CFC-11 Centrifugal Chiller Monitor Installation and Start-up Manual

CFC-11 Centrifugal Chiller Monitor Installation and Start-up Manual
CFC-11 Centrifugal
Chiller Monitor
Installation and Start-up Manual
CFC-11 Centrifugal
Chiller Monitor
Installation and Start-up Manual
This document is the property of Carrier Corporation and is delivered on
the express condition that it is not to be disclosed, reproduced in whole
or in part, or used for manufacture by anyone other than Carrier
Corporation without its written consent, and that no right is granted to
disclose or so use any information contained in said document.
Carrier reserves the right to change or modify the information or product
described without prior notice and without incurring any liability.
© 1994, Carrier Corporation
PREVAC® is a registered trademark of Mechanical Ingenuity
Corporation.
Errata Sheet
Page 1 of 2
CFC-11 Centrifugal Chiller Monitor Installation and Start-up Manual
808-883 3/94
Page 7
The last line on the page should read as follows:
the CFC-11 Chiller Monitor Schematic, which is included with the Chiller Monitor.
Page 23
On Figure 8, the water pipe labeling and the arrows on the water pipes should be reversed, as
shown correctly below.
May 1994
94-1
Errata Sheet
Page 2 of 2
CFC-11 Centrifugal Chiller Monitor Installation and Start-up Manual
808-883 3/94
Page 41
Insert the following before Field Installed Relays:
Connecting CCN
Communication
Bus Wiring
(Optional)
If applicable, connect CCN Communication Bus Wiring to the
Chiller Monitor PSIO Module as shown below:
BLACK
WHITE
RED
SHIELD
FROM
PREVIOUS
CCN SYSTEM
ELEMENT
TO NEXT
CCN SYSTEM
ELEMENT
1
2
3
COMM1
PLUG
4
MASTER
PROCESSOR
MODULE
( PA R T I A L )
R
1
MM
PW
CO
Pages 101 and 102
The cable number for "Safety input" should be listed as 3.
The two rows in the table beginning "Condenser water differential pressure" and "Chilled water
differential pressure" should read as follows:
Condenser water
differential pressure2
✔
22
23
15
Chilled water
differential pressure2
✔
31
32
20
Note: The check marks should fall in the column headed "24 Vdc."
May 1994
94-1
Contents
Introduction .................................................................................. 1
About this Manual ...................................................... 1
Chiller Monitor Overview .......................................... 1
The Base System ................................ 3
Sensor Kit ........................................... 3
Field-Supplied Components ............... 3
Specifications ..................................... 3
Hardware Compatibility ..................... 4
Software Compatibility ...................... 5
Installation Phases ...................................................... 7
Phase One ........................................... 7
Phase Two .......................................... 7
Phase Three ........................................ 7
Phase Four .......................................... 8
Phase Five .......................................... 8
Required Materials ..................................................... 9
Tools................................................... 9
Field-Supplied Items .......................... 9
Reference Materials ........................... 9
Carrier Technician’s Start-up Information .......................... 11
Sensor Installation (Phase Two) .............................. 11
Installing the Water
Temperature Sensors ........................ 11
Installing the Refrigerant
Temperature Sensors ........................ 16
Installing the Water
Differential Pressure
Transducers ...................................... 20
iii
Installing the Condenser
Refrigerant Pressure
Transducer ........................................ 24
Installing the Current to
Voltage Transducer .......................... 27
Installing the Oil Temperature
Sensor (Optional) ............................. 30
Installing the Oil Pressure
Switch (Optional) ............................. 33
Mounting and Wiring (Phases Three and Four)....... 36
Mounting the Chiller Monitor
Enclosure .......................................... 36
Converting the Chiller Monitor
for 220/240 Vac Applications .......... 38
Installing a Second PSIO
Module (Optional)............................ 38
Installing a LID1B (Optional) .......... 38
Installing the Modem ....................... 39
Field Installed Relays ............................................... 41
Mounting the Relay Panel ................ 41
Installing the Commanded
State Relay ....................................... 44
Installing the Safety Relay ............... 45
Installing the Purge Relay ................ 45
Installing the PreVent Relay
(Optional) ......................................... 46
Connecting CFC Detectors (Optional) ..................... 46
Connecting Oil Sense (Optional) ............................. 46
Connecting PREVAC (Optional) ............................. 47
Connecting VaporSaver (Optional) ......................... 47
Pre-power-up Checklist............................................ 48
iv
System Checkout (Phase Five) ................................ 49
Check Sensor Field Wiring .............. 49
Calibrate Sensors.............................. 50
Test Discrete Inputs ......................... 53
Test Oil Sense Input
(Optional) ......................................... 54
Troubleshooting ....................................................... 55
Carrier Part Numbers ....................... 62
Fuse Replacement Procedure ........... 63
Flowcharts ........................................ 63
Appendix A␣ ........................................................................ 97
System Walk-through Form ..................................... 97
Appendix B␣ ....................................................................... 101
Wiring Table for Sensors and Relays .................... 101
Figures
Figure 1
CFC-11 Centrifugal Chiller
Monitor Base System.............................. 6
Figure 2
Water Temperature Sensor
Location and Wiring ............................. 14
Figure 3
Water Temperature Sensor
Mounting .............................................. 15
Figure 4
Refrigerant Temperature
Sensor Location and Wiring ................. 18
Figure 5
Tack-on Refrigerant
Temperature Sensor Mounting ............. 19
Figure 6
Well-type Refrigerant
Temperature Sensor Mounting ............. 19
Figure 7
Water Differential Pressure
Transducer Location and Wiring .......... 22
v
vi
Figure 8
Water Differential Pressure
Transducer Mounting ........................... 23
Figure 9
Condenser Refrigerant Pressure
Transducer Location and Wiring .......... 25
Figure 10
Condenser Refrigerant Pressure
Transducer Mounting ........................... 26
Figure 11
Current to Voltage Transducer
Location and Wiring ............................. 28
Figure 12
Current to Voltage Transducer
Mounting .............................................. 29
Figure 13
Oil Temperature Sensor
Location and Wiring ............................. 31
Figure 14
Oil Temperature Sensor
Mounting .............................................. 32
Figure 15
Oil Pressure Switch Location
and Wiring ............................................ 34
Figure 16
Oil Pressure Switch Mounting .............. 35
Figure 17
Chiller Monitor Enclosure
Mounting .............................................. 37
Figure 18
Duplex Outlet Mounting for
Modem and Service Tool Power .......... 40
Figure 19
Terminal Strip Power Wiring ............... 40
Figure 20
Relay Panel Mounting .......................... 41
Figure 21
32SM Controller Wiring for
Relay Installation .................................. 42
Figure 22
Relay Panel Wiring ............................... 43
Figure 23
Condenser Approach
Calculation Flowchart........................... 64
Figure 24
Condenser Flow and Load
Calculation Flowchart........................... 65
Figure 25
Cooler Approach Calculation
Flowchart .............................................. 68
Tables
Figure 26
Cooler Flow and Load
Calculation Flowchart........................... 69
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart ............................ 72
Figure 28
CLTD vs % Load Prognostic
Flowchart .............................................. 77
Figure 29
CRP vs % Load Prognostic
Flowchart .............................................. 82
Figure 30
ELTD vs % Load Prognostic
Flowchart .............................................. 88
Figure 31
Multiplexed Input Processing
Flowchart .............................................. 93
Figure 32
32MP Gateway Input
Processing Flowchart ............................ 94
Figure 33
Motor Amperes (MTRAMPS)
Input Data Flow .................................... 95
Figure 34
Condenser Refrigerant Pressure
(CRP) Input Data Flow ......................... 95
Figure 35
Chilled Water Pressure
Differential (CWPD) Input
Data Flow ............................................. 96
Figure 36
Oil Pressure Differential
(OILPD) Input Data Flow..................... 96
Table 1
Thermistor Curve for Water,
Oil, and Well-type Refrigerant
Temperature Sensors ............................ 51
Table 2
Thermistor Curve for Tack-on
Type Refrigerant Temperature
Sensors .................................................. 52
Table 3
Points Display Screen
Troubleshooting .................................... 56
vii
viii
Table 4
Prognostic Maintenance Screens
Troubleshooting .................................... 59
Table 5
Off-site Alarm Transmission
Troubleshooting .................................... 60
Table 6
Data Collection Troubleshooting.......... 60
Table 7
Relationship of Motor Amps
Duration to Chiller and Alarm
Status .................................................... 61
Table 8
Base Sensor Package Part
Numbers................................................ 62
Table 9
Optional Sensor Package Part
Numbers................................................ 62
Introduction
Introduction
About this Manual
This manual is for use by Carrier Corporation technical representatives.
The manual is divided into two sections.
Section One is the Introduction; it presents general information on
the CFC-11 Centrifugal Chiller Monitor and the installation and
start-up procedures. It includes a sketch of the Chiller Monitor
modules installed in the cabinet, and a phase by phase outline of the
total installation and start-up process. Lists of required tools and
reference materials are also included.
Section Two is written to guide the Carrier technician through
sensor and relay installation, cabinet mounting and wiring, system
checkout, initial start-up, and troubleshooting of the Chiller Monitor.
Appendix A contains a sample system walk-through form.
Appendix B contains a wiring table.
This manual is written for world-wide use. The engineering measurements are in both English and Metric units.
Startup of the Chiller Monitor must be performed by qualified
service technicians.
Chiller Monitor
Overview
The CFC-11 Centrifugal Chiller Monitor is a Processor (PSIO)
Module-based service retrofit product that monitors operation of
CFC-11 centrifugal chillers and identifies failure conditions before
the failures actually occur. The system provides analog and discrete
input point monitoring and prognostic software, and it is fully
Carrier Comfort Network (CCN) compatible.
The system obtains the following chiller operating data from sensors
mounted on each chiller and through field-installed relays:
•
•
•
Commanded State
Safety Circuit
Entering and Leaving Chilled Water Temperatures
1
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Chilled Water Pressure Differential
Evaporator Refrigerant Temperature
Entering and Leaving Condenser Water Temperatures
Condenser Water Pressure Differential
Condenser Refrigerant Temperature
Condenser Refrigerant Pressure
Purge or PreVent
Oil Temperature
Oil Pressure Differential
Oil Sense
Motor Bearing Temperature
Motor Amps
Motor Winding Temperature
VaporSaver
PREVAC
CFC Detector
If the chiller is part of a CCN, communications are performed using
a three-conductor shielded cable called the CCN Communication
Bus. Operating data can then be gathered through Data Transfer or
through read access to a 32MP gateway.
Prognostic software includes the following four algorithms:
•
•
•
•
Condenser Refrigerant Pressure vs % Load
Evaporator Leaving Temperature Difference (Approach) vs %
Load
Condenser Leaving Temperature Difference (Approach) vs %
Load
% Motor Amps vs % Load
Operator interface is through a Building Supervisor, a Network
Service Tool, or a LID1B local interface device. A local or remote
operator can display a list of input points that show chiller status and
modify the value or status of the points. Using Building Supervisor
capabilities, the remote operator can generate history and performance reports on a monthly basis.
2
The Base System
The Chiller Monitor base system is a factory assembled package
that monitors one chiller. Monitoring two chillers is easily done by
installing a separately available PSIO Module and connecting it to
existing connectors. The base system includes:
•
•
•
•
•
Sensor Kit
a NEMA-1 type, 16-gauge steel cabinet with a locking door
one PSIO Module
an Autodial Gateway III Module
two 21-Vac power supplies for modules, and one 24-Vac power
supply for discrete inputs
an optional LID1B local interface device
A prepackaged sensor kit is available for the Chiller Monitor. It
includes the following:
•
•
•
•
•
•
Four strap-on water temperature sensors
Two tack-on refrigerant temperature sensors
One chilled water differential pressure transducer
One condenser refrigerant pressure transducer
One current to voltage transducer for motor amps
One 500-foot roll of twisted pair wire
The following optional sensors are available in a kit or individually:
•
•
•
•
A condenser water differential pressure transducer
A strap-on or a tack-on oil temperature sensor
An oil pressure switch
Well-type refrigerant temperature sensors
Field-Supplied
Components
The chiller Commanded State, Safety, and Purge or PreVent inputs
require field-supplied and installed relays. The PREVAC input
requires a field fabricated circuit board. The VaporSaver input
requires a field installed pressure switch.
Specifications
Power Requirements:
Pre-Assembled Package
PSIO and Autodial
Gateway Modules
110 Vac, 50/60 Hz (factory wired)
230 Vac, 50/60 Hz (field converted)
Powered by HT01BD113 transformer, included in base system.
3
Analog Inputs (13/Chiller):
Thermistor
Voltage
Milliamp analog inputs
Discrete Inputs (8/chiller):
Voltage
Local Communication
Mode
Remote Communication
Mode
Storage Temperature
Storage Humidity
Operating Temperature
Operating Humidity
Dimensions
Weight (pre-assembled
package)
Hardware
Compatibility
Compatibility
10 KΩ nominal @ 77°F
(25°C)
(2) 5 KΩ nominal @ 77°F
(25°C)
Configurable over 0 to 10 Vdc range
Must be converted to voltage inputs
24 Vac + 15% @ 1.0 VA maximum
RS-485 @ 9600 BPS
RS-232 @ 2400 BPS
-40°F to 185°F
(40°C to 85°C)
10 to 95%, non-condensing
-40°F to 158°F
(40°C to 70°C)
10 to 90%, non-condensing
21 in H x 12 in W x 11 in D
(54 cm H x 30 cm W x 28 cm D)
40 lb
(18 kg)
The Chiller Monitor is compatible with Carrier and other CFC-11
centrifugal chillers, hermetic and open drive, with and without
electronic controls.
It is not currently compatible with the following chiller types:
•
•
•
4
Multi-compressor machines
Engine and turbine driven machines
Chillers used to cool liquids other than water (for example,
brine)
Software Compatibility
The Chiller Monitor is fully compatible with the following Carrier
CCN software:
•
•
•
Building Supervisor, Versions III and above
Network Service Tool
LID1B 16-line local interface device
5
Figure 1
CFC-11
Centrifugal
Chiller Monitor
Base System
1
Ca
3
4
10
5
rr
ier
CO

MF
OR
N ET
TW
OR
K
C HI
SY LL ER
ST
EM PL
M ANT
AN
A GRU N
ER N IN
SU
AC G
PP
TI VE
LY
45
.
RC 2
R
SE
2 5T
CA
PA
5Ø
C IT
ØY
EN
A
B LE
5 6RE TU RN
.3
%
LO
A
5 3D
ON
. AV
2 . A IL
D
3
IS
A
B LE
02
-0
3-
92
17
C
:3
0
4 5O N TR LP T
.Ø
AC
R
SE
T
6Ø
SE
C
PU
M
P
1
M
EN
U
6
11
2
7
R1
PW
R2
12
PW
J7
S1
CO
MM
1
MM
2
S2
8
J6
CO
r
rrie
9
Ca
13
LID1B (OPTIONAL)
6
TRANSFORMER 3
11 P S I O M O D U L E
FUSE
7
TERMINAL BLOCK 1
1 2 A U T O D I A L G AT E WAY M O D U L E
3
CIRCUIT BREAKER
8
TERMINAL BLOCK 2
13 2ND PSIO MODULE
(OPTIONAL)
4
TRANSFORMER 1
9
TERMINAL BLOCK 3
5
TRANSFORMER 2
1
22
6
10 TERMINAL BLOCK 4
The monitoring system is planned, installed, and configured by
Installation Phases Carrier CCN trained technicians and designated contractors. The
installation process is subdivided into five phases, as outlined
below.
Step-by-step procedures for each phase (sensor installation, enclosure mounting and wiring, and system checkout) are included in the
next section of this manual.
Phase One
Complete a system walk-through and installation checklist. Appendix A contains a sample form.
Phase Two
Install the following sensors on each chiller:
Phase Three
1.
Water temperature sensors
2.
Refrigerant temperature sensors
3.
Chilled water differential pressure transducer
4.
Condenser refrigerant pressure transducer
5.
Current to voltage transducer for motor amps
6.
Condenser water differential pressure transducer (optional)
7.
Oil temperature sensor (optional)
8.
Oil pressure switch (optional)
Install the Chiller Monitor enclosure and run wiring:
1.
Install a phone line.
2.
Mount the Chiller Monitor enclosure.
3.
Wire primary power to the enclosure.
4.
If applicable, run CCN Communication Bus wiring to the
enclosure. For more information on the CCN Bus, refer to
the Carrier Comfort Network Contractor’s Manual.
7
Note:
Phase Four
Phase Five
8
If an earlier version of the Autodial Gateway and a
modem already exist in the CCN, you can replace
them with the Autodial Gateway III and modem
included with the Chiller Monitor.
5.
Run sensor wiring to the enclosure.
6.
Fabricate and install additional relays or circuit boards as
required (for commanded state, safety, purge, PreVent, and
PREVAC).
7.
If applicable, install Oil Sense (direct connection) or Vapor
Saver (field-supplied pressure switch needed).
Terminate wiring and complete installation:
1.
Install the modem in the enclosure.
2.
Install a duplex outlet on the Chiller Monitor to power the
modem and the Service Tool.
3.
Terminate CCN Communication Bus wiring (if a network
already exists in the building).
4.
Connect the phone line.
5.
Terminate sensor power wiring to the terminal blocks on the
left side of the enclosure, and other sensor wiring to Phoenix
connectors on the monitor module.
6.
Connect relays if used.
7.
Complete Pre-power-up Checklist.
Start up and verify hardware and wiring:
1.
Power up the Chiller Monitor.
2.
Use a Service Tool or LID1B and a VOM to check sensor
field wiring.
3.
Use a Service Tool or LID1B and a temperature probe to
calibrate the sensors.
Verify network operation and configure software:
4.
Initiate Data Transfer from CCN if required.
5.
Refer to the CFC-11 Centrifugal Chiller Monitor Overview
and Configuration Manual for other configuration procedures.
6.
Refer to the Autodial Gateway III Overview and Configuration Manual for gateway configuration procedures.
Required
Materials
Tools:
Refer to the appropriate installation and checkout procedures for
your Chiller Monitor to determine the tools required. You might
need to use the following:
•
•
•
•
•
•
•
•
Drill
Nut drivers
Pliers
Screwdrivers
Spot welding rig
Standard plumbing tools
Temperature probe
Volt ohmmeter (VOM)
Field-Supplied Items
Mounting the Chiller Monitor enclosure requires a unistrut assembly. When installing basic and optional sensors you will need
miscellaneous hardware, electrical, and piping items. Refer to the
specific procedures to determine requirements for your installation.
Reference Materials:
In addition to this manual, you might need to refer to the following
when installing and starting up the Chiller Monitor:
•
•
CFC-11 Centrifugal Chiller Monitor Overview and Configuration Manual (808-884)
Autodial Gateway III Overview and Configuration Manual
(808-827)
9
•
•
•
•
•
10
Building Supervisor III Operation Manual (808-758)
Carrier Comfort Network Contractor’s Manual (808-710)
Carrier Comfort Network Overview and Configuration Manual
(808-534)
Network Service Tool User’s Manual (808-562)
Instruction sheets and manuals for all sensors and optional
components
Carrier Technician's
Start-up Information
Carrier
Technician's
Start-up
Information
Sensor Installation
(Phase Two)
Installing the Water
Temperature Sensors
This procedure describes how to mount and wire strap-on sensors.
You can also use well-type sensors, which are available optionally.
1.
Identify an appropriate mounting location for the entering
chilled water sensor on the chiller pipe carrying the entering
chilled water. Figure 2 shows four typical water temperature
sensor locations.
Note:
In parallel piped chilled water systems, the sensor
should be mounted on the return chilled water pipe
before any branch or tee. The sensor should be
located so that it monitors entering water temperature regardless of which chiller is operating or the
number of chillers operating. If no single location is
suitable, install an entering chilled water sensor on
each chiller.
2.
Identify an appropriate mounting location for the leaving
chilled water sensor on the pipe carrying the leaving chilled
water for each chiller. Mount the sensor as close to the
machine outlet as possible, typically within 6 ft of piping.
3.
Identify an appropriate mounting location for the entering
condenser water sensor on the condenser water pipe feeding
each chiller.
Note:
4.
In parallel piped chilled water systems, the sensor
should be mounted on the entering condenser water
pipe before any branch or tee. The sensor should be
located so that condenser water always flows
through the pipe where it is attached, regardless of
which chiller is operating or the number of chillers
operating. If no single location is suitable, install a
temperature sensor at each chiller condenser water
inlet.
Identify an appropriate mounting location for the leaving
condenser water sensor on the condenser water pipe leaving
each chiller. Follow the steps below to install each water
temperature sensor.
11
5.
If the pipe that the sensor will contact is insulated, remove the
insulation by cutting it so that it will fit neatly around the
sensor after it is installed. If required, sand or grind the
surface of the pipe to remove rough spots that could prevent
good heat transfer. Removing paint is not necessary.
Note:
There is generally no insulation on the condenser
water pipes.
6.
Apply thermal compound to the flat copper plate on the
sensor.
7.
Tighten the sensor strap around the pipe until the copper plate
conforms to the shape of the pipe. Figure 3 shows water
temperature sensor mounting.
Caution:
8.
After the Chiller Monitor enclosure is mounted, route wires
through a knockout in the sensor’s junction box. Connect the
sensor wires to the cable using wire nuts and tuck them inside
the junction box. Polarity is not important. Figure 2 shows
water temperature sensor wiring.
Note:
9.
You could damage the sensor if you overtighten
it. It should fit snugly, compressing the foam
backing to about 50% of its original thickness.
Connect all temperature sensors to the Chiller
Monitor using two conductor twisted wire pair
cable. For distances up to 50 ft, AWG 18 to 22 wire
is suitable. For distances from 50 to 100 ft, use only
AWG 18 or 20.
If the pipe is insulated, reattach insulation around the pipe and
fasten with tape if necessary. If it is uninsulated, wrap pipe
insulation neatly around the sensor for 6 inches in both
directions. This ensures that the sensor is not affected by
machine room temperatures.
If you are mounting well-type sensors:
1.
12
Coat each sensor and the well with thermal compound before
inserting the sensor in the well.
Note:
2.
The procedure below assumes existing wells. Otherwise, you must drain and tap the pipes to install
wells.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to the cable using wire nuts or
crimp type wire splices. Polarity is not important. Figure 2
shows water temperature sensor wiring.
Note:
Connect all temperature sensors to the Chiller
Monitor using two conductor twisted wire pair
cable. For distances up to 50 ft, AWG 18 to 22 wire
is suitable. For distances from 50 to 100 ft, use only
AWG 18 or 20.
13
Figure 2
Water
Temperature
Sensor
Location
and Wiring
14
Figure 3
Water
Temperature
Sensor
Mounting
W AT E R
PIPE
I N S U L AT I O N
A P P LY
THERMAL
COMPOUND
BEFORE
MOUNTING
COPPER
P L AT E
JUNCTION
BOX FOR
W AT E R
TEMP
SENSOR
PIPE
STRAPS
CUT OUT
PIECE OF
I N S U L AT I O N
(REPLACE
WHEN
DONE)
FOAM
BACKING
T W I S T E D PA I R
TO CHILLER
MONITOR
WIRE
NUT
(TYP)
15
Installing the
Refrigerant
Temperature Sensors
Identify appropriate mounting locations on the chiller vessel for
cooler and evaporator refrigerant temperature sensors. If the chiller
has wells available, you can use optional well-type temperature
sensors. Figure 4 shows typical refrigerant temperature sensor
locations.
Note:
You should mount tack-on sensors where the shell temperature is closest to the internal refrigerant temperature.
Avoid the area directly adjacent to the internal expansion
valve.
If you are mounting tack-on sensors:
1.
If the cooler side of the vessel is insulated, peel back the
insulation. Sand the area where the sensors will be installed.
Note:
2.
Spot weld one 1/8" diameter threaded stud to the vessel on
the cooler side, and one 1/8" diameter threaded stud on the
condenser side. Perform the following steps for each sensor.
3
Apply thermal compound liberally to the underside of the
sensor.
4.
Place the sensor mounting lug onto the stud, and secure it
with the flat washer and nut. Figure 5 shows tack-on refrigerant temperature sensor mounting.
5.
Trim the cooler refrigerant temperature sensor wires to 4
inches minimum length. Trim the evaporator refrigerant
temperature sensor wires to 24 inches minimum length.
6.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to the cable using wire nuts.
Polarity is not important. Figure 4 shows refrigerant temperature sensor wiring.
Note:
16
The cooler side of the vessel is generally insulated,
but the condenser side is not.
Connect all temperature sensors to the Chiller
Monitor using two conductor twisted wire pair
cable. For distances up to 50 ft, AWG 18 to 22 wire
is suitable. For distances from 50 to 100 ft, use only
AWG 18 or 20.
7.
Replace the insulation over the cooler refrigerant temperature
sensor. Glue a 12 in by 12 in by 1 in piece of insulation
blanket over the condenser refrigerant temperature sensor.
If you are mounting well-type sensors:
1.
Coat each sensor and the well with thermal compound before
inserting the sensor in the well. Figure 6 shows well-type
refrigerant temperature sensor mounting.
Caution:
2.
Cutting the sensor wire leads shorter than original equipment manufacturer (OEM) length (8
feet) could damage the thermistor and cause
erratic readings.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to the cable using crimp type
wire splices. Polarity is not important. Figure 4 shows
refrigerant temperature sensor wiring.
Note:
Connect all temperature sensors to the Chiller
Monitor using two conductor twisted wire pair
cable. For distances up to 50 ft, AWG 18 to 22 wire
is suitable. For distances from 50 to 100 ft, use only
AWG 18 or 20.
17
Figure 4
Refrigerant
Temperature
Sensor
Location
and Wiring
I N S U L AT I O N O N E VA P O R AT O R
(TYPICAL)
CHILLER
MONITOR
-ORWELL
TYPE
( E VA P O R AT O R )
ON BACK
SIDE OF
CHILLER
CHILLER
MONITOR
TA C K O N
TYPE
( E VA P O R AT O R )
-ORWELL TYPE
(CONDENSER)
NOTE:
TA C K O N
TYPE
(CONDENSER)
WELL TYPE SENSOR CAN BE
I N S TA L L E D I N T H E P O P P E T
VA LV E C H A M B E R , A S S H O W N ,
FOR CARRIER DH TYPE OR
EARLIER MACHINES.
DO NOT
USE FOR DK TYPE OR OTHER
MACHINES WITH FLASH SUBCOOLER.
1
A
A
CONDENSER
14
15
E VA P O R AT O R
36
37
18
PL
19
17
18
VIEW
A-A
PSIO MODULE
CONNECTOR
T E R M I N AT I O N S
Figure 5
Tack-on
Refrigerant
Temperature
Sensor
Mounting
T W I S T E D PA I R
(TO CHILLER MONITOR)
TRIM LENGTH 24" FOR
E VA P O R AT O R
SIDE
4" FOR
CONDENSER
SIDE
CRIMP TYPE
WIRE SPLICES
CHILLER
MONITOR
P L A C E I N S U L AT I O N
OVER SENSOR
(12" X 12" X 1")
TA C K - O N
SENSOR
(TYP)
NOTE:
SENSOR SHOWN
IS TACKED ON
TO CONDENSER
SIDE.
TYPICALLY,
EVAPORATOR
SIDE IS
ALREADY
IINSULATED.
NUT
F L AT
WA S H E R
S P R AY
ADHESIVE
TO
I N S U L AT I O N
Figure 6
Well-type
Refrigerant
Temperature
Sensor
Mounting
CHILLER
SHELL
1/8"
THREADED
ROD
TA C K
WELDED
TO SHELL
S A N D E D S U R FA C E
WITH
THERMAL COMPOUND
THERMAL
COMPOUND
CHILLER
MONITOR
SEE
NOTE
CRIMP
TYPE
WIRE
SPLICES
CONDENSER
SIDE
WELL
WELL TYPE
SENSOR
(TYPICAL)
TWISTED
PA I R
(TO
CHILLER
MONITOR)
CAUTION: DO NOT CUT SENSOR LEADS. CUTTING SENSOR WIRE
LEADS SHORTER THAN OEM LENGTH (8 FEET) COULD DAMAGE THE
THERMISTOR (DUE TO CONDENSATE) AND CAUSE ERRATIC READINGS.
19
Installing the Water
Differential Pressure
Transducers
Figure 7 shows locations for the chilled water and optional condenser water differential pressure transducers.
1.
For each transducer, close the valve at the base of each
pressure gauge, and remove the gauge.
Note:
2.
Install threaded tee couplings to allow for the bypass valve
assembly and for refitting the gauges. Reinstall the gauges.
3.
Fabricate a bypass valve assembly and mount the differential
pressure transducer as shown in Figure 8. Route and connect
tubing from each tee back to the appropriate point on the
transducer bypass assembly (high side/low side).
4.
To place the transducer in service:
a.
b.
c.
d.
e.
f.
Open the valve at the base of the pressure gauge.
Open Valve 3.
Slowly open Valve 1 and Valve 2 slightly.
Crack the transducer fittings to bleed air from the lines,
then retighten them.
Open Valve 1 and Valve 2 fully.
Close Valve 3.
5.
Check all piping for leaks. If any leaks are found, perform
Step 7 and repair the leaks.
6.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the transducer wires to the cable using crimp
type wire splices. Be sure to observe the correct polarity, and
do not connect the ground wire. Figure 7 shows differential
pressure transducer wiring.
Note:
20
This procedure assumes that valved pressure gauges
are already installed in the entering and leaving
water pipes. If they are not, you must drain and tap
the pipes.
The red wire from the Chiller Monitor (24 Vdc)
connects to the blue wire at the transducer.
7.
If it becomes necessary to take the transducer out of service:
a.
b.
c.
d.
e.
Close the valve at the base of the pressure gauge.
Open Valve 3 to equalize pressure at the transducer.
Close Valve 1 and Valve 2.
Crack the fittings at the transducer to release pressure.
Remove the transducer.
21
Figure 7
Water
Differential
Pressure
Transducer
Location
and Wiring
RED (+)
+24
VDC
1
2
249Ω
0.1%
B
TERMINAL
BLOCK 2
R1
249Ω
0.1%
19
1
22
23
R1
RED (+)
VIEW
BLK
(-)
PL
1
VIEW
A-A
PSIO MODULE
CONNECTOR
T E R M I N AT I O N S
BLK
(-)
A
31
32
B
A
36
37
18
CHILLER
MONITOR
CHILLED
W AT E R
DIFFERENTIAL
PRESSURE
TRANSDUCER
WITH JUNCTION
BOX
LC
LC
DW
EC
EC
22
W
W
DW
C O N D E N S E R W AT E R
DIFFERENTIAL PRESSURE
TRANSDUCER WITH JUNCTION BOX
(OPTIONAL)
Figure 8
Water
Differential
Pressure
Transducer
Mounting
* THESE
VALVES SHOULD
BE MOUNTED NEAR THE
WELLS AT THE WATER
PIPES.
DIFFERENTIAL PRESSURE TRANSDUCER (TYP)
LO
PRESSURE
PORT
JUNCTION BOX (SHOWN WITH
COVER REMOVED)
TWISTED
PA I R T O
CHILLER
MONITOR
VA LV E
3
VA LV E
1*
VA LV E
2*
UNISTRUT
HI
PRESSURE
PORT
BLU
(+)
CHILLED OR
CONDENSER
ENTERING
W AT E R
GRN
(GND)
CHILLED OR
CONDENSER
L E AV I N G
W AT E R
RED
(+)
BLK
(-)
WHT
(-)
WIRE NUT
(TYP)
23
Installing the
Condenser Refrigerant
Pressure Transducer
Figure 9 shows location for the condenser refrigerant pressure
transducer.
1.
Close the valve to isolate the condenser refrigerant line, as
shown in Figure 10.
Note:
2.
Cut into the refrigerant line and install a T connector.
3.
Connect a 1/8 inch National Taper Pipe Thread (NPT) fitting
to the open T connection. Mount the transducer so that its
weight does not stress the refrigerant line.
4.
Slowly open the valve to place the transducer in service.
Check all piping thoroughly for leaks.
5.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the transducer wires to the cable using crimp
type wire splices. Be sure to observe the correct polarity.
Figure 9 shows condenser refrigerant pressure transducer
wiring.
Note:
24
This procedure assumes that the condenser refrigerant line is valved so that the transducer can be
installed without venting refrigerant to the atmosphere. If there is not a valve, you must supply and
install one. The installation procedure requires
removing the refrigerant from the chiller.
The white wire from the transducer is the positive 24
Vdc input. Connect it to the +24 Vdc wire coming
from TB2 in the Chiller Monitor.
Figure 9
Condenser
Refrigerant
Pressure
Transducer
Location and
Wiring
CRIMP TYPE WIRE SPLICE
CHILLER
MONITOR
CONDENSER
REFRIGERANT
PRESSURE
TRANSDUCER
A
B
LC
W
A
RED
(+)
BLK
(-)
19
1
PL
1
25
26
R1
EXISTING
CONTROL
BOX
1
2
VIEW
VIEW
249Ω
0.1%
CHILLER
MONITOR
B
TERMINAL
BLOCK 2
A-A
PSIO MODULE
CONNECTOR
T E R M I N AT I O N S
36
18
37
+24VDC
25
Figure 10
Condenser
Refrigerant
Pressure
Transducer
Mounting
S E R V I C E VA LV E
(TYPICAL)
I S O L AT I O N VA LV E
(TYPICAL)
T W I S T E D PA I R
(TO CHILLER
MONITOR)
CRIMP
TYPE
WIRE
SPLICE
(TYP)
RED (+)
BLK (-)
CHILLER
MONITOR
BLK(-)
WHT(+)
CONDENSER
REFRIGERANT
PRESSURE
TRANSDUCER
26
"T" WITH
1/8" NPT
COUPLING
I S O L AT I O N
VA LV E
( M AY N E E D
TO BE
I N S TA L L E D )
Installing the Current to
Voltage Transducer
Figure 11 shows location for the current to voltage transducer.
Warning:
1.
High voltage is present in the chiller starter panel.
Disconnect power to the starter panel before proceeding. Observe all appropriate safety precautions when
working in the chiller starter panel.
Drill mounting holes close to the existing current transformer
in the chiller starter panel.
Note:
This procedure assumes that a current transformer of
the correct size is already installed on one leg of the
line in the chiller starter panel. If there is no transformer, you must size and supply it.
2.
Mount the 4CTV as shown in Figure 12.
3.
Disconnect the wire to the existing signal resistor from the
existing current transformer. If there is no signal resistor, this
wire is also sometimes available between the existing current
transformer and the starter panel ammeters. Loop this wire
through the core of the 4CTV. For current transformers with
5 A secondaries, pass the wire through the core center four
times.
Note:
If secondary current is not 5 A, you can adjust the
number of turns to provide 20 A turns. For current
transformers with 1 A secondaries, loop the wire
through the core 20 times. For current transformers
with secondary currents other than 5 or 1, add a
transformer rated equal to or greater than the existing one, with a secondary current of 5 A, as shown
in the area enclosed in dashed lines in Figure 12.
4.
Reconnect the end to the terminal on the resistor or ammeter.
5.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the wires from the 4CTV transformer’s signal
output terminals to the cable using crimp type wire splices.
Be sure to observe the polarity shown on the body of the
transducer. Figure 11 shows current to voltage transducer
wiring.
27
Figure 11
Current to
Voltage
Transducer
Location
and Wiring
28
Figure 12
Current to
Voltage
Transducer
Mounting
VIEW
A
CURRENT
TRANSDUCER
WIRED TO
MONITOR
NOTE:
NOTE:
CHLR MONITOR
"CT"
4 TURNS FOR
CT's WITH 5 AMP
SECONDARIES
HI VOLTAGE
"CT"
VIEW
B
IF A CURRENT TRANSDUCER
DOES NOT EXIST ON THE
HIGH VOLTAGE LINE ONE
MUST BE INSTALLED AND
WIRED TO MONITOR'S
CURRENT TRANSDUCER,
AS SHOWN.
A
B
EXISTING
SIGNAL
RESISTOR
+
0-5 VDC
T W I S T E D PA I R
(TO CHILLER
MONITOR)
VIEW
C
EXISTING
CURRENT
TRANSDUCER
C
S TA R T E R
PA N E L
29
Installing the Oil
Temperature Sensor
(Optional)
Identify an appropriate mounting location on the chiller oil reservoir
for the oil temperature sensor. You can mount a strap-on sensor on
the oil supply line of most Carrier centrifugal chillers. All other
chiller models use a tack-on sensor mounted near the oil temperature well thermometer, as shown in Figure 13.
If you are mounting a strap-on sensor:
1.
Sand the location on the oil pipe where you will strap on the
sensor. Apply thermal compound liberally to the sensor
copper plate. Figure 14 shows strap-on oil temperature
sensor mounting.
2.
Strap on the sensor until the copper plate conforms to the pipe
shape. Do not overtighten it.
3.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to the twisted pair cable using
wire nuts. Be sure to observe the correct polarity.
If you are mounting a tack-on sensor:
30
1.
Sand the location on the oil reservoir where you will attach
the sensor. Apply temperature rated Epoxy compound to the
sanded surface and the sensor. Figure 14 shows tack-on oil
temperature sensor mounting.
2.
Attach the sensor to the oil reservoir surface. Cover it with a
6 in x 6 in x 1 in piece of insulation sprayed with adhesive.
Be sure to free the sensor wires before you attach the insulation.
3.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to the twisted pair cable using
crimp type wire splices. Be sure to observe the correct
polarity.
Figure 13
Oil Temperature
Sensor Location
and Wiring
STRAP-ON
OIL TEMP
SENSOR
AT TA C H E D
TO OIL LINE
(SEE NOTE)
EXISTING OIL TEMP
WELL THERMOMETER
CHILLER
MONITOR
OIL
SIGHT
GLASS
COMPRESSOR
HW
A
LC
A
TA C K - O N
OIL TEMP
SENSOR
19
1
PL
1
W
LC
SEE NOTE
OR
W
EC
26
27
HW
EC
NOTE:
A S T R A P - O N O I L T E M P E R AT U R E S E N S O R I S T H E
T Y P E T Y P I C A L LY U S E D O N C A R R I E R ' S 1 9 D K
C H I L L E R S ( AT TA C H E D T O T H E P I P E L I N E F R O M
THE OIL RESERVOIR).
FOR ALL OTHER APPLICAT I O N S , A TA C K - O N T Y P E S E N S O R I S A F F I X E D T O
THE OUTSIDE OF THE OIL RESERVOIR NEAR THE
THERMOMETER.
VIEW
36
18
A-A
PSIO MODULE
CONNECTOR
T E R M I N AT I O N S
37
31
Figure 14
Oil Temperature
Sensor Mounting
32
Installing the Oil
Pressure Switch
(Optional)
Note:
The procedure below requires removing the refrigerant
from the chiller. You can also use a relay to provide
chiller oil pressure to the Chiller Monitor. This method is
shown in Figure 21.
1.
Identify an appropriate mounting location for the oil pressure
switch on the side of the existing chiller control panel. Figure
15 shows oil pressure switch location.
2.
Mount the switch using two screws or bolts through the holes
in the back of the case as shown in Figure 16, or use the
universal mounting bracket included with the switch.
3.
Connect copper tubing from the suction side and the lube side
of the chiller reservoir to the connectors on the switch.
4.
After the Chiller Monitor enclosure is mounted and wires are
run, connect the sensor wires to line1 and M2. Polarity is not
important. Figures 15 and 16 show oil pressure switch
wiring.
5.
Adjust the cut-in and cut-out settings as described in the
Installation and Operation Instructions packaged with the
switch.
Note:
The cut in should be set below the normal operating oil
pressure but above the oil pressure that would cause the
chiller to go down on safety.
33
Figure 15
Oil Pressure
Switch Location
and Wiring
34
Figure 16
Oil Pressure
Switch
Mounting
INSIDE
EXISTING
CONTROL
PA N E L
ENCLOSURE
TO
SUCTION
SIDE
BACK
OF OIL
PRESSURE
SWITCH
CHILLER
MONITOR
RED
MNTG
B O LT
(TYP 2
PLACES)
MNTG
NUT
(TYP 2
PLACES)
BLK
LI
EXISTING
CONTROL
PA N E L
NE
LI
OIL
PRESSURE
SWITCH
NE
M2
M1
TO
LUBE
SIDE
TWISTED
PA I R
(TO CHILLER
MONITOR)
35
Mounting and
Wiring (Phases
Three and Four)
1.
Tack weld the unistrut mounting assembly to the chiller shell
as shown in Figure 17.
2.
Attach the enclosure to the unistrut assembly in four places
with nuts and bolts.
Mounting the Chiller
Monitor Enclosure
36
Figure 17
Chiller Monitor
Enclosure
Mounting
EXISTING
CONTROL
PA N E L
CHILLER
MONITOR
CO

M FO
RT
N ET
WO
RK
N U T & B O LT
(TYPICAL 4 PLACES)
"L" BRACKET
(TYPICAL 2 PLACES)
CHILLER
SHELL
TA C K W E L D T O
SHELL (TYPICAL)
UNISTRUT
M O U N T I N G A S S E M B LY
37
Converting the Chiller
Monitor for 220/240
Vac Applications
Installing a Second
PSIO Module (Optional)
1.
Remove the black and white factory installed wires from
Terminal 2 on Terminal Block 4. Refer to the CFC-11
Chiller Monitor Schematic, which is included with the Chiller
Monitor, for locations. Cap each wire individually with a
wire nut (three total).
2.
Strip 1/4 inch of insulation off the red wires from Transformers 1, 2, and 3, and connect all three to TB4-2 of the power
terminal block as shown on the schematic.
1.
Slide the second module into the available space on the
mounting rail.
2.
Remove the tape from the mounting screw provided. Attach
the ground wire connector to the mounting screw and tighten.
3.
Plug the power connector into the location shown on the
Chiller Monitor Schematic.
Caution:
Installing a LID1B
(Optional)
38
Plugging the connectors into the wrong locations
will damage the PSIO module.
4.
Using the Network Service Tool, change the second module
default address (40) to 41.
5.
Plug the communications connector into the location shown
on the Chiller Monitor Schematic.
1.
Unscrew the four screws and remove the existing top front
panel from the enclosure.
2.
Carefully position the LID until the holes align.
3.
Use the four screws to attach the LID to the enclosure.
4.
LID connections are pre-wired. Plug the power and communications connectors into the existing sockets.
Installing the Modem
The Autodial Gateway III serves as an interface device between the
Chiller Monitor and the CCN. The recommended modem for use in
the USA with the Autodial Gateway III in the Chiller Monitor is the
Hayes Optima 2400. A dedicated phone line is required at the
modem. If there is a CCN in the building, you can remove the
Gateway and modem from the box and install it in a wall-mounted
FID-type enclosure. Configure the modem as described in the
Autodial Gateway III Overview and Configuration Manual. For
complete information on configuring the modem, consult the user’s
guide supplied with it.
Note:
The procedure below also provides an outlet for the
Service Tool used during system checkout.
Follow the steps below to supply power to the modem:
1.
Mount a single gang duplex box on the back of the Chiller
Monitor enclosure using a 1/2" chase bushing and a nut, as
shown in the assembly view in Figure 18.
2.
Install a duplex outlet with a cover in the box. Wire the outlet
to Terminals L1 and L2 on the terminal strip inside the
enclosure, as shown in Figure 19.
Caution:
Do not connect power to, or remove factory
wiring from, Pin 2 on Terminal Block 4.
3.
Enclose power wiring to the outlet in Greenfield type flexible
conduit.
4.
Plug the modem power supply cube into the outlet and route
the cable into the enclosure. Plug it into the back of the
modem.
5.
Connect the modem cable from the COMM2 25-pin connector on the Gateway to the 25-pin connector on the modem.
39
Figure 18
Duplex Outlet
Mounting for
Modem and
Service Tool
Power
BACK OF
CHILLER MONITOR
ENCLOSURE
SINGLE
GANG
DUPLEX
BOX
I/2" CHASE
BUSHING
NUT
DUPLEX
OUTLET
OUTLET
SCREW
(TYP)
L1 & L2
TO
TERMINAL
BLOCK 4
DUPLEX OUTLET
IN JUNCTION
BOX MOUNTED
TO ENCLOSURE
GREENFIELD
FLEXIBLE
CONDUIT
COVER
POWER
WIRING
COVER
SCREW
Figure 19
Terminal Strip
Power Wiring
A
CHILLER
MONITOR
1
2
3
FA C T O R Y
WIRING
VIEW
A
TERMINAL
BLOCK 4
L1
L2
EQUIP
GROUND
PLUG
1 2 0 VA C
FIELD
POWER
GND
CAUTION:
D O N O T C O N N E C T P O W E R T O O R R E M O V E FA C T O R Y
WIRING FROM TERMINAL BLOCK 4, PIN 2.
40
Field Installed
Relays
Mounting the Relay
Panel
Figure 20
Relay Panel Mounting
Before installing relays, refer to the wiring table in Appendix B.
For 32SM Controller wiring and relay contact wiring to the Chiller
Monitor, refer to Figures 21 and 22.
1.
Position a 10" x 10" relay panel (Hoffman box) on top of the
existing chiller controller as shown in Figure 20.
2.
Drill holes, then use sheet metal screws to attach the relay
box to the controller.
1 0 " X 1 0 " R E L AY PA N E L
(i.e. HOFFMAN BOX)
R E L AY
MOUNTING
RACK
EXISTING
CONTROLLER
SHEET
M E TA L
SCREW
(TYP 2
PLACES)
PA N E L
COVER
41
Figure 21
32SM Controller
Wiring for Relay
Installation
K2A
RED
NO
PL
1
C
NC
1
K1
4
1
K1A
BLK
3
NO
C
7
NC
K1B
NO
C
NC
BLK
36
37
TERMINAL
BLOCK 1
IN CHILLER
MONITOR
K3
NO
C
NC
R E L AY C O N TA C T
W IR I N G T O
CHILLER MONITOR
INPUTS
K5
NO
CONNECTOR
T E R M I N AT I O N S
ON PSIO MODULE
IN CHILLER
MONITOR
C
NC
K1
- D P D T R E L AY
K4
BLK
K2 - K5
NO
- S P D T R E L AY
C
NC
NOTE:
L1
R E L AY V O LTA G E M U S T M AT C H
C O N T R O L V O LTA G E .
L2
K2
ON-STOP
KB
COOLER
LTS
KM
40
49
41
COND
HPS
OL'S
42
43
43
17
K1
K4
17
COOLER
FLO
50
COND
FLO
K5
OIL
LPS
46
M3
47
14
K3
K1
RECYCLE
10
LEGEND:
FA C TO RY W I R E D
FIELD WIRED
11
11
OIL
8
V1
T H I S R E L AY
I S PA R T
OF 32SM
CONTROLLER
3 2 S M C O N T R O L L E R W I R I N G ( PA R T I A L V I E W ) F O R R E L AY I N S TA L L AT I O N
42
R E L AY
COIL
W IR I N G
TO 32SM
CONTROLLER
Figure 22
Relay Panel
Wiring
C O M M A N D S TAT E
BLK
C
R E L AY PA N E L
RED
NO
SEE NOTE 1
CONNECTOR
T E R M I N AT I O N S
ON PSIO MODULE
IN CHILLER
MONITOR
RUN
C O N TA C T
C O I L V O LTA G E S A M E A S
R U N C O N TA C T V O LTA G E
PURGE/PREVENT
BLK
C
1
PL
RED
NO
SEE NOTE 2
1
TO
PURGE/PREVENT
S O L E N O I D VA LV E
COIL VOLTAGE SAME AS PURGE/
PREVENT SOLENOID VOLTAGE
4
SAFETY
BLK
7
1
3
4
5
6
7
8
RED
NO
C
NC
10
SEE NOTE 3
34
TO
SAFETYCIRCUIT
C O I L V O LTA G E S A M E A S
S A F E T Y C I R C U I T V O LTA G E
16
17
36
910Ω
2W
RESISTOR
37
OIL PRESSURE
SWITCH
BLK
C
TERMINAL
BLOCK 1
IN CHILLER
MONITOR
RED
NO
SEE NOTE 4
OIL QUALITY
BLK
8
RED
7
T H E P R E VA C S Y S T E M I S
TIED INTO CHILLER
MONITOR THROUGH
T H E D ATA B U S L O C AT E D O N T H E P O W E R
BOARD INSIDE THE PPC.
(RECOMMENDED
A U T O M AT I O N , 1 4 P I N
D I P P L U G - A M P PA R T
#746613-2)
OIL SENSE
UNIT
RED
BLK
(+)
IN4005
3
+
2
6
8
IN
PU
T
1
(+)
WIRE FOR
PIN NO. 1
IS MARKED
IN4005
4
-
I N T E R FA C E
WITH
GORDOS
(G120D10)
SOLID
S TAT E
R E L AY
7
(-)
NOTES:
1
FOR 32MP CONTROLS, THIS IS TERMINAL 18 AND L2.
2
FOR 32MP CONTROLS, THIS IS TERMINAL K1 (BLUE WIRE) AND L2.
3
FOR 32MP CONTROLS, THIS IS TERMINAL 12 AND L2 (ALARM CIRCUIT).
4
F O R 3 2 S M C O N T R O L S , R E L AY ( S ) M AY B E U S E D T O R E P L A C E O I L P R E S S U R E S W I T C H .
5
F O R 3 2 S M C O N T R O L S R E L AY W I R I N G S E E F I G . 2 1 .
SEE FIG. 21.
43
Installing the
Commanded State
Relay
1.
Install a relay of appropriate coil rating for the line voltage in
the relay panel.
Warning:
2.
Wire the relay coil across the run contact so that the relay is
energized whenever the contact operates, as shown in Figures
21 and 22. For 32MP controls, connect to Terminal 18 and
L2.
3.
Connect the relay normally open 24 Vac contact set to the
Chiller Monitor commanded state input, as shown in Figures
21 and 22.
Caution:
44
Disconnect all power to the Chiller Monitor and
the chiller’s control panel before wiring the
relay.
When connecting Cable 1 to the commanded
state relay contacts, do not short the 24 Vac hot
wire to ground.
Installing the Safety
Relay
1.
Install a relay of appropriate coil rating for the line voltage in
the relay panel.
Warning:
2.
Wire the relay coil across the safety circuit so that the relay is
energized whenever the contact operates, as shown in Figures
21 and 22. For 32MP controls, connect to Terminal 12 and
L2.
3.
Connect the relay’s normally open contact set to the Chiller
Monitor safety input, as shown in Figures 21 and 22.
Caution:
Installing the Purge
Relay
Disconnect all power to the Chiller Monitor and
the chiller’s control panel before wiring the
relay.
1.
When connecting Cable 3 to the safety relay contacts, do not short the 24 Vac hot wire to ground.
Install a relay of appropriate coil rating for the line voltage in
the relay panel.
Warning:
Disconnect all power to the Chiller Monitor and
the chiller’s control panel before wiring the
relay.
2.
Wire the relay coil across the purge solenoid valve so that the
relay is energized whenever the solenoid operates, as shown
in Figures 21 and 22. For 32MP controls, connect to K1
(blue wire) and L2.
3.
Connect the relay’s normally open contact set to the Chiller
Monitor purge input, as shown in Figures 21 and 22.
Caution:
When connecting Cable 21 to the purge relay
contacts, do not short the 24 Vac hot wire to
ground.
45
Installing the PreVent
Relay (Optional)
1.
After PreVent high efficiency purge is installed and checked
out, install a 120 Vac relay in the PreVent enclosure. A RDM
90-341 Mars relay or equivalent is recommended.
Warning:
2.
Wire the relay coil across the vent solenoid in the PreVent
unit so that the relay is energized whenever the solenoid
operates, as shown in Figure 22.
3.
Connect the relay’s normally open contact set to the Chiller
Monitor purge input, as shown in Figure 22.
Caution:
Connecting CFC
Detectors
(Optional)
When connecting Cable 21 to the purge relay
contacts, do not short the 24 Vac hot wire to
ground.
In order to connect a CFC Detector to the Chiller Monitor, the
detector unit must provide normally open or normally closed contacts for external alarm outputs. Refer to the Wiring Table in Appendix B for connections.
Warning:
Connecting Oil
Sense (Optional)
1.
Disconnect all power to the Chiller Monitor and the
chiller’s control panel before connecting Oil Sense.
After the OIL SENSE oil quality monitoring device is installed and checked out, connect the dry contact output on the
Oil Sense terminal block (Terminals 7 and 8) to the Chiller
Monitor, as shown in Figure 22.
Caution:
2.
When connecting Cable 7 to Oil Sense, do not
short the 24 Vac hot wire to ground.
When wiring is complete, re-connect power to the Chiller
Monitor.
Note:
46
Disconnect all power to the Chiller Monitor and
the chiller’s control panel before wiring the
relay.
If a LID1B is present on the system, it should
display the default screen within 1 minute.
Connecting
PREVAC
(Optional)
Warning:
1.
Disconnect all power to the Chiller Monitor and the
chiller’s control panel before connecting PREVAC.
After the PREVAC pressure seal and leak test system is
installed on the chiller and checked out, remove the four
screws and the top plate of the Precision Pressure Controller
(PPC). Refer to the PREVAC manual for illustrations
Warning:
Connecting
VaporSaver
(Optional)
Whenever you remove or replace the face panel
and logic board, main power to the PPC must be
off.
2.
Slide out the face panel and its attached logic board. Leave
the ribbon connected and carefully place the panel to the side,
exposing the terminal connections.
3.
Plug a cable into the data bus interface on the PPC power
board (recommended DIP plug Amp Part Number 746613-2,
Carrott Part Number 533-060-024-014).
4.
On a field fabricated circuit board, connect a Gordos
G120D10 solid state relay or equivalent to Pins 6 (low limit),
7 (ground), and 8 (high limit) as shown in Figure 22.
5.
Connect the relay contacts to the Chiller Monitor terminal
strip and PREVAC input, as shown in Figure 22.
6.
Add a 910 Ω, 2 W resistor between the input and ground pins.
7.
Reassemble the PREVAC PPC.
Warning:
Disconnect all power to the Chiller Monitor and the
chiller’s control panel before connecting VaporSaver.
1.
After the VaporSaver low pressure relief valve assembly is
installed and checked out, install a pressure switch on the 3/8"
NPT port in the containment unit. The pressure switch
contacts should close when pressure is >10 psi.
2.
Wire the normally open switch contacts to the terminal block
(24 Vac power) and to the VaporSaver input on the Chiller
Monitor.
47
Pre-power-up
Checklist
48
After you have completed Phase Four of Chiller Monitor installation
and before you perform Phase Five, review the list below. If each
item has been completed correctly, you are ready to power up the
system.
1.
All sensors used in the installation are mounted and wired.
2.
The relay panel is mounted, and field installed relays are
wired.
3.
The Chiller Monitor enclosure is mounted securely.
4.
A duplex outlet is installed on the back of the Chiller Monitor, and it is wired to the terminal strip inside the enclosure
and to primary power.
5.
The unit is clean and free of debris.
6.
Sensor and relay wiring has been brought into the enclosure.
All wires are marked, bundled, and terminated to the proper
connectors as specified in the Wiring Table in Appendix B.
7.
The phone line is installed, and the modem is mounted in the
enclosure.
8.
CCN Communication Bus wiring is connected (if applicable).
9.
Chillers are in operating condition.
System Checkout
(Phase Five)
Check Sensor Field
Wiring
After you power up the Chiller Monitor, perform the checkout
procedures below before you verify network operation. Refer to the
Network Service Tool User’s Manual for instructions on using the
Service Tool, and refer to the CFC-11 Chiller Monitor Overview
and Configuration Manual for instructions on using the LID1B with
the Chiller Monitor.
1.
If you are using the Service Tool directly, plug it into the
duplex outlet previously installed for the modem on the back
of the Chiller Monitor enclosure.
2.
Use the Add command to include the Chiller Monitor in the
Service Tool database.
3.
View the Status Display Screen on the Service Tool or the
LID1B. Normal or default values should be displayed for all
installed input points.
4.
View the Chiller Maintenance Screen. Values within the
acceptable ranges should be displayed for Cooler Pressure
Drop and Condenser Pressure Drop, and the following input
values: CWPD, CDWPD, CRP, MTRAMPS, and OILPD.
5.
Short each sensor at the sensor’s connection. The displayed
values should change correspondingly.
Caution:
6.
Do not short the sensor at the Chiller Monitor, as
this can damage the Chiller Monitor and it does
not verify sensor wiring.
Replace connections.
Note:
You should correct inaccurate inputs or temporarily
force the values and disconnect sensors from field
connectors.
49
Calibrate Sensors
50
1.
Using the Service Tool or the LID1B, view the Status Display
Screen and the Chiller Maintenance Screen.
2.
Calibrate the water differential pressure transducers by
measuring voltage at the Chiller Monitor. If necessary, at no
flow adjust “Z” potentiometer on the transducer to 1.0 V.
3.
Start the chiller and run it until normal operating temperatures
are reached.
4.
Calibrate temperature sensors by using a reference such as a
thermometer or VOM and temperature probe to measure the
temperature at the sensor. If a questionable reading is shown,
compare the actual temperature to the thermistor curves in the
next section.
5.
Calibrate other sensors according to the procedures on their
instruction sheets.
Table 1
Thermistor Curve for
Water, Oil, and Well-type
Refrigerant Temperature
Sensors
Degrees F (C)
Ohms1
0 (-18)
70300
5 (-15)
61000
10 (-12)
53100
15 (-9)
46300
20 (-6)
40400
25 (-4)
35400
30 (-1)
31100
35 (2)
27300
40 (4)
24100
45 (7)
21200
50 (10)
18800
55 (13)
16700
60 (16)
14800
65 (18)
13200
70 (21)
11700
75 (24)
10400
80 (27)
9350
1
Tolerance is + 1%.
(continued)
51
Table 1
Thermistor Curve for
Water, Oil, and Well-type
Refrigerant Temperature
Sensors (continued)
Degrees F (C)
Ohms1
85 (29)
8380
90 (32)
7520
95 (35)
6750
100 (38)
6080
1
Tolerance is + 1%.
Table 2
Thermistor Curve for
Tack-on Type Refrigerant
Temperature Sensors
Degrees F (C)
Ohms1
0 (-18)
86500
5 (-15)
72900
10 (-12)
61700
15 (-9)
52400
20 (-6)
44600
25 (-4)
40200
30 (-1)
34400
35 (2)
29500
40 (4)
26700
1
Tolerance is + 1%.
(continued)
52
Table 2
Thermistor Curve for
Tack-on Type Refrigerant
Temperature Sensors
(continued)
Degrees F (C)
Ohms1
45 (7)
23000
50 (10)
19900
55 (13)
17300
60 (16)
15000
65 (18)
13700
70 (21)
11900
75 (24)
10400
80 (27)
9200
85 (29)
8400
90 (32)
7400
95 (35)
6500
100 (38)
5800
1
Tolerance is + 1%.
Test Discrete Inputs
To test the discrete inputs listed below, measure voltage at the
Chiller Monitor connection pin for that input with a VOM. It
should be 24 Vdc when the connection is shorted (relay is pulled
in).
•
•
•
•
•
Chiller Start Command
Safety Chain Status
Oil Differential Pressure
Oil Sense Alarm
VaporSaver Alarm
53
•
•
•
PREVAC Alarm
CFC Detector
Purge or PreVent Pump Status
If Oil Sense is installed on the chiller, use the next test procedure.
Test Oil Sense Input
(Optional)
54
1.
Refer to the Oil Sense manual. Set up the Oil Sense unit to
fail the test as described.
2.
Press the Test button.
3.
View the Status Display Screen on the Service Tool or
LID1B.
4.
Display the Lube section and Oil Quality.
5.
After Oil Sense completes testing and sampling and its failure
lamp is lit, verify that there is an Oil Quality Alarm. Reset
Oil Sense and remove any testing modifications.
Troubleshooting
This section is provided to help you diagnose and repair problems
that occur with the Chiller Monitor.
The first part of the section consists of tables related to Building
Supervisor screens that display hardware status, wiring, or hardware
configuration problems. It also contains parts lists and a fuse replacement procedure. The second part of the section consists of
flowcharts of prognostics and other algorithms, and input data flow
diagrams:
Calculations:
Condenser Approach
Condenser Flow and Load
Cooler Approach
Cooler Flow and Load
Prognostics:
% MTRAMPS vs % Load
CLTD vs % Load
CRP vs % Load
ELTD vs % Load
Input Processing:
Multiplexed
32MP Gateway
Input Data Flow:
Amps_IO
CRP_IO
CWPD_IO and CDWPD_IO
OILPD_IO
55
Table 3
Points Display Screen
Troubleshooting
Symptoms
Possible Causes
Remedies
Chiller is running.
Commanded State displays Stop.
Status displays On.
Blinking asterisk.
Interposing relay miswired
(NO vs NC contacts).
Check relay wiring at
Chiller Monitor, relay,
and chiller control panel.
Not picking up commanded
state correctly. Relay coil
wired across wrong terminals
in local chiller control panel.
Chiller is running.
Commanded state displays Start.
Status displays Off.
Blinking asterisk.
Chiller is running.
Safety Shutdown displays Alarm.
Blinking asterisk.
Current to voltage
transducer miswired.
Check transducer wiring
at Chiller Monitor,
transducer, and starter
panel.
Incorrect number of
turns of wire through
current transducer.
Use VOM to measure Vdc at
sensor.
Sensor not configured
properly.
Check Motor Amps decisions
in SENS-CFG Table.
Interposing relay miswired
(NO vs NC contacts).
Check relay wiring at Chiller
Monitor, relay, and control
panel.
Not picking up safety chain
correctly. Relay coil wired
across wrong terminals in
local chiller control panel.
(continued)
56
Table 3
Points Display Screen
Troubleshooting (continued)
Symptoms
Possible Causes
Remedies
Temperature point displays
-10 °F (-23.3 °C), blinking C.
Temperature sensor
miswired (open circuit).
Check sensor wiring at
Chiller Monitor and sensor.
Temperature sensor failed
Use a VOM to measure
resistance at sensor. Replace
sensor if necessary.
Temperature sensor
miswired (short circuit).
Check sensor wiring at
Chiller Monitor and sensor.
Temperature sensor
overtightened.
Use a VOM to measure
resistance at sensor.
Loosen pipe strap and
measure resistance at sensor.
Temperature sensor failed.
Replace sensor if necessary.
Water pressure differential
sensor miswired.
Check sensor wiring at
Chiller Monitor and sensor.
Sensor’s blue wire must connect to 24 Vdc.
Isolation valves closed.
Check isolation valves.
Differential water pressure
sensor not configured.
Check configuration of
Cooler or Condenser decisions in LOAD-CFG Table.
Temperature point displays
245 °F (118.3 °C), blinking C.
Cooler or condenser water flow
not updating.
Check CHLR-MNT
Maintenance Table.
(continued)
57
Table 3
Points Display Screen
Troubleshooting (continued)
Symptoms
Condenser Refrigerant Pressure
display incorrect.
Purges occurring, purge counts
display not updating.
Possible Causes
Remedies
Load not configured.
Check configuration for
Chilled or Condenser Water
Pressure in SENS-CFG
Table.
Sensor miswired.
Check wiring at Chiller
Monitor and sensor. Check
that the sensor’s white wire
connects to 24 Vdc.
Sensor not configured.
Check CHLR-MNT
Maintenance Table. Check
configuration for Condenser
Refrigerant Pressure in
SENS-CFG Table.
Purge relay miswired.
Check relay wiring at Chiller
Monitor, relay, control panel,
and PreVent (if applicable).
Check configuration for Max
Purges/Day Limit in the
ALARMLIM Table.
Alarm limit too low.
Normal length purges occurring,
Purge Duration alarm, blinking
asterisk.
Purge relay miswired
(NC vs NO contacts).
Check relay wiring at Chiller
Monitor, relay, control panel,
and PreVent (if applicable).
Alarm limit too low.
Check configuration for Max
Purges on Limit in the
ALARMLIM Table.
Check CHLR-MNT
Maintenance Table.
(continued)
58
Table 3
Points Display Screen
Troubleshooting (continued)
Symptoms
Possible Causes
Remedies
Motor Bearing Temp, Motor
Winding Temp displays -40 °F
(-40 °C), blinking C.
32MP Gateway poll not
enabled (if applicable).
Enable 32MP Gateway poll.
No sensor present.
Force temperature value to
normal operating value.
Current to voltage sensor
miswired.
Check sensor wiring at
Chiller Monitor, sensor, and
starter panel. Use a VOM to
measure Vdc at Chiller Monitor with chiller operating.
Sensor not configured.
Check Motor Amps decisions
in SENS-CFG Table.
Motor amperes display not
updating.
Check CHLR-MNT
Maintenance Table.
Table 4
Prognostic Maintenance
Screens Troubleshooting
Symptoms
Possible Causes
Remedies
Prognostic Active
displays No.
Prognostic algorithm is
not enabled.
Check the Enable decision in
the associated Prognostic
Configuration Table.
Chiller not running long enough.
Let the chiller run longer.
Prognostics are not active
until it has run for five
minutes.
Temperature sensor failed.
Check the Points Display
Table for failed temperature
sensors.
59
Table 5
Off-site Alarm Transmission
Troubleshooting
Symptoms
Possible Causes
Remedies
Remote operator does
not receive alarms.
Alarm routing control bit is
not set at chiller monitor.
Set the second bit from the
left to 1 in the Alarm Routing
Control decision in the
ALARMDEF Configuration
Table. Example: 01000000.
Autodial Gateway is not
configured properly.
Check Autodial Gateway
Configuration.
Symptoms
Possible Causes
Remedies
Operator is unable to
generate reports.
Insufficient time has elapsed for
gathering data.
Wait at least two hours after
start-up before collecting
data.
Chiller Monitor has not received
a time broadcast.
Set Chiller Monitor’s
controller time.
Table 6
Data Collection
Troubleshooting
60
Table 7
Relationship of Motor Amps
Duration to Chiller and
Alarm Status
STATUS
Inputs
CHIL_S_S
SAFETY
Output
Motor Amps (time)
Commanded State
Safety Input
Chiller Status*
On (45 seconds)
On (60 seconds)
On (60 seconds)
On (60 seconds)
Off (120 seconds)
Off (0 seconds)
Off (60 seconds)
Off (0 seconds)
On
On
Off
Off
On
On
Off
Off
Normal
Alarm
Normal
Alarm
Normal
Alarm
Normal
Alarm
On/Normal
On/Alarm
On/Alarm
On/Alarm
Off/Alarm
Off/Alarm
Off/Normal
Off/Alarm
*On transition between states, the new state must persist (time + 15 seconds) before an alarm or
return to normal is generated.
61
Carrier Part Numbers
For purposes of ordering from the Carrier C9 System, part numbers
for base sensor package components are listed below.
Table 8
Base Sensor Package
Part Numbers
Qty. Part
Number
Description
Reference
Designation
ECW, LCW,
ECDW, LCDW
ECW, LCW,
ECDW, LCDW
ERT, CRT
CWPD
4
ACI/10K-AN
Temperature Sensor
4
Pipe Strap
2
1
EXTRASTRAP
9RT1H409-1
152C-P130D
1
1
1
PTX1-02
4CTV
8205
1
RN60C2490F
Temperature Sensor
Differential Pressure
Transducer
Pressure Transducer
Current Transducer
Wire, twisted pair,
500 ft
Resistor, 1/4 watt
CRP
MTRAMPS
R3, R6
For purposes of ordering from the Carrier C9 System, part numbers
for optional sensor package components are listed below.
Table 9
Optional Sensor Package
Part Numbers
62
Qty. Part
Number
1
152C-P130D
1
1
1
2
1
ACI/10K-AN
A1004AB22P1
P74DA-15C
ST-R3R
RN60C2490F
Description
Reference
Designation
Differential Pressure
Transducer
Temperature Sensor
Temperature Sensor
Oil Pressure Switch
Temperature Sensor
Resistor, 1/4 watt
CDWPD
OILT
OILT
OILPD
ERT, CRT
R1, R4
Fuse Replacement
Procedure
The fuse holder for the Chiller Monitor is located in the cutout on
the inside of the enclosure at front left. See Figure 1 for its location.
The fuse holder cover is not lit when power is present and the unit is
operating normally. If it is lit, then the fuse needs to be replaced.
To replace the fuse:
1.
Remove the fuse holder cover and the old fuse.
2.
Replace the fuse with a Littlefuse 10A 3AG fuse (manufacturer Part Number 313010) or equivalent.
Caution:
3.
Flowcharts
Never use anything other than a 10 ampere fuse.
Replace the fuse holder cover.
The flowcharts and diagrams that follow provide detailed information about Chiller Monitor calculations and processing to be used
during troubleshooting.
63
Figure 23
Condenser Approach
Calculation Flowchart
Start
CLTD = CRT - LCDW
CLTD < -10F?
Yes
CLTD = -10F
No
CLTD > 30F?
Yes
CLTD = 30F
No
Is CLTD forced?
No
Exit
64
Yes
CLTD = forced value
Figure 24
Condenser Flow and
Load Calculation
Flowchart
Start
CDWPDFT = CDWPDPSID * 2.307
see note 1
Yes
CDWPDFT < 0?
CDWPDFT = 0
No
Yes
CDWPDFT > 99?
CDWPDFT = 99
No
USMET = US?
Yes
No
System units
are metric.
System units
are US.
CND
MET
CND
US
1
In metric mode, some internal values are calculated in customary
U.S. units.
65
Figure 24
Condenser Flow and
Load Calculation
Flowchart
(continued)
CND
US
KCDWFL =
CDWFLGPM
Sqr Root (CDWPDPSI * 2.307)
CDWFL = KCDWFL * Sqr Root CDWPDFT
Is CDWFL
forced?
Yes
CDWFL = forced
value
No
CNDLOADTON = (CDWFL * (LCDW - ECDW))/24
CNDLOAD TON
< 0?
No
Exit
66
Yes
CNDLOADTON = 0
Figure 24
Condenser Flow and
Load Calculation
Flowchart
(continued)
CND
MET
KCDWFL = (CDWFLLPS / 0.06308)
Sqr Root (CDWPDKPAPSID * 2.307)
see note 1
CDWFL = (KCDWFL * Sqr Root CDWPDFT) * 0.06308
Is CDWFL
forced?
Yes
CDWFL = forced
value
No
CNDLOADKW = [(CDWFL/0.06308) * (LCDWF - ECDWF)/24] * 3.514
see note 1
CNDLOADK
W < 0?
Yes
CNDLOADKW = 0
No
Exit
1
In metric mode, some internal values are calculated in customary
U.S. units.
67
Figure 25
Cooler Approach
Calculation Flowchart
Start
ELTD = LCW - ERT
ELTD < -10F?
Yes
ELTD = -10F
No
ELTD > 30F?
Yes
ELTD = 30F
No
Is ELTD forced?
No
Exit
68
Yes
ELTD = forced value
Figure 26
Cooler Flow and Load
Calculation Flowchart
Start
CWPDFT = CWPD PSID * 2.307
see note 1
Yes
CWPDFT < 0?
CWPDFT = 0
No
Yes
CWPDFT > 99?
CWPDFT = 99
No
USMET = US?
Yes
No
System units
are metric.
System units
are US.
CLR
MET
CLR
US
1
In metric mode, some internal values are calculated in customary
U.S. units.
69
Figure 26
Cooler Flow and Load
Calculation Flowchart
(continued)
CLR
US
KCWFL =
CWFLGPM
Sqr Root (CWPDPSI * 2.307)
CWFL = KCWFL * Sqr Root CWPDFT
Is CWFL
forced?
Yes
CWFL = forced
value
No
CLRLOADTON = (CWFL * (ECW - LCW))/24
CLRLOADTON
< 0?
Yes
CLRLOADTON = 0
No
%LOAD = (CLRLOADTON/ CAPTONS) * 100
Is %LOAD
forced?
No
Exit
70
Yes
%LOAD = forced
value
Figure 26
Cooler Flow and Load
Calculation Flowchart
(continued)
CLR
MET
KCWFL = (CWFLLPS / 0.06308)
Sqr Root (CWPDKPA PSID * 2.307)
see note 1
CWFL = (KCWFL * Sqr Root CWPDFT) * 0.06308
Is CWFL
forced?
Yes
CWFL = forced
value
No
CLRLOADKW = [(CWFL/0.06308) * (ECWF - LCWF)/24] * 3.514
see note 1
CLRLOAD KW
< 0?
Yes
CLRLOADKW = 0
No
%LOAD = (CLRLOADKW/ CAPKW) * 100
Is %LOAD
forced?
Yes
%LOAD = forced
value
No
Exit
1
In metric mode, some internal values are calculated in customary
U.S. units.
71
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart
Start
MTRENA = Yes?
Yes
No
ECW and LCW >
-10F and < 245F?
Yes
No
Send MTRHI return to
normal.
Set MTRTIMR = 0.
CHIL_S_S = Start
STATUS = On
SAFETY = Normal
for > 5 minutes?
Yes
No
72
Set MTRACT = No
Set MTRACT = Yes
Exit
MTR2
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart
(continued)
MTR2
MTRX2 ≠ MTRX1?
No
SLOPE = 0
Yes
SLOPE = MTRY2 - MTRY1
MTRX2 - MTRX1
SLOPE > 1.5?
No
Yes
SLOPE = 1.5
Yes
SLOPE < 0?
No
SLOPE = 0
INTERCEPT = MTRY1 - (SLOPE * MTRX1)
MTRNOM = (%LOAD * SLOPE) + INTERCEPT
MTR3
73
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart
(continued)
MTR3
%LOAD <=
MTRX1?
Yes
MTRVAR = MTRLVAR
No
%LOAD =>
MTRX2?
Yes
MTRVAR = MTRHVAR
No
MTRX2 ≠
MTRX1?
Yes
VARSLOPE = MTRHVAR - MTRLVAR
MTRX2 - MTRX1
No
VARSLOPE = 0
VARINTERCEPT = MTRLVAR - (VARSLOPE * MTRX1)
MTRVAR = (%LOAD * VARSLOPE) + VARINTERCEPT
MTR4
74
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart
(continued)
MTR4
MTRHI = MTRNOM + MTRVAR
MTRHI = MTRNOM + MTRVAR
Is %MTRAMPS <
MTRHI and MTRHI
alarm already sent?
Yes
Send MTRHI return to
normal.
Set MTRTIMR = 0.
No
MTR5
75
Figure 27
% MTRAMPS vs % Load
Prognostic Flowchart
(continued)
MTR5
%MTRAMPS >
MTRHI?
Yes
First time above
limit?
Yes
No
Set MTRTIMR = MTRTIMR+1
MTRTIMR =>
MTRTIME?
No
Yes
Copy %MTRAMPS and
MTRHI into alarm message.
Set MTRTIMR = 0.
Has MTRHI alarm
already been sent?
Yes
No
Send MTRHI alarm.
Exit
76
Figure 28
CLTD vs % Load
Prognostic Flowchart
Start
CLTDENA = Yes?
Yes
No
ECW, LCW, CRT, and
LCDW > -10F and
< 245F?
Yes
No
Send CLTDHI return to
normal.
Set CLTDTIMR = 0.
CHIL_S_S = Start
STATUS = On
SAFETY = Normal
for > 5 minutes?
Yes
No
Set CLTDACT = No
Set CLTDACT = Yes
Exit
CLTD2
77
Figure 28
CLTD vs % Load
Prognostic Flowchart
(continued)
CLTD2
CLTDX2 ≠
CLTDX1?
No
SLOPE = 0
Yes
SLOPE = CLTDY2 - CLTDY1
CLTDX2 - CLTDX1
SLOPE > 0.3?
No
Yes
SLOPE = 0.3
Yes
SLOPE < 0?
No
SLOPE = 0
INTERCEPT = CLTDY1 - (SLOPE * CLTDX1)
CLTDNOM = (%LOAD * SLOPE) + INTERCEPT
CLTD3
78
Figure 28
CLTD vs % Load
Prognostic Flowchart
(continued)
CLTD3
Yes
%LOAD <=
CLTDX1?
CLTDVAR = CLTDLVAR
No
Yes
%LOAD =>
ELTDX2?
CLTDVAR = CLTDHVAR
No
Yes
CLTDX2 ≠
CLTDX1?
VARSLOPE = CLTDHVAR - CLTDLVAR
CLTDX2 - CLTDX1
No
VARSLOPE = 0
VARINTERCEPT = CLTDLVAR - (VARSLOPE * CLTDX1)
CLTDVAR = (%LOAD * VARSLOPE) + VARINTERCEPT
CLTD4
79
Figure 28
CLTD vs % Load
Prognostic Flowchart
(continued)
CLTD4
CLTDHI = CLTDNOM + CLTDVAR
Is CLTD < CLTDHI and
CLTDHI alarm already
sent?
Yes
Send CLTDHI return to
normal.
Set CLTDTIMR = 0.
No
CLTD5
80
Figure 28
CLTD vs % Load
Prognostic Flowchart
(continued)
CLTD5
CLTD >
CLTDHI?
Yes
First time above
limit?
Yes
No
Set CLTDTIMR = CLTDTIMR+1
CLTDTIMR =>
CLTDTIME?
No
Yes
Copy CLTD and CLTDHI
into alarm message.
Set CLTDTIMR = 0.
Has CLTDHI alarm
already been sent?
Yes
No
Send CLTDHI alarm.
Exit
81
Figure 29
CRP vs % Load Prognostic
Flowchart
Start
CRPENA = Yes?
Yes
No
ECW and LCW >
-10F and < 245F?
Yes
No
Send CRPHI, CRPLO
return to normal.
Set CRPTIMR = 0.
CHIL_S_S = Start
STATUS = On
SAFETY = Normal
for > 5 minutes?
Yes
No
82
Set CRPACT = No
Set CRPACT = Yes
Exit
CRP2
Figure 29
CRP vs % Load Prognostic
Flowchart
(continued)
CRP2
CRPX2 ≠ CRPX1?
No
SLOPE = 0
Yes
SLOPE = CRPY2 - CRPY1
CRPX2 - CRPX1
SLOPE > 0.3?
No
Yes
SLOPE = 0.3
Yes
SLOPE < 0?
No
SLOPE = 0
INTERCEPT = CRPY1 - (SLOPE * CRPX1)
CRPNOM = (%LOAD * SLOPE) + INTERCEPT
CRP3
83
Figure 29
CRP vs % Load Prognostic
Flowchart
(continued)
CRP3
%LOAD <=
CRPX1?
Yes
CRPVAR = CRPLVAR
No
Yes
%LOAD =>
CRPX2?
CRPVAR = CRPHVAR
No
CRPX2 ≠
CRPX1?
Yes
VARSLOPE = CRPHVAR - CRPLVAR
CRPX2 - CRPX1
No
VARSLOPE = 0
VARINTERCEPT = CRPLVAR - (VARSLOPE * CRPX1)
CRPVAR = (%LOAD * VARSLOPE) + VARINTERCEPT
CRP4
84
Figure 29
CRP vs % Load Prognostic
Flowchart
(continued)
CRP4
CRPHI = CRPNOM + CRPVAR
CRPLO = CRPNOM - CRPVAR
Is CRP < CRPHI and
CRPHI alarm already sent?
Yes
Send CRPHI return to
normal.
Set CRPTIMR = 0.
Yes
Send CRPLO return to
normal.
Set CRPTIMR = 0.
No
Is CRP > CRPLO and
CRPLO alarm already sent?
No
CRP5
85
Figure 29
CRP vs % Load Prognostic
Flowchart
(continued)
CRP5
Yes
CRP > CRPHI?
First time above
limit?
Yes
No
Set CRPTIMR = CRPTIMR+1
CRPTIMR =>
CRPTIME?
No
Yes
Copy CRP and CRPHI
into alarm message.
Set CRPTIMR = 0.
Has CRPHI alarm
already been sent?
Yes
No
Send CRPHI alarm.
CRP6
86
Figure 29
CRP vs % Load Prognostic
Flowchart
(continued)
CRP6
Yes
CRP < CRPLO?
First time above
limit?
Yes
No
Set CRPTIMR = CRPTIMR+1
CRPTIMR =>
CRPTIME?
No
Yes
Copy CRP and CRPLO
into alarm message.
Set CRPTIMR = 0.
Has CRPLO alarm
already been sent?
Yes
No
Send CRPLO alarm.
Exit
87
Figure 30
ELTD vs % Load Prognostic
Flowchart
Start
ELTDENA = Yes?
Yes
No
ECW, LCW, and ERT >
-10F and < 245F?
Yes
No
Send ELTDHI return to
normal.
Set ELTDTIMR = 0.
CHIL_S_S = Start
STATUS = On
SAFETY = Normal
for > 5 minutes?
Yes
No
88
Set ELTDACT = No
Set ELTDACT = Yes
Exit
ELTD2
Figure 30
ELTD vs % Load Prognostic
Flowchart
(continued)
ELTD2
ELTDX2 ≠
ELTDX1?
No
SLOPE = 0
Yes
SLOPE = ELTDY2 - ELTDY1
ELTDX2 - ELTDX1
SLOPE > 0.3?
No
Yes
SLOPE = 0.3
Yes
SLOPE < 0?
No
SLOPE = 0
INTERCEPT = ELTDY1 - (SLOPE * ELTDX1)
ELTDNOM = (%LOAD * SLOPE) + INTERCEPT
ELTD3
89
Figure 30
ELTD vs % Load Prognostic
Flowchart
(continued)
ELTD3
Yes
%LOAD <=
ELTDX1?
ELTDVAR = ELTDLVAR
No
Yes
%LOAD =>
ELTDX2?
ELTDVAR = ELTDHVAR
No
Yes
ELTDX2 ≠
ELTDX1?
VARSLOPE = ELTDHVAR - ELTDLVAR
ELTDX2 - ELTDX1
No
VARSLOPE = 0
VARINTERCEPT = ELTDLVAR - (VARSLOPE * ELTDX1)
ELTDVAR = (%LOAD * VARSLOPE) + VARINTERCEPT
ELTD4
90
Figure 30
ELTD vs % Load Prognostic
Flowchart
(continued)
ELTD4
ELTDHI = ELTDNOM + ELTDVAR
Is ELTD < ELTDHI and
ELTDHI alarm already
sent?
Yes
Send ELTDHI return to
normal.
Set ELTDTIMR = 0.
No
ELTD5
91
Figure 30
ELTD vs % Load
Prognostic Flowchart
(continued)
ELTD5
Yes
ELTD >
ELTDHI?
First time above
limit?
Yes
No
Set ELTDTIMR = ELTDTIMR+1
ELTDTIMR =>
ELTDTIME?
No
Yes
Copy ELTD and ELTDHI into
alarm message.
Set ELTDTIMR = 0.
Has ELTDHI alarm
already been sent?
Yes
No
Send ELTDHI alarm.
Exit
92
Figure 31
Multiplexed Input
Processing Flowchart
Start
Is any point
forced?
Yes
Use forced value.
No
Read the first set of input points:
ECW, LCW, ECDW, LCDW, CRT,
ERT, MTRW, CDWPD, CRP,
MTRAMPS, CWPD
Wait 30 seconds.
Read the second set of input points:
CHILL_S_S, SAFETY, OILPD,
OILQ, VSALM, PVALM,
CFCALM, MTRB, OILT
Wait 30 seconds.
Exit
93
Figure 32
32MP Gateway Input
Processing Flowchart
Start
READGW =
Yes?
Yes
No
Is any point
forced?
Yes
Use forced value.
No
Read the following 32MP points:
CHIL_S_S, LCW, ERT, CRT,
MTRB, MTRAMPS, MTRW
Communications
OK?
Yes
No
Send alarm.
Exit
94
Figure 33
Motor Amperes
(MTRAMPS) Input Data
Flow
INPUT
CONFIGURATION
(SENS-CFG Table)
DISPLAY
Amps
Input Point
(Hardware)
.
Y2
Display Variable
(Points Screen)
AMPS_IO
MTRAMPS
Y1
.
X1
X2
Vdc (or mA)
Data Transfer
Vdc or mA value
or
Data Transfer
Motor Amps value
Figure 34
Condenser Refrigerant
Pressure (CRP) Input Data
Flow
INPUT
CONFIGURATION
(SENS-CFG Table)
DISPLAY
PSI
(kPa)
Input Point
(Hardware)
.
Y2
Display Variable
(Points Screen)
CRP_IO
CRP
Y1
.
X1
X2
Vdc (or mA)
Data Transfer
Vdc or mA value
or
Data Transfer
PSI (kPa) value
95
Figure 35
Chilled Water Pressure
Differential (CWPD) Input
Data Flow
INPUT
CONFIGURATION
(SENS-CFG Table)
DISPLAY
PSI
(kPa)
Input Point
(Hardware)
.
Y2
Display Variable
(CHLR-MNT Table)
CWPD_IO
CWPD
Y1
.
X1
X2
Vdc (or mA)
Data Transfer
Vdc or mA value
or
Data Transfer
PSI (kPa) value
Note:
Figure 36
Oil Pressure Differential
(OILPD) Input Data Flow
Data flow is the same for the condenser water differential
pressure input. The hardware point is CDWPD_IO, and
the display variable is CDWPD.
INPUT
Input Point
(Hardware)
CONFIGURATION
(SENS-CFG Table)
DISPLAY
open
INPUT SENSE = normal
open
open
INPUT SENSE = invert
close
OILPD_IO
Data Transfer
0=open, 1=closed
96
Display Variable
(Points Screen)
OILPD
(normal/alarm)
Appendixes
Appendix A
System Walk-through Form
Job Name & Location:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Number of Chillers: __________________________________________________________
System Description:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Chiller 1 Design Data (size, s/n, volts, amps, flows, controls, etc.):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Chiller 2 Design Data (size, s/n, volts, amps, flows, controls, etc.):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
97
Water Temperature Sensor Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Refrigerant Temperature Sensor Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Water Differential Pressure Transducer Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Condenser Refrigerant Pressure Transducer Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Current Transducer Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Oil Temperature Sensor Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
98
Oil Pressure Sensor Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Oil Sense Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Purge/PreVent Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
PREVAC Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
VaporSaver Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Control System Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
99
Phone Line Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Other Notes:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
100
Appendix B
Wiring Table for Sensors and Relays
Signal
Input
Signal
Type
Commanded state
DI
Entering chilled
water temperature
10K therm.
Safety input
DI
Leaving chilled
water temperature
10K therm.
Oil pressure switch
DI
Entering condenser
water temperature
10K therm.
Oil quality
DI
Leaving condenser
water temperature
10K therm.
VaporSaver
DI
24 Vdc
24 Vac
(+)
✔
1
3
✔
✔
Condenser refrigerant
temperature
10K therm.
PREVAC
DI
Evaporator refrigerant
temperature
10K therm.
✔
5
8
6
7
11
8
9
14
16
18
4
5
13
15
2
4
10
12
✔
2
7
9
Cable #
1
4
6
✔
(-)
10
11
17
12
(continued)
101
Signal
Input
Signal
Type
Local CFC detector
DI
Motor winding
temperature
5K therm.
Condenser water
differential pressure
Motor bearing
temperature
24 Vac
(+)
✔
19
✔
5K therm.
Condenser refrigerant
pressure2
Oil temperature
24 Vdc1
✔
10K therm.
Motor amps3
(-)
Cable #
13
21
20
14
22
23
15
24
23
16
25
26
17
27
26
18
28
29
19
Chilled water
differential pressure2
Purge/PreVent
Pulse DI
✔
34
21
1
When a second PSIO Module is installed, all sensors wired to the first module that use +24
Vdc are wired to TB2. Those for the second module are wired to TB3.
2
Transducer output of 4-20 mA converted to 1-5 Vdc input at module by adding 249Ω .1%
1/2 W resistor across input + and - terminals. Connect cable to 24 Vdc bus and + terminal.
3
Transducer output voltage of 0 to 5 Vdc. Requires shielded cable with shield grounded only
at Chiller Monitor end.
102
Reader's
Comments
Your comments regarding this manual will help us improve future
editions. Please comment on the usefulness and readability of this
manual, suggest additions and deletions, and list specific errors and
omissions.
Document Name:
Publication Date:
Usefulness and Readability:
Suggested Additions and Deletions:
Errors and Omissions (Please give page numbers):
Date:
Name:
Title or Position:
Organization:
Address:
Fold so that the mailing address is visible, staple closed,
and mail.
Carrier Corporation
Carrier World Headquarters Building
One Carrier Place
Farmington, CT 06034-4015
Attn: CCN Documentation
SCP
Printed in U.S.A.
808 - 883 3/94
Reader's
Comments
Your comments regarding this manual will help us improve future
editions. Please comment on the usefulness and readability of this
manual, suggest additions and deletions, and list specific errors and
omissions.
Document Name:
Publication Date:
Usefulness and Readability:
Suggested Additions and Deletions:
Errors and Omissions (Please give page numbers):
Date:
Name:
Title or Position:
Organization:
Address:
Fold so that the mailing address is visible, staple closed,
and mail.
Carrier Corporation
Carrier World Headquarters Building
One Carrier Place
Farmington, CT 06034-4015
Attn: CCN Documentation
SCP
Printed in U.S.A.
808 - 883 3/94
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement