auto, cool / heat override, Auto optimize cool / heat

LOAD LIMIT 0-100% 100

FAIL INDIC 0-100% 0

LEAD COMPRESSOR 1-14 1

# OF COMPRESSORS 1-14 1

SEQUENCING STD or ODD/EVEN

INDEXING ON OR OFF ON

HP CUTOUT 400-650 585

FLUSH TIME 0 – 24:00 12:00

FLUSH DURATION 0 – 30 sec 5 sec

Specification 236422 - Page 91 of 159

Standard Application ECHW Control Program Version Format MSHR.103.07

System Variable Ranges & Default Settings

The following table defines all of the SYSTEM VARIABLE ranges and default values for the standard program.

HEAT UPSETPOINT 60-140 120

HEAT LOSETPOINT 50-135 110

HEAT VSP 20-100% 50%

COOL UPSETPOINT 45-95 55

COOL LOSETPOINT 38-80 45

COOL VSP 20-100% 50%

T-DIFF 15-360 90%

MODE OF OPERATON auto, cool / heat override, Auto optimize cool / heat

LOAD LIMIT 0-100% 100

FAIL INDIC 0-100% 0

LEAD COMPRESSOR 1-14 1

# OF COMPRESSORS 1-14 1

SEQUENCING STD or ODD/EVEN

INDEXING ON OR OFF ON

HP CUTOUT 400-650 585

FLUSH TIME 0 – 24:00 12:00

FLUSH DURATION 0 – 30 sec 5 sec

Standard Module Cutouts and Reset Points

Low Suction Temp Cutout 25°F Reset @ 30°F Low Leaving CHW Cutout 34°F Reset @ 38°F Low Pressure Cutout 40 psig Reset @ 60 psig High Pressure Cutout 650 PSIG Reset below 600 psig

Specification 236422 - Page 92 of 159

Mechanical Cooling – Manual Mode Each module’s slave board can now also be used to set the Manual Mode Setpoints. For this mode to take effect the selector switch in the module should be moved to “Manual”. On controller push ESC button. Select Manual Mode Setup In manual mode operation, each module acts independently, depending on the sensor inputs to that module.

The loading of the compressor is done by its module board. The control is based on the LCHW temperature of that module. The following are SYSTEM VARIABLES that are used in manual mode operation:

1. MAN. SETPOINT: The LCHW temperature that the compressor will control to.

2. MAN. RANGE: A value, when added to the MAN. SETPOINT where the first compressor will turn on.

3. MAN. OFFSET: A value, when added to the MAN. RANGE, where the compressor will turn on;

and, when subtracted from the MAN. RANGE, the point where the compressor will turn off.

Caution: Operation of chiller in manual mode bypasses the flow protection and power phase monitor safeties. Operation of the chiller in this mode is not recommended for extended periods. Proper precautions must be made to prevent freezing of the heat exchangers.

Manual Mode Ranges and Default Settings

MAN. SETPOINT 40°F to 70°F 45°F MAN. RANGE 2°F to 20°F 10°F MAN. OFFSET 0°F to 5°F 2°F

TURN COMPR. 2 OFF

47.0 °F

OFFSET = 2.0 °F

SETPOINT = 45.0 °F

45.0 °F

55.0 °F

RANGE = 10.0 °F

TURN COMPR.1 OFF

TURN COMPR. 1 ON

57.0 °F

TURN COMPR. 2 ON

Specification 236422 - Page 93 of 159

Master Controller Status Screens

System Screens

The main status screen displays information about the chiller system.

A. SYSTEM STATUS

1. DEMAND: A percentage of current load needed compared to the maximum design load.

This value is determined by the system ECHW, or ECW depending on the Mode the chiller is running in and temperature and the settings of the SYSTEM VARIABLES.

2. CAPACITY: A percentage of the chiller that is operating. It is calculated by adding the demand of each compressor (0-100%) This value is then divided by the product of the total number of compresors times 100. This value will be displayed in the range of 0-100%. An asterisk (*) displayed next to capacity indicates that it is being controlled by an external source, either LOAD LIMIT or CHILLED / CONDENSER WATER RESET.

3. DELAY: A time in seconds between demand increases or compressor starts. A compressor should only turn on or ramp to a new demand if the delay time counter is at zero. This is determined by the system variable T-DIFF.

4. FAULTS: A value showing how many current faults are in the chiller system.

5. ECHW: The common Entering Chilled Water temperature to the chiller.

6. LCHW: The common leaving Chilled Water temperature from the chiller.

7. ECW: The common Entering Condenser Water temperature to the chiller.

8. LCW: The common Leaving Condenser Water temperature from the chiller.

Press the DOWN arrow button once to display the next main status screen with system information.

9. DEMAND HEATING: Percent called for based on Heat Demand

10. CAPACITY HEATING: Percent running based on Heat Demand

11. DEMAND COOLING: Percent called for based on Cool Demand

12. CAPACITY COOLING: Percent running based on Cool Demand

13. LOAD LIMIT: A percentage value to limit the max number of compressors available at any given time. An asterisk (*) indicates the external LOAD LIMIT RESET signal is enabled.

14. CHILLED WATER OFFSET:

15. CONDENSER WATER OFFSET:

16. CHILLED WATER PUMP OUTPUT: On or Off

Specification 236422 - Page 94 of 159

17. CONDENSER WATER PUMP OUTPUT: On or Off

Module Information Screens (at the master controller)

Press the DOWN arrow button while on the second main status screen will display information for the first module. The following information is available for each module in the chiller

MODULE 1A STATUS

1. MOD 1 A & B STATUS: On or Off

2. EVD ONLINE:

3. ECHW: The Entering Chilled Water temperature in the system.

4. LCHW: The Leaving Chilled Water temperature in the module, measured at the leaving of each heat exchanger coil.

5. ECW: The Entering Condenser Water temperature in the system.

6. LCW: The Leaving Condenser Water temperature in the module, measured at the leaving of each heat exchanger coil.

Press the DOWN arrow button again. Additional information is displayed

7. MOD 1A STATUS: Tells On / OFF state of both compressors for Module 1A

8. RUN TIME HOURS: This displays the total number of hours that the compressor has run. To reset the run hours, press and hold the ALARM and DOWN arrow buttons simultaneously on the screen of the module whose hours need to be reset. The SYSTEM VARIABLES must be unlocked to clear compressor run hours

9. HP: The High Pressure reading in psig based on the transducer in the compressor for that module.

10. LP: The Low Pressure reading in psig based on the transducer in the compressor for that module.

11. SUCT: The Suction temperature in the module, located on the compressor suction line.

12. SUPERHEAT: Calculated refrigerant suction superheat to the compressor.

13. PRESSURE RATIO: Percentage difference between HP and LP

14. EVD PERCENT: Percent open of the electronic expansion valve

Press the DOWN arrow button again. The same information for Module 1B will be displayed.

Press the DOWN arrow button again. The same information for additional modules will be displayed.

Module Information Screens at the Module Boards

Specification 236422 - Page 95 of 159

On the module board push the ESC key. Select Module Status menu

1. STATUS: Compressor A &B On or Off

2. ECHW: The Entering Chilled Water temperature in the system

3. LCHW: The Leaving Chilled Water temperature in the module, measured at the leaving of the cooling system.

4. ECW: The Entering Condenser Water temperature in the system.

5. LCW: The Leaving Condenser Water temperature in the module, measured at the leaving of each heat exchanger coil.

6. Any current fault is displayed

7. MOD 1A STATUS: Tells On / OFF state of both compressors for Module 1A

8. RUN TIME HOURS: This displays the total number of hours that the compressor has run. To reset the run hours, press and hold the ALARM and DOWN arrow buttons simultaneously on the screen of the module whose hours need to be reset. The SYSTEM VARIABLES must be unlocked to clear compressor run hours

9. HP: The High Pressure reading in psig based on the transducer in the compressor for that module.

10. LP: The Low Pressure reading in psig based on the transducer in the compressor for that module.

11. SUCT: The Suction temperature in the module, located on the compressor suction line.

12. SUPERHEAT: Calculated refrigerant suction superheat to the compressor.

13. PRESSURE RATIO: Percentage difference between HP and LP

Press the DOWN arrow button once to display same information for Module 1B.

Manual Mode Module Screens

At the Module Board Press the PRG button when in Manual Mode to change the manual mode variables.

1. CONTROL MODE: Select Heat or Cool

2. HEAT SETPOINT: The LCW temperature that the compressor will control to.

3. HEART RANGE: A value, when added to the HEAT. SETPOINT where the first compressor will turn on

4. HEAT OFFSET: A value, when subtracted to the HEAT. RANGE, where the compressor will turn on;

and, when added from the HEAT RANGE, the point where the compressor will turn off.

5. COOL SETPOINT: The LCHW temperature that the compressor will control to.

6. COOL RANGE: A value, when added to the COOL SETPOINT where the first compressor will turn on

7. COOL OFFSET: A value, when added to the COOL RANGE, where the compressor will turn on; and, when subtracted from the COOL RANGE, the point where the compressor will turn off.

Valve Override Module Screens

At the Module Board Press the PRG button then select Valve Override

1. CHW Valve Override: Yes or No? Select percent to override valve to by using arrow keys

2. CW Valve Override: Yes or No? Select percent to override valve to by using arrow keys 3.

MOD Fault Review. See page 17

Customer Settings Module Screens

Specification 236422 - Page 96 of 159

Enter password Save Run Hours?

Save manual Setpoints?

Restore Run Hours?

Restore Manual Setpoints?

Clear Perm memory?

Factory Defaults

Inputs and Outputs

Master Controller Inputs

1. Customer Chilled Water Reset Signal or Customer Load Limit Reset Signal: A 0-10Volt, 0-20 mA, or 4-20 mA, customer supplied, external signal that shifts the UPPER and LOWER SETPOINTS from 0 to 10°F or allows the customer to change the LOAD LIMIT from 0 to 100%.

2. Entering Chilled Water Sensor: A NTC type sensor that measures the temperature of the ECHW going into the chiller.

3. Leaving Chilled Water Sensor: A NTC type sensor that measures the temperature of the LCHW coming out of the chiller.

4. Entering Condenser Water Sensor: A NTC type sensor that measures the temperature of the system

ECW going into the chiller.

5. Leaving CondenserWater Sensor: A NTC type sensor that measures the temperature of the system LCW coming out of the chiller.

6. EX1: A customer supplied “Dry Contact” input that is required to be closed circuit to operate; open to stop operation. Requires manual reset to resume operation. This input will create a fault.

7. Remote Start/Stop: An input that is a closed circuit to operate; open to stop operation. Automatic restart of the chiller. This input does NOT create a fault.

8. Power Phase Monitor: An input that is a closed circuit to operate; open to stop operation. Automatic restart returns the chiller to the previous on/off state of the chiller. This input will create a fault.

9. CHW Flow Switch: An input that is a closed circuit to operate; open to stop operation. This circuit has a 4 second delay between the time it opens and when the system shuts down. Requires a reset and a restart to resume operation.

10. Condenser Flow Switch: An input that is a closed circuit to operate; open to stop operation. This circuit will allow the system to start when open. There is a 10 second delay on start-up before this circuit will shut the system down. This is to allow time for the condenser water pump to start with the first compressor and provide water flow stabilization. After the initial 10 second delay expires, then the fault only requires a 4 second delay between the time it opens and the time the system shuts down during normal operation.

Requires a reset and a restart to resume operation.

Master Controller Outputs

1. Customer Alarm Relay: This is a 24V AC, 5VA max signal that can power a relay to trigger an alarm.

The output is controlled by the failure indicator setting in the SYSTEM VARIABLES.

2. Full Load Indicator Relay: This is a 24V AC, 5VA max signal that can power a relay to show when the chiller system is at full load.

Specification 236422 - Page 97 of 159

3. Condenser Pump Starter Relay: This is a 24V AC, 5VA max signal that can power a small relay to control the condenser water pump. In DHRC applications this output is energized whenever the chiller is commanded ON so we have CW flow even with no compressors running.

4. Remote Pump Enable: This is a contact closure, 5VA max signal that can be used to remotely enable the pump. The contact will be closed anytime the chiller is on. When the chiller is turned off, the pump will continue to run for two times the amount of time of TDIFF. The exception is when the Power Phase Monitor is tripped; the contact will open with no time delay.

Module Board Inputs

1. High Pressure Transducer: A ratiometric input sensor that measures the high side pressure of the refrigerant in each module.

2. Low Pressure Transducer: A ratiometric input sensor that measures the low side pressure of the refrigerant in each module.

3. Suction Sensor: A NTC type sensor that measures the temperature of the suction line.

4. Leaving Chilled Water Sensor: A NTC type sensor that measures the temperature of the LCHW in the

5. Leaving Condenser Water Sensor: A NTC type sensor that measures the temperature of the LCW in the module. This sensor is not required but highly recommended for DHRC if doing LEAVING water control

6. Manual Mode/Auto Mode: Inputs that identify whether the module is in manual, auto, or disabled mode.

7. High Pressure Switch: An input that indicates when the switch for the high side pressure of the refrigerant circuit has tripped.

8. Circuit Faults: An input that monitors the control circuit of each compressor for abnormal operating conditions. A 1 or 2 would be displayed to show which compressor circuit has a fault.

Module Board Outputs

1. Compressor Start Signal: A 24V output to start the compressors.

2. Alarm Light: A 24V output to a light on the module that would indicate a fault has occurred within the

FAULT REVIEW MENU

- System Faults: System Fault information is stored in the Master Control

- Module Faults Overview: Any non system faults will now have their information stored in its respective module board. An overview only of the fault is available at the Master

If a fault condition has occurred, the ALARM button will illuminate. To view the current fault(s), press the ALARM button. Use the UP and DOWN arrow and ENTER buttons to view and clear the fault(s). If the fault does not clear, then the fault is still current.

System Faults

If any of the following fault conditions occur, all compressors in the system will be turned off.

Specification 236422 - Page 98 of 159

1. EX1: Customer Input – EX1 requires a reset and restart command at the master controller.

2. Remote Start/Stop: Customer Input – This condition does not log as a fault. This circuit operates like an on/off switch. If closed, the chiller is enabled. If open, the chiller is disabled and the compressors will not run.

3. Power Phase Monitor: When the Power Phase Monitor Input opens, the chiller is disabled until the input is closed again. There is no reset required at the master controller to resume operation, only to clear the alarm from the current fault log. Automatic restart returns the chiller to the previous on/off state of the chiller.

4. Condenser Water Flow: Signal from the condenser water flow switch that alerts the master controller of

NO FLOW on the condenser side of the chiller and disables all modules. This fault requires a manual reset and a restart at the master controller.

5. Chilled Water Flow: Signal from the Chilled water flow switch that alerts the master controller of NO FLOW on the chilled water side of the chiller and disables all modules in the chiller. If the flow switch opens and the chiller has not been commanded ON, a warning will appear at the bottom of the start/stop screen, however, no fault will occur. This fault requires a manual reset and restart at the master controller.

6. LOCHW Temp: Low Leaving Chilled Water temperature. If the system LCHW falls below 34°F, all compressors will turn off. The water temperature must rise to 38°F before the fault can change from current to reset. This requires a manual reset and restart at the master controller.

7. ECHW Sensor Failure: The sensor for the system ECHW has either opened or shorted to the master controller. This fault requires resetting at the master controller.

8. LCHW Sensor Failure: The sensor for the system LCHW has either opened or shorted to the master controller. This fault requires resetting at the master controller.

9. ECW Sensor Failure: The sensor for the system ECW has either opened or shorted to the master controller. This fault does not affect the operation of the chiller.

10. LCW Sensor Failure: The sensor for the system LCW has either opened or shorted to the master controller. This fault does not affect the operation of the chiller.

Mechanical Cooling Module Warnings

1. LOCHW TEMP WARNING: Low Leaving Chilled Water Temperature WARNING: This is a feature that will help protect from faults on Low CHW Temp. This is measured by the module LCHW temperature sensor. If the temperature falls below 38°F, one of the circuits (2 compressors) will shut off and the module’s status will display this warning. The temperature must rise to 40°F before the compressor can restart and warning goes away. This warning is auto reset and will be displayed in the Fault Review though it does not create an alarm and need resetting. This feature is only active when in LCHW Control.

2. LCW TEMP WARNING: High leaving Condenser Water Temperature warning. This is a feature that will help protect the module from faulting on HP faults. If the LCW temp gets above this setting.one of the circuits (2 compressors) will shut down and the module’s status will display this warning. . This warning is auto reset and will be displayed in the Fault Review though it does not create an alarm and need resetting.

This feature is only active when in LCW Control.

Mechanical Cooling Module Faults Must Go to each module board for these

Specification 236422 - Page 99 of 159

If a fault condition has occurred, the ALARM button will illuminate. To view the current fault(s), press the ALARM button. Use the UP and DOWN arrow and ENTER buttons to view and clear the fault(s). If the fault does not clear, then the fault is still current.

The following faults will only affect the module that they are associated with.

3. High Pressure: High Pressure Cutout. This high pressure fault can comes from the transducer reading of the compressor . When the HP transducer reading reaches the value of the HP CUTOUT the alarm goes off, shutting down that module. The fault can be reset at the master controller after the high side pressure drops below xxx psig.

4. High Pressure Switch: If the HP Switch senses that the pressure is greater than the mechanical setpoint of the switch, the switch will trip and trigger this fault to occur. If the HP switch trips, it requires resetting at the module HP switch and the master controller to resume operation. The fault will remain current until the HP switch is manually reset.

5. Low Pressure: Low Pressure Cutout. If the reading from the LP transducer falls below 50 psig, then that module will be shut down and will be in an alarm state. This fault will remain current until the low side pressure rises above 60 psig. The fault can then be reset at the master controller. (Typically indicates loss of refrigerant charge.)

6. LOSUCT: Low Suction Temperature: This is measured by the module suction sensor. If during operation this temperature should drop below 25°F, the module’s compressor will shut down. This requires resetting at the master controller, but only after the temperature has risen above 30°F. The system has to be on for this fault to occur.

7. SUCT SENSOR FAILURE: Suction Sensor Failure. This would occur if the suction line sensor reading is outside the range of the sensor. This fault requires resetting at the master controller.

8. LOCHW TEMP: Low Leaving Chilled Water Temperature: This is measured by the module LCHW temperature sensor. If the temperature falls below 36°F, the module’s compressor will turn off. The temperature must rise to 38°F before the fault can be reset at the master controller.

9. LCHW SENSOR FAILURE: Leaving Chilled Water Sensor Failure: This would occur if the sensor opened or shorted to the module board. This fault requires resetting at the master controller.

10. COMMUNICATIONS ERROR: Communication errors can occur when the master controller is not properly communicating with the module boards in the chiller. This fault is an automatic reset. The alarm will still need to be cleared in the alarm screens; however, this will not hold back the operation of the module if the master controller begins communicating again.

11. HP or LP SENSOR FAIL: The HP or LP transducer is not reading to the controller. Normally results in a “0” reading on the fault stamp. On the HP transducer the “0” reading must last 10 seconds or longer. On the LP transducer it must read for 2 seconds. Cause could be a loose connection, defective transducer, or defective cable.

12. Circuit Fault: A CIRCUIT FAULT will occur if the compressor contactor is not operating normally. Four conditions could potentially create a CIRCUIT FAULT. One would be, if the program signals for a contactor to be closed and it does not close within 5 seconds. Once the contactor has been closed for 5 seconds, if the contactor ever opens for 1 second while under normal operating conditions (indicating a chattering contactor), a fault will occur. The third condition would be if the program turns a contactor off and the contactor remains closed for an additional 10 seconds then this fault would occur (indicating a welded contactor). The last condition that could create a circuit fault is if the differential between the high pressure and the low pressure does not exceed 50 psig within 60 seconds after the compressor starts.

This fault requires resetting at the master controller to resume normal operation

13. Thermal Fault: A Thermal Fault will occur when the compressor motor’s internal thermal

Specification 236422 - Page 100 of 159 protection sensor senses a motor overheating condition is present. The motor protector will shut down the motor until a safe operating temperature is reached and will trigger this error to occur. This fault requires resetting at the master controller once the motor protector has determined that a safe operating temperature has been reached to resume operation.

Fault Review

Mechanical Cooling Module Faults Note again: Module fault information is now found in the respective module board. System Faults have all info in the Master Control.

GO TO THE MODULE BOARD FOR FAULT DETAILS

The FAULT REVIEW is a history of the faults that have occurred in the chiller system. The review holds up to 25 faults. The review can be found in the MAIN MENU. The faults are in order by the most recent to the oldest. Pushing the UP and DOWN arrow buttons allows scrolling through the faults. Pushing the ENTER button on a particular System fault allows for viewing of a second screen of information. Pushing ENTER again returns to the first screen of the fault. The following is a sample of what the screens contain.

MASTER CONTROL FAULT SCREENS

MODULE BOARD FAULT SCREENS

Mod1A Mod1B

Screen #2Screen #1

SYSTEM MODULE

ECHW 55.0 SUCT 0.0

LCHW 45.0 LCHW 0.0

ECW 85.0 HP 0

LCW 95.0 LP 0

FAULT 01 CURRENT

MASTER SYSTEM

POWER PHASE FAULT

4/4/12 12:35

PRESS ENTER FOR MORE

Specification 236422 - Page 101 of 159

Screen one displays information about the fault. The status of the fault will be displayed as CURRENT, RESET, or RECORD. CURRENT means that the fault is still present, RESET means that the fault can be reset at the master controller, or modul board and RECORD means that the fault is part of the history for future reference. The date and time of the fault, the fault that occurred and where the fault occurred are also displayed on the first screen. On screen two, the system temperatures at the time the fault occurred will be displayed on the left side of the screen and are starred with an asterisk (*). On the right side of the screen is module information that was current at the time of the fault. If the fault is a system fault the module information will display all zeros.

Clearing the faults from the FAULT REVIEW removes all the faults at once. Hold down the Prg and UP arrow buttons simultaneously for all faults to be removed from the FAULT REVIEW. When a message of NO MORE ALARMS appears on the screen, release the buttons.

Time and Date

The TIME AND DATE option is located in the SYSTEM VARIABLES’ MENU. Press ENTER on the TIME AND DATE option. The time appears first and is displayed in 24 hour time. To change the time, press the ENTER button, putting the program into edit mode. The cursor is now in the hour field, use the UP and DOWN arrow buttons to change the hour to the correct time. Press the ENTER button again to move the cursor to the minute field to change it. Press the ENTER button one more time to set the TIME. Press the Esc button, at anytime, to abort the time change.

After setting the TIME, use the DOWN arrow button to move to the DATE screen. Press ENTER to move the cursor into the month field. Using the UP and DOWN arrow buttons, change the value to the current month.

Press ENTER again to move the cursor to the day field, adjust the day accordingly. Press ENTER again to move to the year field, adjust the year accordingly. Press ENTER one more time to accept the DATE. Press the Esc button, at anytime, to abort the date change.

Customer Resets

CHILLED WATER RESET (CHW) and LOAD LIMIT RESET are external inputs that are program selectable as 0-10Volt, 0-20 mA, or 4-20 mA. The customer can send a signal to change these values remotely. The CHW RESET will increase the UPPER and LOWER SETPOINTS in the chiller from 0 to 10 °F. The LOAD LIMIT RESET will allow the LOAD LIMIT of the chiller to be changed from 0 to 100%. There will be an asterisk (*) by the LW OFFSET or the LOAD LIMIT values on the second system status screen, if they are enabled. The CUSTOMER RESET options are located in the SYSTEM VARIABLES’ MENU. An asterisk (*) also appears next to CAPACITY on the main status screen when either reset is enabled. Press ENTER and use the UP and DOWN arrow buttons to enable the feature to be used. Both default to OFF, but when enabling the user must select the type of input being used. (0-10 Volt, 0-20 mA, or 4-20 mA)

Screen #2Screen #1

COMP1 ON COMP2 ON

HP 375 ECHW 55

LP 115 LCHW 45

PR 2.5 ECW 85

SHEAT 12.0 LCW 95

SUCT 42

FAULT 01 CURRENT

HP SWITCH CIRC B

4/4/12 12:35

PRESS ENTER FOR MORE

COMP1 ON COMP2 ON

HP 375 ECHW 55

LP 115 LCHW 45

PR 2.5 ECW 85

SHEAT 12.0 LCW 95

SUCT 42

VARIABLE FLOW

OUTPUT ACTUAL

COND 0% 0%

EVAP 0% 0%

Specification 236422 - Page 102 of 159

Temperature Display

The temperature readings default to Fahrenheit (°F). The readings may be set to display in Celsius (°C), by going to the SYSTEM VARIABLES’ MENU. Press ENTER on TEMP. READINGS option. Press ENTER again to move the cursor into the field. Use the UP or DOWN arrow button to change the field from Fahrenheit to Celsius. Press ENTER again to accept the change.

Interface Options

Security

The security option in the MAIN MENU is used to lock the SYSTEM VARIABLES. The first screen tells whether the variables are locked or unlocked. Initially the screen will say ‘SYSTEM VARIABLES UNLOCKED’.

Press ENTER to change the status of the security. The cursor will be on the first letter of the password code.

Enter a five letter password, using the UP and DOWN arrow buttons to change the letter and press ENTER to move to the next letter. After entering the last letter, the next screen is to accept the password or clear the password. Press ENTER again to set the password or Esc to clear the password. The screen will then display the status of the SYSTEM VARIABLES as LOCKED. An asterisk (*) is displayed within the SYSTEM VARIABLES’ MENU in place of the greater than sign (>) as a cursor for the menu. If the asterisk is seen, the SYSTEM VARIABLES need to be unlocked before trying to make any changes to them.

If the password is forgotten, please call your Multistack Service Representative at 608-366-2400.

Board LED’s

Five LED’s are present on the master controller board. Two LED’s are located at the bottom of the board, one yellow and one red. The yellow one indicates that the board is receiving power. The red one is an alarm LED that would indicate that something is wrong with the board internally. Three more LED’s are located at the top of the board . These LED’s indicate that the connection, address definition and pLan (network of the modules) are working correctly. The green and yellow LED’s should be lit for the network to be working properly.

Four LED’s are present on each module board. They are all located at the top of the board. One single yellow LED indicates that the board is receiving power.