Daikin | AGZ 140D | Operating and Maintenance Manual

Operating & Maintenance Manual
OMM 1166
Group: Chiller
Part No. OMM 1166
Effective: April 2013
Supersedes: August 2012
Air-Cooled Scroll Compressor Chiller
AGZ025D – AGZ190D (Rev 0A) 25 to 190 Tons
50 - 60-Hertz, R-410A
Software Version 251699201
Table of Contents
Introduction ........................................3
Operating/Standby Limits ............................ 9
Pressure Drop Curves ........................9
Minimum Allowable Flow Rates ................. 9
Pressure Drop Curves ................................ 10
MicroTech III Controller .............13
Controller Section Table of Contents ......... 13
Security ...................................................... 20
Unit Functions ..................................20
Definitions ................................................. 20
Unit Enable ................................................ 21
Unit Mode Selection .................................. 22
Unit States.................................................. 22
Power Up Start Delay ................................ 23
Ice Mode Start Delay ................................. 23
Unit Status ................................................. 23
Evaporator Pump Control .......................... 24
LWT Target ................................................ 25
Unit Capacity Control ................................ 26
Unit Capacity Overrides ............................ 27
Circuit Functions..............................29
Definitions ................................................. 29
Circuit Control Logic ................................. 29
Pumpdown Procedure ................................ 31
Low Ambient Starts ................................... 31
Circuit Status ............................................. 31
Compressor Control ................................... 31
Condenser Fan Control .............................. 32
EXV Control .............................................. 34
Liquid Line Solenoid Valve ....................... 35
Hot Gas Bypass Solenoid Valve ................ 35
Capacity Overrides – Limits of Operation . 35
Unit Problem Alarms .................................. 37
Unit Warning Alarms .................................. 38
Circuit Fault Alarms ................................... 38
Circuit Events ............................................. 40
Circuit Warning Alarms .............................. 41
Events ............................................... 41
Unit Events ................................................. 42
Circuit Events ............................................. 42
Clearing AlarmsError! Bookmark not defined.
Using the Controller........................ 44
Navigating .................................................. 45
Menus ......................................................... 47
Optional Low Ambient Fan VFD .. 60
VFD Interface (HMI) ................................. 61
Recommended Periodic Inspection ............ 65
Optional BAS Interface .................. 65
Startup .............................................. 66
Operation ......................................... 68
Unit Maintenance ............................ 73
Planned Maintenance Schedule .................. 74
Service .............................................. 75
R-410A....................................................... 75
Refrigerant Charging .................................. 76
Evaporator .................................................. 78
AGZ-D Troubleshooting Chart ...... 79
Warranty Statement ........................ 80
Alarms ...............................................35
Unit Fault Alarms....................................... 35
Cover picture: AGZ 190D, 190 nominal tons capacity.
Our facility is ISO Certified
©2013 Daikin Applied. Illustrations and data cover the Daikin Applied product at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice. ™® The following are trademarks or registered trademarks of their
respective companies: BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by
LONMARK International under a license granted by Echelon Corporation; Compliant Scroll from Copeland Corporation; ElectroFin from
AST ElectroFin Inc.; Modbus from Schneider Electric; FanTrol, MicroTech III, Open Choices from Daikin Applied. *Unit Controllers are
LONMARK certified with an optional LONWORKS communication module.
2
AGZ 025D through 190D
OMM 1166
Introduction
General Description
NOTE: Vintage changes; this manual covers
Revision 0A to the original AGZD version
“00”. The units are very close in appearance
but can be differentiated by their nameplate.
Version OO name plate is AGZ……….E10
Revision OA nameplate is AGZ………E11
Daikin Air-Cooled Global Water Chillers are
complete, self-contained automatic
refrigerating units. Every unit is completely
assembled, factory wired, charged, and tested
(except remote evaporator option). Each unit
consists of twin air-cooled condensers with
integral subcooler sections, two tandem or
triple scroll compressors, brazed-plate or
replaceable tube, dual circuit shell-and-tube
evaporator, and complete refrigerant piping.
Liquid line components include manual liquid
line shutoff valves, sight-glass/moisture
indicators, solenoid valves, and thermal
expansion valves.
Other features include compressor crankcase
heaters, an evaporator heater for chilled water
freeze protection, , automatic compressor leadlag to alternate the compressor starting
sequence, and sequenced starting of
compressors.
The electrical control center includes all
equipment protection and operating controls
necessary for dependable automatic operation.
This manual covers units with Software
Version 251699201 which must be used with
firmware version 9.XX.
Installation, information is in IM 1165 (or
current, latest dash number) manual.
Nomenclature
A G Z - XXX D H
Application
H= Packaged Chiller
B= Remote Evaporator
Air-Cooled
Design Vintage
Global
Model Size
(Nominal Tons)
Scroll Compressor
Hazard Identification Information
!
DANGER
Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.
!
WARNING
Warnings indicate potentially hazardous situations, which can result in property damage, severe
personal injury, or death if not avoided.
!
CAUTION
Cautions indicate potentially hazardous situations, which can result in personal injury or equipment
damage if not avoided.
OMM 1166
AGZ 025D through 190D
3
Ambient Air Temperature
Limitations
water flow is slow and the minimum and
maximum flow rates for the vessel are not
exceeded.
Standard/High Ambient Panels
The recommended maximum change in water
flow is 10 percent of the change per minute.
The maximum operating ambient temperature
for standard units is 104°F (40°C). AGZ-D
units for high ambient operation (105°F to
125°F maximum) require the addition of the
High Ambient Control Panel Option, which
includes the addition of a small fan with a
filter in the air intake to cool the control panel.
All units with the optional variable frequency
drive (VFD) low ambient fan control
automatically include the High Ambient
Control Panel Option. Operation of the VFD
generates a quantity of panel heat best
removed by use of a control panel fan.
System Water Volume
Considerations
Water Flow Limitations
The evaporator flow rates and pressure drops
shown on page 11 are for full load design
purposes in order to maintain proper unit
control. The maximum flow rate and pressure
drop are based on a 6 degree temperature drop.
Avoid higher flow rates with resulting lower
temperature drops to prevent potential control
problems resulting from very small control
bands and limited start up/shut off temperature
changes.
The minimum flow and pressure drop is
dependent on whether constant or variable
flow is employed in the chilled water system.
See 9 for details. Evaporator flow rates below
the minimum values can result in laminar flow
causing freeze-up problems, scaling and poor
control. Flow rates above the maximum values
will result in unacceptable pressure drops and
can cause excessive erosion, potentially
leading to failure.
Variable Speed Pumping
Variable water flow involves changing the
water flow through the evaporator as the load
changes. Daikin chillers are designed for this
duty provided that the rate of change in
4
When units are operated with flow rates
less than nominal (see
Table 8 on page 11), the “Evap Delta T”
setpoint must be changed proportionally to
match the minimum operating flow rate. The
“Delta T” setting should be increased by the
same percentage as the flow reduction is from
the nominal rating in order to prevent short
cycling. This will require reevaluation of
“Cool LWT”, “Startup Delta T”, and “Stop
Delta T” settings as well
All chilled water systems need adequate time
to recognize a load change, respond to that
load change and stabilize without undesirable
short cycling of the compressors or loss of
temperature control. In air conditioning
systems, the potential for short cycling usually
exists when the building load falls below the
minimum chiller plant capacity or on closecoupled systems with very small water
volumes.
Some of the things the designer should
consider when looking at water volume are the
minimum cooling load, the minimum chiller
plant capacity during the low load period and
the desired cycle time for the compressors.
Assuming that there are no sudden load
changes and that the chiller plant has
reasonable turndown, a rule of thumb of
“gallons of water volume equal to two to three
times the chilled water gpm flow rate” is often
used.
A properly designed storage tank should be
added if the system components do not provide
sufficient water volume.
AGZ 025D through 190D
OMM 1166
Glycol Solutions
The use of a glycol/water mixture in the evaporator to prevent freezing reduces system capacity and
efficiency, as well as increase pressure drop. The system capacity, required glycol solution flow rate,
and pressure drop with glycol may be calculated using Table 1.
1. Capacity – Multiply the capacity based on water by the Capacity correction factor from Table 2
through Table 5.
2. Flow – Multiply the water evaporator flow by the Flow correction factor from Table 2 through
Table 5 to determine the increased evaporator flow due to glycol.
If the flow is unknown, it can be calculated from the following equation
3. Pressure drop -- Multiply the water pressure drop from page 9 by Pressure Drop correction factor
from Table 2 through Table 5. High concentrations of propylene glycol at low temperatures can
cause unacceptably high pressure drops.
4. Power -- Multiply the water system power by Power correction factor from Table 2 - Table 5.
Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service
stations) to determine the freezing point. Obtain percent glycol from the freezing point tables below.
It is recommended that a minimum of 25% solution by weight be used for protection against corrosion
or that additional compatible inhibitors be added.
Concentrations above 35 % do not provide any additional burst protection and should be carefully
considered before using.
Table 1, Flow/Tons/Delta-T Relationship
Glycol Flow (gpm)
24 × Tons Capacity ( glycol )
Delta
kW Capacity
Glycol Flow (l/s)
4.18 × Delta − T
!
× Flow Correction Factor
T
× Flow Correction Factor
WARNING
Do not use an automotive grade antifreeze. Industrial grade glycols must be used. Automotive
antifreeze contains inhibitors which will cause plating on the copper tubes within the chiller evaporator.
The type and handling of glycol used must be consistent with local codes
Table 2, Ethylene Glycol Factors for Models AGZ 025D to 130D
% E.G.
10
20
30
40
50
Freeze Point
o
F
26
18
7
-7
-28
o
C
-3.3
-7.8
-13.9
-21.7
-33.3
Capacity
Power
Flow
PD
0.998
0.993
0.987
0.980
0.973
0.998
0.997
0.995
0.992
0.991
1.036
1.060
1.092
1.132
1.182
1.097
1.226
1.369
1.557
1.791
Table 3, Propylene Glycol Factors for Models AGZ 025D to 130D
% P.G.
10
20
30
40
50
OMM 1166
Freeze Point
o
F
26
19
9
-5
-27
o
C
-3.3
-7.2
-12.8
-20.6
-32.8
Capacity
Power
Flow
PD
0.995
0.987
0.978
0.964
0.952
0.997
0.995
0.992
0.987
0.983
1.016
1.032
1.057
1.092
1.140
1.100
1.211
1.380
1.703
2.251
AGZ 025D through 190D
5
Table 4, Ethylene Glycol Factors for Models AGZ 140D to 190D
% E.G.
10
20
30
40
50
Freeze Point
o
F
26
18
7
-7
-28
o
C
-3.3
-7.8
-13.9
-21.7
-33.3
Capacity
Power
Flow
PD
0.994
0.982
0.970
0.955
0.939
0.998
0.995
0.992
0.987
0.983
1.038
1.063
1.095
1.134
1.184
1.101
1.224
1.358
1.536
1.755
Table 5, Propylene Glycol Factors for Models AGZ 140D to 190D
% P.G.
10
20
30
40
50
Freeze Point
o
F
26
19
9
-5
-27
o
C
-3.3
-7.2
-12.8
-20.6
-32.8
Capacity
Power
Flow
PD
0.988
0.972
0.951
0.926
0.906
0.996
0.992
0.987
0.979
0.974
1.019
1.035
1.059
1.095
1.142
1.097
1.201
1.351
1.598
2.039
Altitude Correction Factors
Performance tables are based at sea level.
Elevations other than sea level affect the
performance of the unit. The decreased air
density will reduce condenser capacity
consequently reducing the unit's performance.
For performance at elevations other than sea
level, refer to Table 6 and Table 7.
Evaporator Temperature Drop
Factors
Performance tables are based on a 10°F (5°C)
temperature drop through the evaporator.
Adjustment factors for applications with
temperature ranges from 6°F to 16°F (3.3°C to
8.9°C) are in Table 6 and Table 7.
Temperature drops outside this 6°F to 16°F
(3.3°C to 8.9°C) range can affect the control
system's capability to maintain acceptable
control and are not recommended.
6
The maximum water temperature that can be
circulated through the evaporator in a nonoperating mode is 100°F (37.8°C).
Fouling Factor
Performance tables are based on water with a
fouling factor of:
2
0.0001 ft × hr × ° F / BTU
or
2
(0.0176m × °C / kW )
per ARI 550/590-98.
As fouling is increased, performance
decreases. For performance at other than
0.0001 (0.0176) fouling factor, refer to Table 6
or Table 7.
Foreign matter in the chilled water
system will adversely affect the heat
transfer capability of the evaporator
and could increase the pressure drop
and reduce the water flow. Maintain
proper water treatment to provide
optimum unit operation.
AGZ 025D through 190D
OMM 1166
Table 6, Capacity and Power Derates, Models AGZ 025D to 130D
Altitude
Sea
Level
2000 feet
4000 feet
6000 feet
OMM 1166
Chilled Water Delta
T
Fouling Factor
0.0001 (0.0176)
0.00025 (0.044)
0.00075 (0.132)
0.00175 (0.308)
°F
°C
Cap.
Power
Cap.
Power
Cap.
Power
Cap.
Power
6
3.3
0.978
0.993
0.975
0.991
0.963
0.987
0.940
0.980
8
4.4
0.989
0.996
0.986
0.994
0.973
0.990
0.950
0.983
10
5.6
1.000
1.000
0.996
0.999
0.984
0.994
0.961
0.987
12
6.7
1.009
1.003
1.005
1.001
0.993
0.997
0.969
0.990
14
7.7
1.018
1.004
1.014
1.003
1.002
0.999
0.978
0.991
16
8.9
1.025
1.007
1.021
1.006
1.009
1.001
0.985
0.994
6
3.3
0.977
1.001
0.973
1.000
0.961
0.996
0.938
0.989
8
4.4
0.987
1.006
0.984
1.004
0.971
1.000
0.948
0.993
10
5.6
0.998
1.009
0.995
1.007
0.982
1.003
0.959
0.996
12
6.7
1.007
1.011
1.004
1.010
0.991
1.006
0.967
0.998
14
7.7
1.014
1.014
1.011
1.013
0.998
1.009
0.974
1.001
16
8.9
1.022
1.016
1.018
1.014
1.005
1.010
0.981
1.003
6
3.3
0.973
1.011
0.970
1.010
0.957
1.006
0.935
0.998
8
4.4
0.984
1.014
0.980
1.013
0.968
1.009
0.945
1.001
10
5.6
0.995
1.019
0.991
1.017
0.979
1.013
0.955
1.005
12
6.7
1.004
1.021
1.000
1.020
0.987
1.016
0.964
1.008
14
7.7
1.011
1.024
1.007
1.023
0.994
1.018
0.971
1.011
16
8.9
1.018
1.027
1.014
1.026
1.002
1.021
0.978
1.014
6
3.3
0.969
1.021
0.966
1.020
0.954
1.016
0.931
1.008
8
4.4
0.980
1.026
0.977
1.024
0.964
1.020
0.942
1.013
10
5.6
0.989
1.029
0.986
1.027
0.973
1.023
0.950
1.015
12
6.7
0.998
1.033
0.995
1.031
0.982
1.027
0.959
1.020
14
7.7
1.007
1.036
1.004
1.034
0.991
1.030
0.967
1.022
16
8.9
1.014
1.037
1.011
1.036
0.998
1.031
0.974
1.024
AGZ 025D through 190D
7
Table 7, Capacity and Power Derates, Models AGZ 140D to 190D
Altitude
Sea
Level
2000 feet
4000 feet
6000 feet
8000 feet
Chilled Water
Delta T
Fouling Factor
0.0001 (0.0176)
0.00025 (0.044)
0.00075 (0.132)
0.00175 (0.308)
°F
°C
Cap.
Power
Cap.
Power
Cap.
Power
Cap.
Power
6
3.3
0.990
0.997
0.976
0.994
0.937
0.983
0.868
0.964
8
4.4
0.994
0.998
0.981
0.995
0.942
0.984
0.872
0.965
10
5.6
1.000
1.000
0.987
0.996
0.947
0.986
0.877
0.967
12
6.7
1.005
1.001
0.991
0.997
0.951
0.986
0.881
0.968
14
7.7
1.009
1.002
0.995
0.998
0.955
0.987
0.884
0.968
16
8.9
1.013
1.004
1.000
1.000
0.960
0.989
0.889
0.970
6
3.3
0.987
1.005
0.974
1.002
0.934
0.991
0.865
0.972
8
4.4
0.992
1.006
0.979
1.003
0.940
0.992
0.870
0.973
10
5.6
0.997
1.008
0.984
1.004
0.944
0.994
0.875
0.975
12
6.7
1.002
1.009
0.989
1.005
0.949
0.994
0.879
0.975
14
7.7
1.007
1.011
0.993
1.007
0.953
0.996
0.883
0.977
16
8.9
1.011
1.012
0.998
1.008
0.958
0.997
0.887
0.978
6
3.3
0.985
1.014
0.972
1.010
0.933
0.999
0.864
0.980
8
4.4
0.991
1.015
0.977
1.012
0.938
1.001
0.869
0.981
10
5.6
0.995
1.016
0.982
1.013
0.943
1.002
0.873
0.982
12
6.7
1.000
1.018
0.987
1.014
0.947
1.003
0.877
0.984
14
6.8
1.005
1.019
0.991
1.015
0.951
1.004
0.881
0.985
16
8.9
1.009
1.021
0.995
1.017
0.955
1.006
0.884
0.987
6
3.3
0.982
1.023
0.969
1.020
0.930
1.009
0.861
0.989
8
4.4
0.988
1.025
0.975
1.022
0.935
1.010
0.866
0.991
10
5.6
0.992
1.026
0.979
1.022
0.940
1.011
0.870
0.992
12
6.7
0.997
1.028
0.984
1.024
0.944
1.013
0.875
0.994
14
7.7
1.002
1.029
0.989
1.025
0.949
1.014
0.879
0.995
16
8.9
1.006
1.031
0.992
1.027
0.952
1.016
0.882
0.996
6
3.3
0.979
1.034
0.966
1.031
0.927
1.019
0.859
1.000
8
4.4
0.984
1.036
0.971
1.032
0.932
1.021
0.863
1.002
10
5.6
0.990
1.037
0.976
1.033
0.937
1.022
0.868
1.002
12
6.7
0.993
1.039
0.980
1.035
0.941
1.024
0.871
1.004
14
7.7
0.998
1.041
0.985
1.037
0.945
1.026
0.875
1.006
16
8.9
1.003
1.041
0.990
1.038
0.950
1.026
0.879
1.007
Evaporator Freeze Protection
Evaporator freeze-up can be a concern in the
application of air-cooled water chillers. To
protect against freeze-up, insulation and an
electric heater cable are furnished with the
unit. This protects the evaporator down to 20°F (-29°C) ambient air temperature.
Although the evaporator is equipped with
freeze protection, it does not protect water
piping external to the unit or the evaporator
itself if there is a power failure or heater cable
burnout. Consider the following
recommendations for additional protection.
1. If the unit will not be operated during the
winter, drain evaporator and chilled water
piping and flush with glycol. Drain and
8
vent connections are provided on the
evaporator to ease draining.
2. Add a glycol solution to the chilled water
system to provide freeze protection.
Freeze point should be approximately ten
degrees below minimum design ambient
temperature.
3. The addition of thermostatically controlled
heat and insulation to exposed piping.
4. Continuous circulation of water through
the chilled water piping and evaporator.
The evaporator heater cable is factory wired to
the 115-volt circuit in the control box. This
power should be supplied from a separate
source, but it can be supplied from the control
circuit. Operation of the heater cable is
AGZ 025D through 190D
OMM 1166
automatic through the ambient sensing
thermostat that energizes the evaporator heater
cable for protection against freeze-up. Unless
the evaporator is drained in the winter, the
disconnect switch to the evaporator heater
must not be open.
Operating/Standby Limits
• Maximum standby ambient air temperature, 130° F (55° C)
• Maximum operating ambient air temperature 105° F (40.6° C)
• Minimum operating ambient temperature (standard), 35° F (2° C)
• Minimum operating ambient temperature (with optional low-ambient control), -10° F (-23.3°C)
• Leaving chilled water temperature, 40°F to 60°F (4.4° C to 15.6° C)
• Leaving chilled fluid temperatures (with anti-freeze), 15° F to 60° F (-9.4°C to 15.6°C)
• Chilled water Delta-T range, 6 degrees F to 16 degrees F (3.3 degrees C to 8.9 degrees C)
• Part load minimum flow for variable flow systems, varies with unit size; see Table 8, page 11.
• Maximum operating inlet fluid temperature, 76° F (24° C)
• Maximum non-operating inlet fluid temperature, 100°F (38° C).
Pressure Drop Curves
Minimum Allowable Flow Rates
In order to maximize energy savings from variable flow systems, the AGZD chiller employs different
control strategies for constant-f low chilled water systems as compared to variable-flow systems.
A chiller controller setpoint selects the proper controller operation. The software setting of Variable
Evap. Flow equals YES or NO is located just below the “Full Cap D-T” setting screen.
The Full Cap D-T setting will continue to allow settings from 6 to 16 F Delta-T for full load operation.
Constant-Chilled Water Flow Systems
The minimum allowable flow is determined by the chiller model. Operating with flows below these
values can cause unstable operation.
Variable-Chilled Water Flow Systems
For models AGZ 025D through AGZ 130D the part load flow rate in a variable chilled water flow
system is 40% of nominal catalog full load flow (rated catalog tons x 2.4 = full load GPM). These
minimum allowable flows are calculated to allow the chilled water flow to decrease progressively as
the unit capacity decreases, but is restricted to 40% of rated full load flow.
The larger AGZ 140D to190D units have shell and tube evaporators and will operate at the same
minimum flow rate as for constant flow (62.5% of nominal catalog full load flow rate.)
When “Variable Evap Flow” is selected as YES – the unit software will increase the control band
progressively as the unit capacity steps to the lower stages of 75%, 50% and 25% load for the four
compressors. This prevents short cycling and allows for decreasing minimum water flow as the unit
capacity decreases. The 6 compressor units will have a similar operation but with software
calculations based on 6 capacity steps.
Refer to Table 8 on page 11 for the allowable reduced minimum flows.
OMM 1166
AGZ 025D through 190D
9
Pressure Drop Curves
The pressure drop for any given unit is the same regardless of constant or variable flow. Only the
lower cutoff point for minimum flow will change.
Table 8 on page 11 contains the evaporator reference letter and the minimum and maximum flows
allowed for each unit. Occasionally the same evaporator is used on multiple units resulting in
overlapping lines.
The nominal and maximum flow and pressure drop are the same for a given unit size regardless of
having fixed or variable flow.
The curves are based on water use only. Use glycol adjustment factors located in the catalog
Performance Section as required.
Figure 1, Evaporator Pressure Drops. See following page for curve cross-reference
See following page for curve cross-reference and min/max flow rates.
10
AGZ 025D through 190D
OMM 1166
Table 8, Curve Cross-Reference, Min/Nominal/Max Flows
AGZ
Curve
Model
Ref.
Variable Flow System
Only
Fixed Flow System
Only
Minimum Flow Rate
Minimum Flow Rate
IP
SI
IP
GPM DP ft.
lps
DP
kpa
Fixed and Variable Flow Systems
Nominal Flow Rate
SI
IP
Maximum Flow Rate
SI
IP
SI
GPM
DP ft.
lps
DP kpa
GPM
DP ft.
lps
DP kpa
GPM
DP ft.
lps
DP kpa
025D
A
26.4
1.6
1.7
4.8
41.3
3.8
2.6
11.5
66.0
9.4
4.2
28.1
110.0
24.8
6.9
74.1
030D
B
30.3
2.2
1.9
6.4
47.4
5.0
3.0
15.0
75.8
12.3
4.8
36.7
126.3
32.4
8.0
96.8
035D
C
33.5
2.4
2.1
7.1
52.4
5.4
3.3
16.1
83.8
13.6
5.3
40.6
139.7
35.9
8.8
107.3
040D
D
36.4
2.4
2.3
7.1
56.9
5.4
3.6
16.1
91.0
13.5
5.7
40.4
151.7
35.6
9.6
106.4
045D
E
40.9
2.3
2.6
6.9
63.9
5.3
4.0
15.8
102.2
13.2
6.4
39.5
170.3
34.8
10.7
104.0
050D
F
46.2
2.6
2.9
7.8
72.1
6.1
4.6
18.2
115.4
14.9
7.3
44.5
192.3
39.3
12.1
117.5
055D
G
49.5
2.3
3.1
7.0
77.4
5.4
4.9
16.3
123.8
13.3
7.8
39.7
206.3
35.1
13.0
104.9
060D
H
53.8
2.2
3.4
6.6
84.1
5.1
5.3
15.3
134.6
12.5
8.5
37.3
224.3
33.0
14.2
98.6
065D
I
55.8
1.9
3.5
5.8
87.1
4.5
5.5
13.4
139.4
11.0
8.8
32.8
232.3
29.0
14.7
86.7
070D
J
61.5
2.3
3.9
7.0
96.1
5.4
6.1
16.3
153.8
13.3
9.7
39.7
256.3
35.1
16.2
104.9
075D
J
70.2
2.3
4.4
6.8
109.6
5.3
6.9
15.8
175.4
12.9
11.1
38.5
292.3
34.0
18.4
101.6
080D
L
77.8
2.2
4.9
6.7
121.6
5.2
7.7
15.6
194.6
12.8
12.3
38.2
324.3
33.8
20.5
101.0
090D
M
85.6
2.4
5.4
7.1
133.8
5.4
8.4
16.1
214.1
13.5
13.5
40.4
356.8
35.1
22.5
104.9
100D
N
95.8
2.2
6.0
6.6
149.7
5.2
9.4
15.4
239.5
12.6
15.1
37.6
399.2
33.3
25.2
99.5
110D
O
101.8
2.3
6.4
6.8
159.1
5.3
10.0
15.9
254.6
13.0
16.1
38.8
424.3
34.3
26.8
102.5
125D
P
112.4
2.3
7.1
6.9
175.6
5.4
11.1
16.1
281.0
13.2
17.7
39.7
468.3
34.8
29.5
104.0
130D
Q
124.3
2.4
7.8
7.2
194.3
5.5
12.3
16.5
310.8
13.5
19.6
40.4
518.0
35.6
32.7
106.4
140D
R
204.3
4.8
12.9
14.4
204.3
4.8
12.9
14.4
326.9
11.8
20.6
35.2
544.8
31.1
34.4
93.0
160D
S
229.9
5.9
14.5
17.7
229.9
5.9
14.5
17.7
367.9
14.5
23.2
43.3
613.2
38.3
38.7
114.5
180D
T
258.3
7.4
16.3
22.0
258.3
7.4
16.3
22.0
413.3
18.0
26.1
53.7
688.8
47.5
43.5
142.0
190D
U
270.1
9.0
17.0
26.9
270.1
9.0
17.0
26.9
432.2
22.0
27.3
65.7
720.3
58.1
45.4
173.7
OMM 1166
AGZ 025D through 190D
11
Figure 2, Typical Field Control Wiring
12
AGZ 025D through 190D
OMM 1166
MicroTech III Controller
Controller Section Table of Contents
Overview........................................................................................................................14
Controller Inputs and Outputs .......................................................................................14
Setpoints ........................................................................................................................16
Security ..........................................................................................................................20
Unit Control Functions ..................................................................................................20
Unit Enable ....................................................................................................................21
Unit Mode Selection ......................................................................................................22
Unit States ......................................................................................................................22
Start Delays ....................................................................................................................23
Evaporator Pump Control ..............................................................................................24
Leaving Water Temperature (LWT) Reset/Target .........................................................25
Unit Capacity Control ....................................................................................................26
Unit Capacity Overrides……………………………………………………………….27
Circuit Control Functions ..............................................................................................29
Circuit Control Logic.....................................................................................................29
Pumpdown Procedure ....................................................................................................31
Compressor Control .......................................................................................................31
Condenser Fan Control ..................................................................................................32
EXV Control ..................................................................................................................34
Liquid Line Solenoid .....................................................................................................35
Hot Gas Bypass Solenoid ..............................................................................................35
Alarms............................................................................................................................35
Events…………………………………………………………………………....…….41
Clearing Alarms .............................................................................................................43
Using the Controller…………………………………………………………………...44
OMM 1166
AGZ 025D through 190D
13
Overview
The MicroTech® III controller’s state-of-the-art design not only permits the chiller to run more
efficiently, but also can simplify troubleshooting if a system failure occurs. Every MicroTech IIII
controller is programmed and tested prior to shipment to facilitate start-up.
Operator-friendly
The MicroTech III controller menu structure is separated into three distinct categories that provide the
operator or service technician with a full description of :
1. current unit status
2. control parameters
3. alarms. Security protection prevents unauthorized changing of the setpoints and control parameters.
MicroTech III control continuously performs self-diagnostic checks, monitoring system temperatures,
pressures and protection devices, and will automatically shut down a compressor or the entire unit
should a fault occur. The cause of the shutdown will be retained in memory and can be easily
displayed in plain English for operator review. The MicroTech III chiller controller will also retain
and display the date/time the fault occurred. In addition to displaying alarm diagnostics, the
MicroTech III chiller controller also provides the operator with a warning of limit (pre-alarm)
conditions.
Controller Inputs and Outputs
Main Controller
Table 9, Analog Inputs
#
AI1
AI2
AI3
X1
X4
Description
Evaporator EWT
Evaporator LWT
Outside Ambient
Temperature
Demand Limit
LWT Reset
Type
Expected Range
NTC 10k
NTC 10k
340 to 300k Ω
340 to 300k Ω
NTC 10k
340 to 300k Ω
4-20 mA
4-20 mA
1 to 23 mA
1 to 23 mA
Output Type
Range
Voltage
Voltage
0 to 10 volts
0 to 10 volts
Table 10, Analog Outputs
#
X5
X6
Description
Circuit 1 Fan VFD Speed
Circuit 2 Fan VFD Speed
Table 11, Digital Inputs
Description
DI1 External Alarm/Event
DI2 Evaporator Flow Switch
Double Set Point/ Mode
DI3
Switch
DI4 Remote Switch
DI5 Unit Switch
14
Signal Off
Signal On
External Fault
No External Fault
No Flow
Flow
See sections on Unit Mode Selection and LWT
Target
Remote Disable
Remote Enable
Unit Disable
Unit Enable
AGZ 025D through 190D
OMM 1166
Table 12, Digital Outputs
Description
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
DO9
DO10
Evaporator Water Pump 1
Alarm Indicator
Circuit 1 Fan Output 1
Circuit 1 Fan Output 2
Circuit 1 Fan Output 3
Circuit 1 Fan Output 4
Circuit 2 Fan Output 1
Circuit 2 Fan Output 2
Circuit 2 Fan Output 3
Circuit 2 Fan Output 4
Output Off
Output On
Pump Off
Alarm Not Active
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Pump On
Alarm Active
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Compressor Module 1
Analog Inputs
X1
X2
X4
Description
Circuit 1 Suction Temperature
Circuit 1 Evaporator Pressure
Circuit 1 Condenser Pressure
Signal Type
NTC 10k
Voltage
Voltage
Expected Range
340 to 300k Ω
0.4 to 4.6 volts
0.4 to 4.6 volts
Signal Off
Signal On
Digital Inputs
Description
X6
X7
X8
DI1
Circuit 1 Switch
Circuit 1 MHP Switch
Circuit 1 Motor Protection
Circuit 1 (or Unit) PVM/GFP
Circuit Disable
Fault
Fault
Fault
Circuit Enable
No fault
No fault
No fault
Digital Outputs
Description
DO1
DO2
DO3
DO4
DO5
DO6
Compressor #1
Compressor #3
Compressor #5
Evaporator Water Pump 2
Circuit 1 Hot Gas Bypass SV
Circuit 1 Liquid Line SV
Output Off
Output On
Compressor Off
Compressor Off
Compressor Off
Pump Off
Solenoid Closed
Solenoid Closed
Compressor On
Compressor On
Compressor On
Pump On
Solenoid Open
Solenoid Open
Compressor Module 2
Analog Inputs
Description
X1
X2
X4
Circuit 2 Suction Temperature
Circuit 2 Evaporator Pressure
Circuit 2 Condenser Pressure
Signal Type
Expected Range
NTC 10k
Voltage
Voltage
340 to 300k Ω
0.4 to 4.6 volts
0.4 to 4.6 volts
Digital Inputs
Description
X6
X7
X8
DI1
Circuit 2 Switch
Circuit 2 MHP Switch
Circuit 2 Motor Protection
Circuit 2 PVM/GFP
Signal Off
Signal On
Circuit Disable
Fault
Fault
Fault
Circuit Enable
No fault
No fault
No fault
Note: The Motor Protection and MHP input signal are wired in series. If Motor Protection input is
open, MHP Switch input will also be open.
OMM 1166
AGZ 025D through 190D
15
Digital Outputs
Description
DO1
DO2
DO3
DO5
DO6
Compressor #2
Compressor #4
Compressor #6
Circuit 2 Hot Gas Bypass SV
Circuit 2 Liquid Line SV
Output Off
Output On
Compressor Off
Compressor Off
Compressor Off
Solenoid Closed
Solenoid Closed
Compressor On
Compressor On
Compressor On
Solenoid Open
Solenoid Open
EXV Module 1 and 2
These modules will be used only when the expansion valve type is electronic.
Digital Outputs
Description
DO1
Circuit 1 Fan Output 5
Output Off
Output On
Fan(s) Off
Fan(s) On
Stepper Motor Output
Description
M1+, M1M2+, M2-
EXV Stepper Coil 1
EXV Stepper Coil 2
Sensor Information
Temperature
All temperature sensors will be Daikin Applied part number
1934146.
Pressure
Pressure inputs will be read using 0 to 5 volt ratiometric sensors. Nominal voltage range will be 0.5
to 4.5 volts.
Pressure on the low side will be measured using Daikin Applied part number 331764501.
Pressure on the high side will be measured using Daikin Applied part number 331764601.
Actuator Information
•
The electronic expansion valves used are Daikin Applied part number 33038620X. These valves are
Sporlan supplied and all use the same bipolar stepper motor.
Setpoints
Setpoints are stored in permanent memory.
SetPoint Tables
Setpoints are initially set to the values in the Default column, and can be adjusted to any value in the
Range column.
16
AGZ 025D through 190D
OMM 1166
Unit Level Setpoints:
Description
Default
Range
Unit Enable
Enable
Disable, Enable
Network Unit Enable
Control source
Disable
Local
Mode/Enabling
Available Modes
Cool
Network Mode Command
Cool
Disable, Enable
Local, Network
Cool, Cool w/Glycol, Cool/Ice w/Glycol
Ice, Test
Cool, Ice
7°C (44.6°F)
7°C (44.6°F)
4.4°C (39.9°F)
7°C (44.6°F)
4.4°C (39.9°F)
5.6°C (10.1°F)
0.3°C (0.5°F)
0.6°C/min (1.1°F/min)
5.6 °C (10.1°F)
Off
100%
Off
See Auto Adjusted Ranges, page 19
See Auto Adjusted Ranges, page 19
-9.5 to 4.4 °C (14.9 to 39.9 °F)
See Auto Adjusted Ranges, page 19
-9.5 to 4.4 °C (14.9 to 39.9 °F)
0.6 to 8.3 °C (1.1 to 14.9 °F)
0.3 to 1.7 °C (0.5 to 3.1 °F)
0.1 to 2.7 °C/min (0.2 to 4.9 °F/min)
3.3 to 8.9 °C (5.9 to 16 °F)
Off, On
0 to 100%
Off, On
Single Point
Staging and Capacity Control
Cool LWT 1
Cool LWT 2
Ice LWT
Network Cool Set Point
Network Ice Set Point
Startup Delta T
Shut Down Delta T
Max Pulldown
Nominal Evap Delta T
Demand Limit Enable
Network Capacity Limit
LWT Reset Enable
Configuration
Power Input
Evap Control
#1 Only
Number of Compressors
Expansion Valve Type
Fan VFD enable
Number of fans
4
Thermal
No
4
Single Point, Multi Point
#1 Only, #2 Only, Auto,
#1 Primary, #2 Primary
4,6
Thermal, Electronic
No, Yes
4,6,8,10,12,14
Timers
Evap Recirc Timer
Stage Up Delay
Stage Down Delay
Stage Delay Clear
Start-start timer
Stop-start timer
Clear Cycle Timers
Ice Time Delay
Clear Ice Timer
30
240 sec
30 sec
No
15 min
5 min
No
12
No
15 to 300 seconds
120 to 480 sec
20 to 60 sec
No, Yes
10-60 minutes
3-20 minutes
No, yes
1-23 hours
No,Yes
0°C (0°F)
0°C (0°F)
0°C (0°F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
689.5 KPA(100 PSI)
696.4 KPA(101 PSI)
4240 KPA(615 PSI)
See section 5.1.1
See section 5.1.1
3310 to 4275 KPA (480 to 620 PSI)
Sensor Offsets
Evap LWT sensor offset
Evap EWT sensor offset
OAT sensor offset
Alarm Settings
Low Evap Pressure Unload
Low Evap Pressure Hold
High Condenser Pressure
Continued next page.
OMM 1166
AGZ 025D through 190D
17
Description
Default
Range
High Condenser Pressure Unload
Evaporator Flow Proof
Recirculate Timeout
Evaporator Water Freeze
Low OAT Start Time
External Alarm Configuration
Clear Alarms
Network Clear Alarms
4137 KPA(600 PSI)
5 sec
3 min
2.2°C (36°F)
165 sec
Event
Off
Off
3241 to 4137 KPA (470 to 600 PSI)
5 to 15 sec
1 to 10 min
See Auto Adjusted Ranges, page 19
150 to 240 sec
Event, Alarm
Off, On
Off, On
Circuit Setpoints (exist individually for each circuit):
Description
Default
Range
Mode/Enabling
Circuit mode
Compressor 1 Enable
Compressor 2 Enable
Compressor 3 Enable
Network Compressor 1 Enable
Network Compressor 2 Enable
Network Compressor 3 Enable
EXV control
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Auto
Disable, Enable, Test
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Auto, manual
EXV position
See Special Setpoints,
page 19
0% to 100%
Suction SH Target
Max Evap Pressure
5.56°C (10°F )
1076 KPA(156.1 PSI)
4.44 to 6.67 °C (8 to 12 °F)
979 to 1172 KPA (142 to 170 PSI)
37.8°C (100°F)
32.2°C (90°F)
32.2°C (90°F)
29.4°C (85°F)
32.22 to 48.9 °C (90 to 120 °F)
32.22 to 48.9 °C (90 to 120 °F)
29.44 to 43.3 °C (85 to 110 °F)
29.44 to 43.3 °C (85 to 110 °F)
100%
25%
8.33°C (15°F)
5.56°C (10°F)
5.56°C (10°F)
5.56°C (10°F)
11.11°C (20°F)
11.11°C (20°F)
8.33 °C (15 °F)
5.56 °C (10 °F)
90 to 110%
25 to 60%
8.33 to 13.89 °C (15 to 25 °F)
5.56 to 8.33 °C (10 to 15 °F)
5.56 to 8.33 °C (10 to 15 °F)
5.56 to 8.33 °C (10 to 15 °F)
8.33 to11.11 °C (15 to 20 °F)
8.33 to11.11 °C (15 to 20 °F)
5.56 to 8.33 °C (10 to 15 °F)
3.33 to 5.56 °C (6 to 10 °F)
0 KPA (0 PSI)
0 KPA (0 PSI)
0°C (0°F)
-100 to 100 KPA (-14.5 to 14.5 PSI)
-100 to 100 KPA (-14.5 to 14.5 PSI)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
Condenser
Condenser Target
Condenser Target
Condenser Target
Condenser Target
100%
67%
50%
33%
VFD Max Speed
VFD Min Speed
Fan Stage Up Deadband 1
Fan Stage Up Deadband 2
Fan Stage Up Deadband 3
Fan Stage Up Deadband 4
Fan Stage Down Deadband 1
Fan Stage Down Deadband 2
Fan Stage Down Deadband 3
Fan Stage Down Deadband 4
Sensor Offsets
Evap pressure offset
Cond pressure offset
Suction temp offset
Note – Condenser Target 67% and Condenser Target 33% will be available only when Number of
Compressors is 6. Condenser Target 50% will be available only when Number of Compressors is 4.
18
AGZ 025D through 190D
OMM 1166
Auto Adjusted Ranges
Some settings have different ranges of adjustment based on other settings:
Cool LWT 1, Cool LWT 2, and Network Cool Set Point
Available Mode Selection
Range
Without Glycol
4.4 to 15.6 °C (39.9 to 60.1 °F)
With Glycol
-9.5 to 15.6 °C (14.9 to 60.1 °F)
Evaporator Water Freeze
Available Mode Selection
Without Glycol
With Glycol
Range
2.2 to 5.6 °C (36 to 42.1 °F)
-10.8 to 5.6 °C (12.6 to 42.1 °F)
Low Evaporator Pressure Hold and Unload
Available Mode Selection
Range
Without Glycol
669 to 793 KPA (97 to 115 PSI)
With Glycol
407 to 793 KPA (59 to 115 PSI)
Special Set Point Operations
The following setpoints are not changeable unless the unit switch is off:
• Available Modes
• Number of Compressors
• Expansion Valve Type
• Number of Fans
• Fan VFD Enable
The Circuit Mode setpoints should not be changeable unless the corresponding circuit switch is off.
The Compressor Enable setpoints should not be changeable unless the corresponding compressor is
not running.
EXV Position set point on each circuit follows the actual EXV position while EXV Control = Auto.
When EXV Control = Manual, the position set point should be changeable.
The Clear Alarms and Network Clear Alarms settings are automatically set back to Off after being On
for 1 second.
OMM 1166
AGZ 025D through 190D
19
Security
All setpoints are protected using passwords. A four-digit password provides operator access to changeable
parameters. Service level passwords are reserved for authorized service personnel. .
Operator password: 5321
Entering Passwords
Passwords are entered on the first screen on the unit controller,
If the wrong password is entered, a message will temporarily appear stating this. If no valid password is
active the active password level displays “none”.
Editing Setpoints
After a valid password has been entered at the unit controller, setpoints may be changed. If the operator
attempts to edit a setpoint for which the necessary password level is not active, no action will be taken.
Once a password has been entered, it remains valid for 10 minutes after the last key-press on the unit
controller.
Unit Functions
Definitions
The calculations in this section are used in unit level and circuit control logic.
LWT Slope
LWT slope is calculated such that the slope represents the estimated change in LWT over a time frame of one
minute.
Pulldown Rate
The slope value calculated above will be a negative value as the water temperature is dropping. A pulldown
rate is calculated by inverting the slope value and limiting to a minimum value of 0°C/min.
LWT Error
LWT error is calculated as:
LWT – LWT target
20
AGZ 025D through 190D
OMM 1166
•
Stage Up temperature = LWT target +
Control Band – (LWT target – 3.9°C)
If the unit is configured for use with glycol, the
compressor staging temperatures are calculated as
shown below:
Unit Capacity
For applying unit capacity limits, an estimate of
total unit capacity is needed. Unit capacity will be
based on the estimated circuit capacities.
The unit capacity is the number of compressors
running (on circuits that are not pumping down)
divided by the number of compressors on the unit.
•
Stage Up Temperature = LWT target +
(Control Band/2)
•
Stage Down Temperature = LWT target –
(Control Band/2)
Control Band
The Control Band defines the band in which unit
capacity will not be increased or decreased.
The Control Band is calculated as follows:
•
Four compressor units: Control Band =
Nominal Evap Delta T Set Point * 0.3
•
Six compressor units: Control Band =
Nominal Evap Delta T Set Point * 0.2
The Start up and Shutdown temperatures are
referenced from the Control Band:
Start Up Temperature = Stage
Temperature + Start Up Delta set point
•
Shutdown Temperature = Stage Down
Temperature – Shutdown Delta set point
Up
Unit Enable
Staging Temperatures
Enabling and disabling the chiller is accomplished
using setpoints and inputs to the chiller. The unit
switch, remote switch input, and Unit Enable Set
Point all are required to be ‘on’ for the unit to be
enabled when the control source is set to ‘local’.
The same is true if the control source is set to
‘network’, with the additional requirement that the
building automation system (BAS) Enable set
point must be ‘on’. The BAS should enable the
chiller only when there is a demand for cooling.
If the unit is configured for use without glycol:
When the LWT target is more than half the
Control Band above 3.9°C (39.0°F)
•
Stage Up Temperature = LWT target +
(Control Band/2)
•
Stage Down Temperature = LWT target –
(Control Band/2)
If the LWT target is less than half the Control
Band above 3.9°C (39.0°F)
•
•
Unit is enabled according to the following table
Stage Down Temperature = LWT target –
(LWT target - 3.9°C)
:
Unit
Switch
Off
Control Source
Set Point
Remote
Switch Input
Unit Enable
Set Point
BAS Enable
Set Point
Off
On
On
OMM 1166
Local
Network
Network
Off
On
On
On
On
AGZ 025D through 190D
Off
On
Unit Enable
Off
Off
Off
On
Off
On
21
Unit Mode Selection
The operating mode of the unit is determined by
setpoints and inputs to the chiller. The Available
Modes Set Point determines what modes of
operation can be used. This set point also
determines whether the unit is configured for
glycol use.
The Control Source Set Point
determines where a command to change modes
will come from. A digital input switches between
cool mode and ice mode if they are available and
the control source is set to ‘local.’ The BAS mode
Control Source
Set Point
Local
Local
Network
Network
Mode
Input
BAS
Request
request switches between cool mode and ice mode
if they are both available and the control source is
set to ‘network.’
The Available Modes Set Point should only be
changeable when the unit switch is off. This is to
avoid changing modes of operation inadvertently
while the chiller is running.
Unit Mode is set according to the following table:
Available Modes
Set Point
Cool
Unit Mode
Cool
Cool w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Ice w/Glycol
Test
Off
On
Cool
Ice
Cool
Cool
Ice
Cool
Ice
Ice
Test
Glycol Configuration
If the Available Modes Set Point is set to an option ‘w/Glycol’, then glycol operation should be enabled for
the unit. Glycol operation should only be disabled when the Available Modes Set Point is set to ‘Cool’.
Unit States
The unit will always be in one of three states:
Off – Unit is not enabled to run
Auto – Unit is enabled to run
Pumpdown – Unit is doing a normal shutdown
Transitions between these states are shown in the following diagram.
POWER
ON
OFF
T3
T1
T4
PUMPDOWN
T2
AUTO
Diagram explanation on following page.
22
AGZ 025D through 190D
OMM 1166
T1 - Off to Auto
All of the following are required:
• Unit Enable = On
• No Unit Alarm
• A circuit is enabled to start
• If Unit Mode = Ice then Ice Delay not active
T2 - Auto to Pumpdown
Any of the following are required:
• Unit Enable = Off and Unit Switch is closed
• Unit Mode = Ice AND LWT target is reached
• Unit Pumpdown Alarm active
T3 - Pumpdown to Off
Any of the following are required:
• Unit rapid stop alarm active
• All circuits complete pumpdown
• Unit Switch open
T4 - Auto to Off
Any of the following are required:
• Unit rapid stop alarm active
• No circuit enabled and no compressors running
• Unit Switch open
Power Up Start Delay
After powering up the unit, the motor protectors
may not be engaged for up to 150 seconds.
Therefore, after the control is powered up, no
compressor can start for 150 seconds. In addition,
the motor protect inputs are ignored during this
time so as to avoid tripping a false alarm.
Ice Mode Start Delay
start in Ice mode. The timer starts when the first
compressor starts while the unit is in ice mode.
While this timer is active, the chiller cannot restart
in Ice mode. The time delay is adjustable via the
Ice Time Delay set point.
The ice delay timer may be manually cleared to
force a restart in ice mode. A set point specifically
for clearing the ice mode delay is available. In
addition, cycling the power to the controller
should clear the ice delay timer.
An adjustable start to start ice delay timer will
limit the frequency with which the chiller may
Unit Status
The displayed unit status should be determined by the conditions in the following table:
Enum
0
1
2
3
4
5
Status
Auto
Motor Prot Delay
Off:Ice Mode Timer
Off:OAT Lockout
Off:All Cir Disabled
Off:Unit Alarm
Conditions
Unit State = Auto
Unit State = Auto and MP start up delay is active
Unit State = Off, Unit Mode = Ice, and Ice Delay = Active
Unit State = Off and Low OAT Lockout is active
Unit State = Off and both circuits unavailable
Unit State = Off and Unit Alarm active
Continued next page.
OMM 1166
AGZ 025D through 190D
23
Enum
Status
6
7
Off:Keypad Disable
Off:Remote Switch
8
Off:BAS Disable
9
10
Off:Unit Switch
Off:Test Mode
11
Auto:Wait for load
12
Auto:Evap Recirc
13
Auto:Wait for flow
14
15
16
17
Auto:Pumpdown
Auto:Max Pulldown
Auto:Unit Cap Limit
18
Conditions
Unit State = Off and Unit Enable Set Point = Disable
Unit State = Off and Remote Switch is open
Unit State = Off, Control Source = Network, and BAS Enable =
false
Unit State = Off and Unit Switch = Disable
Unit State = Off and Unit Mode = Test
Unit State = Auto, no circuits running, and LWT is less than the
active set point + startup delta
Unit State = Auto and Evaporator State = Start
Unit State = Auto, Evaporator State = Start, and Flow Switch is
open
Unit State = Pumpdown
Unit State = Auto, max pulldown rate has been met or exceeded
Unit State = Auto, unit capacity limit has been met or exceeded
--A configuration change requiring a reboot has occurred but
controller has not been rebooted yet.
Auto: High Ambient Limit
Config Changed, Reboot
Required
Evaporator Pump Control
For control of the evaporator pumps, three evaporator pump control states should be used:
Off - No pump on.
• Start – Pump is on, water loop is being recirculated.
• Run – Pump is on, water loop has been recirculated and circuits can start if needed.
Transitions between these states are shown in the following diagram.
POWER
ON
OFF
T3
T1
T4
T2
RUN
START
T5
T1 – Off to Start
Requires any of the following
• Unit state = Auto
• LWT is less than the Evap Freeze set point – 0.6°C (1.1°F) and LWT sensor fault isn’t active
T2 – Start to Run
Requires the following
• Flow ok for time longer than evaporator recirculate time set point
24
AGZ 025D through 190D
OMM 1166
T3 – Run to Off
Requires all of the following
• Unit state is Off
• LWT is higher than the Evap Freeze set point or LWT sensor fault is active
T4 – Start to Off
Requires all of the following
• Unit state is Off
• LWT is higher than the Evap Freeze set point or LWT sensor fault is active
T5 – Run to Start
This transition should occur per the requirements for pump staging and evaporator flow loss alarm.
Pump selection
The pump output used will be determined by the Evap Pump Control set point. This setting allows the
following configurations:
•
•
•
•
•
#1 only – Pump 1 will always be used
#2 only – Pump 2 will always be used
Auto – The primary pump is the one with the least run hours, the other is used as a backup
#1 Primary – Pump 1 is used normally, with pump 2 as a backup
#2 Primary – Pump 2 is used normally, with pump 1 as a backup
Primary/Standby Pump Staging
The pump designated as primary will start first. If the evaporator state is start for a time greater than the
recirculate timeout set point and there is no flow, then the primary pump will shut off and the standby
pump will start. When the evaporator is in the run state, if flow is lost for more than half of the flow
proof set point value, the primary pump will shut off and the standby pump will start. Once the standby
pump is started, the flow loss alarm logic will apply if flow cannot be established in the evaporator start
state, or if flow is lost in the evaporator run state.
Auto Control
If auto pump control is selected, the primary/standby logic above is still used. When the evaporator is
not in the run state, the run hours of the pumps will be compared. The pump with the least hours will be
designated as the primary at this time.
LWT Target
The LWT Target varies based on settings and inputs.
The base LWT Target is selected as follows:
Control Source
Set Point
Local
Mode
Input
OFF
Local
ON
Network
Local
Local
Network
OMM 1166
OFF
ON
BAS
Request
Available Modes
Set Point
COOL
Base LWT Target
Cool Set Point 1
COOL
Cool Set Point 2
COOL
BAS Cool Set Point
COOL w/Glycol
COOL w/Glycol
COOL w/Glycol
Cool Set Point 1
Cool Set Point 2
BAS Cool Set Point
AGZ 025D through 190D
25
Local
OFF
Local
ON
Network
COOL
Network
ICE
Local
Network
COOL/ICE
w/Glycol
COOL/ICE
w/Glycol
COOL/ICE
w/Glycol
COOL/ICE
w/Glycol
ICE w/Glycol
ICE w/Glycol
Cool Set Point 1
Ice Set Point
BAS Cool Set Point
BAS Ice Set Point
Ice Set Point
BAS Ice Set Point
Leaving Water Temperature (LWT) Reset
The base LWT target may be reset if the unit is in Cool mode and LWT reset is enabled via the set
point.
The reset amount is adjusted based on the 4 to 20 mA reset input. Reset is 0° if the reset signal is less
than or equal to 4 mA. Reset is 5.56°C (10.0°F) if the reset signal equals or exceeds 20 mA. The
amount of reset will vary linearly between these extremes if the reset signal is between 4 mA and 20
mA.
When the reset amount increases, the Active LWT Target is changed at a rate of 0.1°C every 10
seconds. When the active reset decreases, the Active LWT Target is changed all at once.
After the reset is applied, the LWT target can never exceed a value of 15.56°C (60°F).
Unit Capacity Control
Unit capacity control will be performed as described in this section. All unit capacity limits described in
following sections must be applied as described.
Compressor Staging in Cool Mode
The first compressor on the unit should be started when evaporator LWT is higher than the Startup
Temperature.
Additional compressors can be started when Evaporator LWT is higher than the Stage Up Temperature and
the Stage Up Delay is not active.
When multiple compressors are running, one should shut down if evaporator LWT is lower than the Stage
Down Temperature and the Stage Down Delay is not active.
All running compressors should shut down when the evaporator LWT is lower than the Shut Down
Temperature.
Stage Up Delay
A minimum amount of time, defined by the Stage Up Delay set point, should pass between increases in the
capacity stage. This delay should only apply when at least one compressor is running. If the first compressor
starts and quickly shuts off for some reason, another compressor may start without this minimum time
passing.
Stage Down Delay
A minimum amount of time, defined by the Stage Down Delay set point, should pass between decreases in
the capacity stage. This delay should not apply when the LWT drops below the Shut Down Temperature
(unit should immediately shut down).
26
AGZ 025D through 190D
OMM 1166
Compressor Staging in Ice Mode
The first compressor on the unit should be started when evaporator LWT is higher than the Startup
Temperature.
Additional compressors should be started as quickly as possible with respect to the Stage Up Delay.
The unit should shut down when evaporator LWT is less than the LWT target.
Stage Up Delay
A fixed stage up delay of one minute between compressor starts should be used in this mode.
Staging Sequence
This section defines which compressor is the next one to start or stop. In general, compressors with fewer
starts will normally start first, and compressors with more run hours will normally stop first.
If possible circuits will be balanced in stage. If a circuit is unavailable for any reason, the other circuit shall
be allowed to stage all compressors on. When staging down, one compressor on each circuit shall be left on
until each circuit has only one compressor running.
Next To Start
If both circuits have an equal number of compressors running or a circuit has no compressors available to
start:
• -the available compressor with the least starts will be next to start
• -if starts are equal, the one with the least run hours will be next to start
• -if run hours are equal, the lowest numbered one will be next to start
If the circuits have an unequal number of compressors running, the next compressor to start will be on the
circuit with the least compressors running if it has at least one compressor available to start. Within that
circuit:
• -the available compressor with the least starts will be next to start
• -if starts are equal, the one with the least run hours will be next to start
• -if run hours are equal, the lowest numbered one will be next to start
Next to Stop
If both circuits have an equal number of compressors running:
• -the running compressor with the most run hours will be next to stop
• -if run hours are equal, the one with the least starts will be next to stop
• -if starts are equal, the lowest numbered one will be next to stop
If the circuits have an unequal number of compressors running, the next compressor to stop will be on the
circuit with the most compressors running. Within that circuit:
• -the running compressor with the most run hours will be next to stop
• -if run hours are equal, the one with the least starts will be next to stop
• -if starts are equal, the lowest numbered one will be next to stop
Unit Capacity Overrides
Unit capacity limits can be used to limit total unit capacity in Cool mode only. Multiple limits may be active at any time,
and the lowest limit is always used in the unit capacity control.
Demand Limit
The maximum unit capacity can be limited by a 4 to 20 mA signal on the Demand Limit analog input. This
function is only enabled if the Demand Limit set point is set to ON. The maximum unit capacity stage is
determined as shown in the following tables:
OMM 1166
AGZ 025D through 190D
27
Four Compressors:
Demand Limit Signal (%)
Limit ≥ 75%
75% > Limit ≥ 50%
50% > Limit ≥ 25%
25% > Limit
Demand Limit (mA)
Limit ≥ 16 mA
16 mA > Limit ≥ 12 mA
12 mA > Limit ≥ 8 mA
8 mA > Limit
Stage Limit
1
2
3
4
Demand Limit (mA)
Limit ≥ 17.3 mA
17.3 mA > Limit ≥ 14.7 mA
14.7 mA > Limit ≥ 12mA
12 mA > Limit ≥ 9.3 mA
9.3 mA > Limit ≥ 6.7 mA
6.7 mA > Limit
Stage Limit
1
2
3
4
5
6
Six Compressors:
Demand Limit Signal (%)
Limit ≥ 83.3%
83.3% > Limit ≥ 66.7%
66.7% > Limit ≥ 50%
50% > Limit ≥ 33.3%
33.3% > Limit ≥ 16.7%
16.7% > Limit
Network Limit
The maximum unit capacity can be limited by a network signal. This function is only enabled if the control
source is set to network. The maximum unit capacity stage is based on the network limit value received from
the BAS, and is determined as shown in the following tables:
Four compressors:
Network Limit
Stage Limit
Limit ≥ 100%
100% > Limit ≥ 75%
75% > Limit ≥ 50%
50% > Limit
4
3
2
1
Six compressors:
Network Limit
Limit ≥ 100%
100% > Limit ≥ 83.3%
83.3% > Limit ≥ 66.7%
66.7% > Limit ≥ 50%
50% > Limit ≥ 33.3%
33.3% > Limit
Stage Limit
6
5
4
3
2
1
Maximum LWT Pulldown Rate
The maximum rate at which the leaving water temperature can drop shall be limited by the Maximum
Pulldown Rate set point, only when the unit mode is Cool.
If the rate exceeds this set point, no more compressors shall be started until the pulldown rate is less than the
set point.
Running compressors will not be stopped as a result of exceeding the maximum pulldown rate.
High Ambient Limit
On units configured with single point power connections, the maximum load amps could be exceeded at high
ambient temperatures. If all compressors are running on circuit 1 or all but one compressor on circuit 1,
power connection is single point, and the outdoor air temperature OAT is greater than 46.6°C (115.9°F),
circuit 2 is limited to running all but one compressor. This limit will allow the unit to operate at higher
temperatures than 46.6°C (115.9°F).
28
AGZ 025D through 190D
OMM 1166
Circuit Functions
Definitions
Refrigerant Saturated Temperature
•
Refrigerant saturated temperature shall be calculated from the pressure sensor readings for each circuit.
Evaporator Approach
The evaporator approach shall be calculated for each circuit. The equation is as follows:
Evaporator Approach = LWT – Evaporator Saturated Temperature
Condenser Approach
The condenser approach shall be calculated for each circuit. The equation is as follows:
Condenser Approach = Condenser Saturated Temperature - OAT
Suction Superheat
Suction superheat shall be calculated for each circuit using the following equation:
Suction superheat = Suction Temperature – Evaporator Saturated Temperature
Pumpdown Pressure
The pressure to which a circuit will pumpdown is based on the Low Evaporator Pressure Unload set point.
The equation is as follows:
Pumpdown pressure = Low Evap Pressure Unload set point – 103KPA (15 PSI)
Circuit Control Logic
Circuit Enabling
A circuit should be enabled to start if the following conditions are true:
• Circuit switch is closed
• No circuit alarms are active
• Circuit Mode set point is set to Enable
• At least one compressor is enabled to start (according to enable setpoints)
Compressor Availability
A compressor is considered available to start if all the following are true:
•
•
•
•
•
•
The corresponding circuit is enabled
The corresponding circuit is not in pumpdown
No cycle timers are active for the compressor
No limit events are active for the corresponding circuit
The compressor is enabled via the enable setpoints
The compressor is not already running
Circuit States
The circuit will always be in one of four states:
Off – Circuit is not running
Preopen – Circuit is preparing to start
Run – Circuit is running
Pumpdown – Circuit is doing a normal shutdown
OMM 1166
AGZ 025D through 190D
29
Transitions between these states are shown in the following diagram.
POWER
ON
OFF
T1
PREOPEN
T6
T4
T5
T2
PUMPDOWN
T3
RUN
T1 – Off to Preopen
• No compressors are running and any compressor on circuit is commanded to start (see unit capacity
control)
•
T2 – Preopen to Run
• 5 seconds has passed
T3 – Run to Pumpdown
Any of the following are required:
• Last compressor on circuit is commanded to stop
• Unit State = Pumpdown
• Circuit switch is open
• Circuit mode is disable
• Circuit Pumpdown alarm is active
T4 – Pumpdown to Off
Any of the following are required:
• Evaporator Pressure < Pumpdown Pressure Value
• Unit State = Off
• Circuit Rapid Stop alarm is active
T5 – Run to Off
Any of the following are required:
• Unit State = Off
• Circuit Rapid Stop alarm is active
• A low ambient start attempt failed
T6 – Preopen to Off
Any of the following are required:
• Unit State = Off
• Unit State = Pumpdown
• Circuit switch is open
• Circuit mode is disable
• Circuit Rapid Stop alarm is active
• Circuit Pumpdown alarm is active
30
AGZ 025D through 190D
OMM 1166
and unload alarms are disabled. The absolute limit
for low evaporator pressure is enforced and the
low evaporator pressure alarm should trigger if the
evaporator pressure drops below that limit.
Pumpdown Procedure
Pumpdown is performed as follows:
•
•
•
•
If multiple compressors are running, shut off
the appropriate compressors based on
sequencing logic and leave only one running
Turn off hot gas output and liquid line output
Keep running until evaporator pressure
reaches the pumpdown pressure, then stop
compressor
If evaporator pressure does not reach
pumpdown pressure within two minutes, stop
compressor
Low Ambient Starts
A low OAT start is initiated if the condenser
refrigerant saturated temperature is less than
29.5°C (85.1° F) when the first compressor starts.
Once the compressor starts the circuit is in a low
OAT start state for a time equal to the Low OAT
Start Time set point. During Low OAT Starts, the
freezestat logic for the low evaporator pressure
alarm as well as the low evaporator pressure hold
When the Low OAT Start Timer has expired, if
the evaporator pressure is greater than or equal to
the Low Evaporator Pressure Unload set point, the
start is considered successful and normal alarm
and event logic is reinstated. If the evaporator
pressure is less than the Low Evaporator Pressure
Unload set point when the Low OAT Start Timer
expires, the start is unsuccessful and the
compressor will shutdown.
Multiple Low Ambient Start attempts are allowed.
On the third failed Low Ambient Start attempt the
Restart Alarm is triggered and the circuit will not
attempt to restart until the Restart alarm has been
cleared.
The restart counter should be reset when either a
startup is successful, the Low OAT Restart alarm
is triggered, or the unit time clock shows that a
new day has started.
Circuit Status
The displayed circuit status should be determined by the conditions in the following table:
Enum
Status
Conditions
0
Off:Ready
1
Off:Cycle Timers
2
Off:All Comp Disable
3
4
5
6
7
8
9
10
Off:Keypad Disable
Off:Circuit Switch
Off:Alarm
Off:Test Mode
Preopen
Run:Pumpdown
Run:Normal
Run:Evap Press Low
11
Run:Cond Press High
12
Run:High OAT Limit
Circuit is ready to start when needed.
Circuit is off and cannot start due to active cycle timer on all
compressors.
Circuit is off and cannot start due to all compressors being
disabled.
Circuit is off and cannot start due to circuit enable set point.
Circuit is off and circuit switch is off.
Circuit is off and cannot start due to active circuit alarm.
Circuit is in test mode.
Circuit is in preopen state.
Circuit is in pumpdown state.
Circuit is in run state and running normally.
Circuit is running and cannot load due to low evaporator pressure.
Circuit is running and cannot load due to high condenser
pressure.
Circuit is running and cannot add more compressors due to the
high ambient limit on unit capacity. Applies only to circuit 2.
Compressor Control
Compressors should run only when the circuit is in a run or pumpdown state. They should not be running
when the circuit is in any other state.
OMM 1166
AGZ 025D through 190D
31
Starting a Compressor
A compressor should start if it receives a start command from the unit capacity control logic.
Stopping a Compressor
A compressor should be turned off if any of the following occur:
• Unit capacity control logic commands it off
• An unload alarm occurs and the sequencing requires this compressor to be next off
• Circuit state is pumpdown and sequencing requires this compressor to be next off
Cycle Timers
A minimum time between starts of the compressor and a minimum time between shutdown and start of the
compressor shall be enforced. The time values are determined by the Start-start Timer and Stop-start Timer
setpoints.
These cycle timers should not be enforced through cycling of power to the chiller. This means that if power
is cycled, the cycle timers should not be active.
These timers may be cleared via a setting on the human machine interface (HMI).
Condenser Fan Control
Condenser fan control should stage fans as needed any time compressors are running on the circuit. All
running fans should turn off when the circuit goes to the off state.
Fan Staging
Fan staging shall accommodate anywhere from 2 to 7 fans on a circuit using up to 5 outputs for control. The
total number of fans on shall be adjusted with changes of one fan at a time. The tables below show the
outputs energized for each stage.
Stage
1
2
3
4
Fan Stage
1
2
3
4
5
32
2 Through 4 Fans
Fan Outputs On
1
1,2
1,2,3
1,2,3,4
5 Fans
Fan Outputs On
1
1,2
1,2,3
1,2,4
1,2,3,4
Fan Stage
1
2
3
4
5
6
6 Fans
Fan Outputs On
1
1,2
1,2,3
1,2,4
1,2,3,4
1,2,3,4,5
Fan Stage
1
2
3
4
5
6
7
7 Fans
Fan Outputs On
1
1,2
1,2,3
1,2,4
1,2,3,4
1,2,4,5
1,2,3,4,5
AGZ 025D through 190D
OMM 1166
Condenser Target
A condenser target should be selected from the
setpoints based on the number of compressors on
the unit and the number of compressors running.
Each stage of capacity on a circuit will use a
different condensing target set point.
A minimum condenser target should be enforced.
This minimum will be calculated based on the
evaporator LWT. As the LWT varies from 7.2°C
(45°F) to 32.2°C (90°F), the minimum condenser
target will vary from 23.9°C (75°F) to 48.9°C
(120°F).
Staging Up
The first fan should turn on when the saturated
condenser temperature exceeds the condenser
target. After this, the four stage up dead bands
shall be used. Stages one through four should use
their respective dead bands. Stages five through
six should all use the Stage Up Dead Band 4.
When the saturated condenser temperature is
above the target + the active deadband, a stage up
error is accumulated.
Stage Up Error Step = Saturated Condenser
Temperature – (Target + Stage Up dead band)
The Stage Up Error Step is added to Stage Up
Accumulator once every 5 seconds, only if the
Saturated Condenser Refrigerant Temperature is
not falling. When Stage Up Error Accumulator is
greater than 11°C (19.8°F) another stage is added.
When a stage up occurs or the saturated condenser
temperature falls back within the stage up dead
band the Stage Up Accumulator is reset to zero.
respective dead bands. Stages five through seven
should all use Stage Down Dead Band 4.
When the saturated condenser refrigerant
temperature is below the target – the active
deadband, a stage down error is accumulated.
Stage Down Error Step = (Target - Stage Down
dead band) - Saturated Condenser Temperature
The Stage Down Error Step is added to Stage
Down Accumulator once every 5 seconds. When
the Stage Down Error Accumulator is greater than
2.8°C (5°F) another stage of condenser fans is
removed.
When a stage down occurs or the saturated
temperature rises back within the Stage Down
dead band the Stage Down Error Accumulator is
reset to zero.
VFD
Condenser pressure trim control is accomplished
using an optional VFD on the first fan. This VFD
control should vary the fan speed to drive the
saturated condenser temperature to a target value.
The target value is normally the same as the
saturated condenser temperature target.
The speed should be controlled between the
minimum and maximum speed setpoints.
VFD State
The VFD speed signal should always be 0 when
the fan stage is 0.
When the fan stage is greater than 0, the VFD
speed signal should be enabled and control the
speed as needed.
Staging Down
Four stage down dead bands shall be used.
Stages one through four should use their
Stage Up Compensation
In order to create a smoother transition when another fan is staged on, the VFD compensates by slowing
down initially. This is accomplished by adding the new fan stage up deadband to the VFD target. The higher
target causes the VFD logic to decrease fan speed. Then, every 2 seconds, 0.1°C (0.18°F) is subtracted from
the VFD target until it is equal to the saturated condenser temperature target set point.
OMM 1166
AGZ 025D through 190D
33
EXV Control
Auto Control
Any time the circuit is not in the run state, the
EXV position should be 0. The EXV control state
should display that the EXV state is closed when
this is the case.
While a circuit is in the run state, the EXV should
go into superheat control. While in superheat
control, the EXV controls suction superheat. The
suction superheat target is set by a set point. A
PID function will be used to control the superheat
to the target value.
Evaporator Pressure set point. This is done by
using another PID function to control evaporator
pressure to the maximum evaporator pressure.
The EXV position should be lesser position output
from the two PID functions.
EXV Position Range
The following table shows the EXV range based
on the number of compressors running and the
total number of fans on the unit.
The EXV should also prevent the evaporator
pressure from exceeding the Maximum
Num Fans = 4
EXV Min
EXV Max
Compressors Running
1
2
3
8%
8%
40%
60%
-
Num Fans = 6
EXV Min
EXV Max
8%
60%
8%
100%
-
Num Fans = 8
EXV Min
EXV Max
8%
40%
8%
55%
8%
70%
Num Fans ≥ 10
EXV Min
EXV Max
8%
30%
8%
40%
8%
50%
On units equipped with 10 or more condenser fans
(shell and tube type evaporator):
When staging down a compressor the
maximum position is reduced by 10% for
one minute to prevent liquid from getting
to compressors. After this initial one
minute delay, the valve’s maximum is
allowed to return to its normal value at a
rate of 0.1% every six seconds. This
offset to the maximum position should not
occur if the stage down is due to a low
pressure unload.
In addition, the expansion valve maximum
position may be increased if after two
minutes both the suction superheat is
greater than 7.2°C (13°F) and the
expansion valve has been within 5% of its
current maximum position. The maximum
should increase at a rate of 0.1% every six
34
seconds up to a total of an additional 10%.
This offset to the maximum position
should be reset when the EXV is no
longer in the Superheat Control state or a
compressor on the circuit stages.
Manual Control
The EXV position can be set manually. Manual
control can only be selected when the circuit is in
the run state. At any other time, the EXV control
set point is forced to auto.
When EXV control is set to manual, the EXV
position is equal to the manual EXV position
setting. If set to manual when the circuit state
transitions from run to another state, the control
setting is automatically set back to auto. When in
manual control, the EXV control state displayed
should reflect that it is manual control.
AGZ 025D through 190D
OMM 1166
Liquid Line Solenoid Valve
The liquid line solenoid output should be on when
the circuit state is either Pre-open or Run. This
output should be off at all other times.
Hot Gas Bypass Solenoid
Valve
This output shall be on when circuit state is Run
and one compressor on the circuit is running. The
output should be off at all other times.
Capacity Overrides – Limits
of Operation
The following conditions shall override automatic
capacity control as described. These overrides
Alarms
Situations may arise that require some action from
the chiller or that should be logged for future
reference. Alarms are classified in the following
sections per the Global Chiller Protocol Standard
using the Fault/Problem/Warning scheme.
keep the circuit from entering a condition in which
it is not designed to run.
Low Evaporator Pressure
If the Low Evaporator Pressure Hold or Low
Evaporator Pressure Unload alarms are triggered,
the circuit capacity may be limited or reduced.
See the Circuit Events section for details on
triggering, reset, and actions taken.
High Condenser Pressure
If the High Condenser Pressure Unload alarm is
triggered, the circuit capacity may be limited or
reduced. See the Circuit Events section for details
on triggering, reset, and actions taken.
Fault Alarm is active, but any Circuit Fault Alarm
is active, the alarm digital output should alternate
five seconds on and five seconds off continuously.
All alarms appear in the active alarm list while
active. All alarms are added to the alarm log
when triggered and when cleared.
When any Unit Fault Alarm is active, the alarm
digital output should be turned on. If no Unit
Unit Fault Alarms
PVM/GFP Fault
Trigger: Power Configuration = Single Point and PVM/GFP Input #1 is open.
Action Taken: Rapid stop all circuits
Reset: Auto reset when input is closed for at least 5 seconds or if Power Configuration = Multi Point.
Evaporator Flow Loss
Trigger:
1: Evaporator Pump State = Run AND Evaporator Flow Digital Input = No Flow for time > Flow Proof Set
Point AND at least one compressor running
2: Evaporator Pump State = Start for time greater than Recirc Timeout Set Point and all pumps have been
tried and Evaporator Flow Digital Input = No Flow
Action Taken: Rapid stop all circuits
Reset:
This alarm can be cleared at any time manually via the keypad or via the BAS clear alarm command.
If active via trigger condition 1:
When the alarm occurs due to this trigger, it can auto reset the first two times each day with the third
occurrence being manual reset.
OMM 1166
AGZ 025D through 190D
35
For the auto reset occurrences, the alarm will reset automatically when the evaporator state is Run again.
This means the alarm stays active while the unit waits for flow, then it goes through the recirculation process
after flow is detected. Once the recirculation is complete, the evaporator goes to the Run state which will
clear the alarm. After three occurrences, the count of occurrences is reset and the cycle starts over if the
manual reset flow loss alarm is cleared.
If active via trigger condition 2:
If the flow loss alarm has occurred due to this trigger, it is always a manual reset alarm.
Evaporator Water Freeze Protect
Trigger: Evaporator LWT drops below evaporator freeze protect set point and LWT sensor fault is not active.
Action Taken: Rapid stop all circuits
Reset: This alarm can be cleared manually via the keypad, but only if the alarm trigger conditions no longer
exist.
Evaporator LWT Sensor Fault
Trigger: Sensor shorted or open
Action Taken: Normal stop all circuits
Reset: This alarm can be cleared manually via the keypad or BAS command, but only if the sensor is back in
range.
Outdoor Air Temperature Sensor Fault
Trigger: Sensor shorted or open
Action Taken: Normal stop of all circuits.
Reset: This alarm can be cleared manually via the keypad or via BAS command if the sensor is back in
range.
External Alarm
Trigger: External Alarm/Event opens for at least 5 seconds and external fault input is configured as an alarm.
Action Taken: Rapid stop of all circuits.
Reset: Auto clear when digital input is closed.
Compressor Module 1 Comm Failure
Trigger: Communication with the I/O extension module has failed.
Action Taken: Rapid stop of circuit 1.
Reset: This alarm can be cleared manually via the keypad or BAS command when communication between
main controller and the extension module is working for 5 seconds.
Compressor Module 2 Comm Failure
Trigger: Communication with the I/O extension module has failed.
Action Taken: Rapid stop of circuit 2.
36
AGZ 025D through 190D
OMM 1166
Reset: This alarm can be cleared manually via the keypad or BAS command when communication between
main controller and the extension module is working for 5 seconds.
EXV Module 1 Comm Failure
Trigger: Expansion Valve Type = Electronic and communication with the I/O extension module has failed.
Action Taken: Rapid stop of circuit 1.
Reset: This alarm can be cleared manually via the keypad or BAS command when communication between
main controller and the extension module is working for 5 seconds or Expansion Valve Type = Thermal.
EXV Module 2 Comm Failure
Trigger: Expansion Valve Type = Electronic and communication with the I/O extension module has failed.
Action Taken: Rapid stop of circuit 2.
Reset: This alarm can be cleared manually via the keypad or BAS command when communication between
main controller and the extension module is working for 5 seconds or Expansion Valve Type = Thermal.
Unit Problem Alarms
Low Ambient Lockout (No longer an alarm from version 251699201 on)
Trigger: The OAT drops below the low ambient lockout set point AND the OAT sensor fault is not active.
Action Taken: Normal shutdown of all circuits.
Reset: The lockout should clear when OAT rises to the lockout set point plus 2.8°C (5°F).
Evaporator Pump #1 Failure
Trigger: Unit is configured with primary and backup pumps, pump #1 is running, and the pump control
logic switches to pump #2.
Action Taken: Backup pump is used.
Reset: This alarm can be cleared manually via the keypad or BAS command
Evaporator Pump #2 Failure
Trigger: Unit is configured with primary and backup pumps, pump #2 is running, and the pump control
logic switches to pump #1.
Action Taken: Backup pump is used.
Reset: This alarm can be cleared manually via the keypad or BAS command
OMM 1166
AGZ 025D through 190D
37
Unit Warning Alarms
External Event
Trigger: External Alarm/Event input is open for at least 5 seconds and external fault is configured as
an event.
Action Taken: None
.
Reset: Auto clear when digital input is closed.
Bad Demand Limit Input
Trigger: Demand limit input out of range and demand limit is enabled. For this alarm out of range is
considered to be a signal less than 3mA or more than 21mA.
Action Taken: Cannot use demand limit function.
Reset: Auto clear when demand limit disabled or demand limit input back in range for 5 seconds.
Bad LWT Reset Input
Trigger: LWT reset input out of range and LWT reset is enabled. For this alarm out of range is
considered to be a signal less than 3mA or more than 21mA.
Action Taken: Cannot use LWT reset function.
Reset: Auto clear when LWT reset is disabled or LWT reset input back in range for 5 seconds.
Evaporator EWT Sensor Fault
Trigger: Sensor shorted or open
Action Taken: None.
Reset: Auto clear when the sensor is back in range.
Circuit Fault Alarms
PVM/GFP Fault
Trigger: Power Configuration = Multi Point and circuit PVM/GFP input is open.
Action Taken: Rapid stop circuit.
Reset: Auto reset when input is closed for at least 5 seconds or if Power Configuration = Single Point.
Low Evaporator Pressure
Trigger:
This alarm should trigger when Freeze time is exceeded, Low Ambient Start is not active, and Circuit
State = Run. It should also trigger if Evaporator Press < 137.9 KPA (20 PSI) and Circuit State = Run.
38
AGZ 025D through 190D
OMM 1166
Freezestat logic allows the circuit to run for varying times at low pressures. The lower the pressure,
the shorter the time the compressor can run. This time is calculated as follows:
Freeze error = Low Evaporator Pressure Unload – Evaporator Pressure
Freeze time =
For units equipped with 10 or more condenser fans (shell and tube type evaporator):
80 – freeze error, limited to a range of 40 to 80 seconds
For all other configurations (plate to plate type evaporator):
60 – freeze error, limited to a range of 20 to 60 seconds
When the evaporator pressure goes below the Low Evaporator Pressure Unload set point, a timer
starts. If this timer exceeds the freeze time, then a freezestat trip occurs. If the evaporator pressure
rises to the unload set point or higher, and the freeze time has not been exceeded, the timer will reset.
The alarm cannot trigger if the evaporator pressure sensor fault is active.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the keypad if the evaporator pressure is above 137.9
KPA (20 PSI).
High Condenser Pressure
Trigger: Condenser Pressure > High Condenser Pressure set point
Action Taken: Rapid stop circuit
Reset: This alarm can be cleared manually via the controller keypad
Mechanical High Pressure Switch
Trigger: Mechanical High Pressure switch input is open, Motor Protection input is closed, and power
up start delay is not active.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the controller keypad if the MHP switch input is
closed.
Motor Protection Fault
Trigger: Motor Protection input is open and power up start delay is not active.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the controller keypad if the input is closed.
Low OAT Restart Fault
Trigger: Circuit has failed three low OAT start attempts.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the keypad or via BAS command.
OMM 1166
AGZ 025D through 190D
39
No Pressure Change After Start
Trigger: After start of compressor, at least a 7 KPA (1 PSI) drop in evaporator pressure OR 35 KPA
(5.1 PSI) increase in condenser pressure has not occurred after 30 seconds. The actual alarm will not
be triggered until the second occurrence.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the keypad or via BAS command.
Evaporator Pressure Sensor Fault
Trigger: Sensor shorted or open.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the keypad or BAS command, but only if the sensor is
back in range.
Condenser Pressure Sensor Fault
Trigger: Sensor shorted or open.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the keypad or BAS command, but only if the sensor is
back in range.
Suction Temperature Sensor Fault
Trigger: Sensor shorted or open and Expansion Valve Type = Electronic.
Action Taken: Normal shutdown of circuit.
Reset: This alarm can be cleared manually via the keypad or BAS command, but only if the sensor is
back in range.
Circuit Events
Low Evaporator Pressure - Hold
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• evaporator pressure <= Low Evaporator Pressure - Hold set point
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has started on the circuit.
Action Taken: Inhibit starting of additional compressors on the circuit.
Reset: While still running, the event will be reset if evaporator pressure > Low Evaporator Pressure
Hold SP + 90 KPA(13 PSI). The event is also reset if the circuit is no longer in the run state.
40
AGZ 025D through 190D
OMM 1166
Low Evaporator Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the circuit
• evaporator pressure <= Low Evaporator Pressure - Unload set point for a time greater than
half of the current freezestat time
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has started on the circuit.
On units equipped with 6 compressors, electronic expansion valves, and 10 or more fans, when each
compressors starts, there should be a 2 minute window during which the evaporator pressure must
drop an additional 27 KPA (3.9 PSI) to trigger the alarm. After this 2 minute window, the trigger point
should return to normal.
Action Taken: Stage off one compressor on the circuit every 10 seconds, except the last one.
Reset: While still running, the event will be reset if evaporator pressure > Low Evaporator Pressure
Hold SP + 90 KPA(13 PSI). The event is also reset if the circuit is no longer in the run state.
High Condenser Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the circuit
• condenser pressure > High Condenser Pressure – Unload set point
Action Taken: Stage off one compressor on the circuit every 10 seconds while condenser pressure is
higher than the unload set point, except the last one. Inhibit staging more compressors on until the
condition resets.
Reset: While still running, the event will be reset if condenser pressure <= High Condenser Pressure
Unload SP – 862 KPA(125 PSI). The event is also reset if the circuit is no longer in the run state.
Circuit Warning Alarms
Failed Pumpdown
Trigger: Circuit state = pumpdown for longer than 2 minutes
Action Taken: Rapid stop circuit
Reset: N/A.
Events
Situations may arise that require some action from the chiller or that should be logged for future
reference, but aren’t severe enough to track as alarms. These events are stored in a log separate from
alarms. This log shows the time and date of the latest occurrence, the count of occurrences for the
current day, and the count of occurrences for each of the previous 7 days.
OMM 1166
AGZ 025D through 190D
41
Unit Events
Unit Power Restore
Trigger: Unit controller is powered up.
Action Taken: none.
Reset: none.
Circuit Events
Low Evaporator Pressure - Hold
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• evaporator pressure <= Low Evaporator Pressure - Hold set point
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has started on the circuit.
Action Taken: Inhibit starting of additional compressors on the circuit.
Reset: While still running, the event will be reset if evaporator pressure > Low Evaporator Pressure
Hold SP + 90 KPA(13 PSI). The event is also reset if the circuit is no longer in the run state.
Low Evaporator Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the circuit
• evaporator pressure <= Low Evaporator Pressure - Unload set point for a time greater than
half of the current freezestat time
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has started on the circuit
On units equipped with 6 compressors, electronic expansion valves, and 10 or more fans, when each
compressors starts, there should be a 2 minute window during which the evaporator pressure must
drop an additional 27 KPA (3.9 PSI) to trigger the alarm. After this 2 minute window, the trigger point
should return to normal.
Action Taken: Stage off one compressor on the circuit every 10 seconds while evaporator pressure is
less than the unload set point, except the last one.
Reset: While still running, the event will be reset if evaporator pressure > Low Evaporator Pressure
Hold SP + 90 KPA(13 PSI). The event is also reset if the circuit is no longer in the run state.
High Condenser Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the circuit
• condenser pressure > High Condenser Pressure – Unload set point
42
AGZ 025D through 190D
OMM 1166
Action Taken: Stage off one compressor on the circuit every 10 seconds while condenser pressure is
higher than the unload set point, except the last one. Inhibit staging more compressors on until the
condition resets.
Reset: While still running, the event will be reset if condenser pressure <= High Condenser Pressure
Unload SP – 862 KPA(125 PSI). The event is also reset if the circuit is no longer in the run state.
current day and for each of the last seven days.
Events do not appear in the Active Alarm list.
Alarm Logs
NOTE: refer to Figure 3 on the following
page for controller components. Press the
alarm button on the controller to go to the
alarm section. Three alarm sub-sections will
appear. Turn the navigating wheel to highlight
among them and press the wheel to select.
1. Active Alarms
When an alarm or event occurs, it appears in
the active alarm list. The active alarm list holds
a record of all active alarms not yet cleared and
includes the date and time each occurred.
When cleared, the alarm transfers to the Alarm
Log that contains an alarm history with
time/date stamp. A (+) before an alarm
indicates that it is active, a (-) indicates a
cleared alarm. The Active Alarm list is only
limited by the number of alarms since any
given alarm cannot appear twice.
2. Alarm Log
An alarm log stores the last 50 occurrences or
resets that occur. When an alarm or event
occurs, it is put into the first slot in the alarm
log and all others are moved down one,
dropping the last entry. The date and time the
alarm occurred are stored in the alarm log.
3. Event Log
An Event Log similar to the Alarm Log stores
the last 50 event occurrences. Each Event Log
entry includes an event description and a time
and date stamp for the event occurrence plus
the count of the event occurrences on the
Clearing Alarms
Active alarms can be cleared through the
keypad/display or a BAS network. Alarms are
automatically cleared when controller power is
cycled. Alarms are cleared only if the
conditions required to initiate the alarm no
longer exist. All alarms and groups of alarms
can be cleared via the keypad or network via
LON using nviClearAlarms and via BACnet
using the ClearAlarms object.
To use the keypad, follow the Alarm links to
the Alarms screen, which will show Active
Alarms and Alarm Log. Select Active Alarm
and press the wheel to view the Alarm List (list
of current active alarms). They are in order of
occurrence with the most recent on top. The
second line on the screen shows Alm Cnt
(number of alarms currently active) and the
status of the alarm clear function. Off indicates
that the Clear function is off and the alarm is
not cleared. Press the wheel to go to the edit
mode. The Alm Clr (alarm clear) parameter
will be highlighted with OFF showing. To
clear all alarms, rotate the wheel to select ON
and enter it by pressing the wheel.
An active password is not necessary to clear
alarms.
If the problem(s) causing the alarm have been
corrected, the alarms will be cleared, disappear
from the Active Alarm list and be posted in the
Alarm Log. If not corrected, the On will
immediately change back to OFF and the unit
will remain in the alarm condition
.
OMM 1166
AGZ 025D through 190D
43
Using the Controller
Figure 3, Unit Controller
Alarm Button
Menu Button
Navigation Wheel
Return Button
Display
The keypad/display consists of a 5-line by 22-character display, three buttons (keys) and a “push and
roll” navigation wheel. There is an Alarm Button, Menu (Home) Button, and a Back Button. The
wheel is used to navigate between lines on a screen (page) and to increase and decrease changeable
values when editing. Pushing the wheel acts as an Enter Button and will jump from a link to the next
set of parameters.
Figure 4, Typical Screen
♦6
View/Set Unit
Status/Settings
Set Up
Temperature
Date/Time/Schedule
3
>
>
>
>
Generally, each line on the display contains a menu title, a parameter (such as a value or a setpoint),
or a link (which will have an arrow in the right of the line) to a further menu.
The first line visible on each display includes the menu title and the line number to which the cursor
is currently “pointing”, in the above case 3, Temperature.
The left most position of the title line includes an “up” arrow ▲ to indicate there are lines
(parameters) “above” the currently displayed line; and/or a “down” arrow ▼ to indicate there are
lines (parameters) “below” the currently displayed items or an “up/down” arrow ♦ to indicate there
are lines “above and below” the currently displayed line. The selected line is highlighted.
Each line on a screen can contain status-only information or include changeable data fields
(setpoints).
44
AGZ 025D through 190D
OMM 1166
When the cursor is on a line the highlights will look like this:
If line contains a changeable value>
Evaporator Delta T= 10.0F
If the line contains status-only information>
Unit Status=
Run
Or a line in a menu may be a link to further menus. This is often referred to as a jump line,
meaning pushing the navigation wheel will cause a “jump” to a new menu. An arrow (>)is
displayed to the far right of the line to indicate it is a “jump” line and the entire line is
highlighted when the cursor is on that line.
NOTE - Only menus and items that are applicable to the specific unit configuration are displayed.
This manual includes information relative to the operator level of parameters; data and setpoints
necessary for the every day operation of the chiller. There are more extensive menus available
for the use of service technicians.
Navigating
When power is applied to the control circuit, the controller screen will be active and display the Home
screen, which can also be accessed by pressing the Menu Button The navigating wheel is the only
navigating device necessary, although the MENU, ALARM, and BACK buttons can provide shortcuts as
explained later.
Passwords
Enter passwords from the Main Menu:
Enter Password, links to the Entry screen, which is an editable screen So pressing the wheel goes
to the edit mode where the password (5321) can be entered. The first (*) will be highlighted,
rotate the wheel clockwise to the first number and set it by pressing the wheel. Repeat for the
remaining three numbers.
The password will time out after 10 minutes, and is cancelled if a new password is entered or the
control powers down.
Figure 5, Password Menu
Main Menu
Enter Password
Unit Status
Off: Unit Sw
ACTIVE SETPT
>
44.6°F
Figure 6, Password Entry Page
Enter Password
Enter PW
****
Entering an invalid password has the same effect as not entering a password.
Once a valid password has been entered, the controller allows further changes and access without
requiring the user to enter a password until either the password timer expires or a different password is
entered.
OMM 1166
AGZ 025D through 190D
45
Navigation Mode
When the navigation wheel is turned clockwise, the cursor moves to the next line (down) on the
page. When the wheel is turned counter-clockwise the cursor moves to the previous line (up) on
the page. The faster the wheel is turned the faster the cursor moves. Pushing the wheel acts as an
“Enter” button.
Three types of lines exist:
•
Menu title, displayed in the first line as in Figure 6.
•
Link (also called Jump) having an arrow ( > ) in the right of the line and used to link to
the next menu.
•
Parameters with a value or adjustable setpoint.
For example, “Time Until Restart” jumps from level 1 to level 2 and stops there.
When the Back Button is pressed the display reverts back to the previously displayed page. If the
Back button is repeatedly pressed the display continues to revert one page back along the current
navigation path until the “main menu” is reached.
When the Menu (Home) Button is pressed the display reverts to the “main page.”
When the Alarm Button is depressed, the Alarm Lists menu is displayed.
Edit Mode
The Editing Mode is entered by pressing the navigation wheel while the cursor is pointing to a
line containing an editable field. Turning the wheel clockwise while the editable field is
highlighted causes the value to be increased. Turning the wheel counter-clockwise while the
editable field is highlighted causes the value to be decreased. The faster the wheel is turned the
faster the value is increased or decreased. Pressing the wheel again cause the new value to be
saved and the keypad/display to leave the edit mode and return to the navigation mode.
A parameter with an “R” is read only; it is giving a value or description of a condition. An “R/W”
indicates a read and/or write opportunity; a value can be read or changed (providing the proper
password has been entered).
Example 1: Check Status, for example-is the unit being controlled locally or by an external network?
We are looking for the Unit Control Source. Since this is a unit status parameter, start at Main Menu and
select View/Set Unit. There will be an arrow at the right side of the box, indicating that a jump to the next
level is required. Press the wheel to execute the jump.
You will arrive at the Status/Settings link. There is an arrow indicating that this line is a link to a further
menu. Press the wheel again to jump to the next menu, Unit Status/Settings.
Rotate the wheel to scroll down to Control Source and read the result.
Example 2; Change a Setpoint, the chilled water setpoint for example. This parameter is designated as
Cool LWT 1 setpoint and is a unit parameter. From the Main Menu select View/Set Unit. The arrow
indicated that this is link to a further menu.
Press the wheel and jump to the next menu View/Set Unit and use the wheel to scroll down to
Temperatures. This again has an arrow and is a link to a further menu. Press the wheel and jump to the
Temperatures menu, which contains temperatures values and setpoints. The first line is Evap LWT, rotate
wheel until Cool LWT 1 is highlighted. Press the wheel to enter edit mode. Rotate wheel until new
setpoint is reached, then press wheel to accept the new value and exit edit mode.
46
AGZ 025D through 190D
OMM 1166
Example 3; Clear an Alarm, from the Main Menu scroll down to the Alarms line. Note the arrow
indicating this line is a link. Press the wheel to jump to the next menu Alarms There are two lines here;
Alarm Active and Alarm Log. Alarms are cleared from the Active Alarm link. Press the wheel to jump
to the next screen. With the first line highlighted, press the wheel to enter edit mode. Rotate wheel
until AlmClr is set to On, then press wheel to clear the alarms.
Menus
Screens with titles and contents are shown in leftmost column of Table 13. An identifier for each
screen is also found in this column. Screen contents can include:
• Data
• Setpoints
• Links to other screens
Note that some parameters or links may not be visible due to the unit configuration.
Link visibility as well as read and write access to parameters is defined for each password level:
• R = readable/visible
• R/W = readable/writeable
• blank = not visible/accessible
Screen Navigational Links:
For each link on a screen, the linked screen is indicated in the rightmost column.
Example; the Enter Password screen links to screen U-2
For each screen, the screen(s) from which you can navigate to it is also shown on the same row as the
screen identifier.
Example: Enter Password in screen U-2 is linked from Screen U-1
For most circuit or compressor level parameters, there is a link to a screen that shows the values for all
circuits/compressors which is indicated in the 'Links to screen' column as *.
For many of the circuit level screens, only one screen will be shown in this document. The same set of
screens exists for each circuit and compressor. These screens are identified with 'Cx' and Cmpx'
identifiers. 'U' designates a unit related screen.
Table 13, Menu Screens
NOTE: Bold entries indicate screens with links to other screens.
Screen U-1
Main Menu
Enter Password
Quick Menu
View/Set Unit
View/Set Circuit
Unit Status
Active Setpoint
Evap Leaving Water Temp
Unit Capacity
Unit Mode
Time Until Restart
Alarms
Scheduled Maintenance
Review Operation
Manual Control
Commission Unit
About Chiller
OMM 1166
No password
R
R
R
R
R
R
R
R
R
Operator
R
R
R
R
R
R
R
R
R
R
R
R
R
AGZ 025D through 190D
Links to screen
U-2
U-3
U-4
U-5
U-6
U-7
U-8
U-9
U-10
U-11
U-12
47
Screen U-2
Enter Password
Enter PW
From Screen U-1
No password
R/W
Screen U-3
Quick Menu
Unit Status
Active Setpoint
Evap Leaving Water Temp
Evap Entering Water Temp
Unit Capacity
Network Limit Value
Demand Limit Value
Unit Mode
Control Source
From Screen U-1
No password
Screen U-4
View/Set Unit
Status/Settings
Set-Up
Temperatures
Date/Time/Schedules
Power Conservation
LON Setup
BACnet IP Setup
BACnet MSTP Setup
Modbus Setup
AWM Setup
Configuration
Ctrlr IP Setup
Design Conditions
Alarm Limits
Calibrate Sensors
Settings Change History
Menu Password
From Screen U-1
No password
Screen U-5
View/Set Circuit
Circuit #1
Circuit #2
From Screen U-1
No password
Screen U-6
Time Until Restart
Compressor 1 Cycle Time
Remaining
Compressor 2 Cycle Time
Remaining
Compressor 3 Cycle Time
Remaining
Continued next page.
48
Operator
R/W
Links to screen
Operator
R
R
R
R
R
R
R
R
R/W
Links to screen
Operator
R
R
R
R
R
R
R
R
R
R
R
Links to screen
U-13
U-14
U-15
U-16
U-17
U-18
U-19
U-20
U-21
U-22
U-23
U-24
U-25
U-26
U-27
U-28
U-29
Operator
R
R
Links to screen
Cx-1
Cx-1
From Screen U-1
No password
Operator
Links to screen
R
R
R
R
R
R
R
R
R
AGZ 025D through 190D
OMM 1166
Screen U-6
Time Until Restart
Compressor 4 Cycle Time
Remaining
Compressor 5 Cycle Time
Remaining
Compressor 6 Cycle Time
Remaining
Clear Cycle Timers
Screen U-7
Alarms
Alarm Active
Alarm Log
Event Log
From Screen U-1
No password
Operator
R
R
R
R
R
R
From Screen U-1
No password
R
R
Operator
R
R
R
Links to screen
Links to screen
U-30
U-31
U-32
Screen U-8
Scheduled Maintenance
Next Maintenance Month/Year
Service Support Reference
From Screen U-1, U-9, U-11
No password
Operator
R
R/W
R
R
Screen U-9
Review Operation
Alarm Active
Alarm Log
Unit Status/Settings
Circuit 1 Status/Settings
Circuit 2 Status/Settings
Scheduled Maintenance
From Screen U-1
No password
Operator
Links to screen
U-30
U-31
U-33
Cx-2
Cx-2
U-8
U-10
Manual Control
Unit
Circuit 1
Circuit 2
From Screen U-1
No password
Operator
Links to screen
U-34
Cx-3
Cx-3
From Screen U-1
No password
Operator
Links to screen
U-12
U-23
U-14
U-16
U-17
U-26
U-27
U-35
U-18
U-19
U-20
Screen U-11
Commission Unit
About This Chiller
Configuration
Set-Up
Date/Time/Schedules
Power Conservation
Alarm Limits
Calibrate Unit Sensors
Calibrate Circuit Sensors
LON Setup
BACnet IP Setup
BACnet MSTP Setup
Continued next page.
OMM 1166
AGZ 025D through 190D
Links to screen
49
Screen U-11
Commission Unit
Modbus Setup
AWM Setup
Ctrlr IP Setup
Alarm Active
Alarm Log
Scheduled Maintenance
Manual Control Unit
Manual Control Circuit 1
Manual Control Circuit 2
From Screen U-1
No password
Screen U-12
About Chiller
Model Number
G. O. Number
Unit Serial Number
BSP Version
Application Version
HMI GUID
OBH GUID
From Screen U-1, U11
No password
Operator
R
R
R
R
R
R
R
R
R
R
R
R
R
R
Screen U-13
Status/Settings
Unit Status
Next Compressor On
Next Compressor Off
Chiller Enable
Control Source
Chiller Enable Setpoint – Network
Chiller Mode Setpoint – Network
Cool Setpoint – Network
Capacity Limit Setpoint – Network
Stage Up Delay Remaining
Stage Down Delay Remaining
Clear Stage Delays
Ice Setpoint – Network
Ice Cycle Time Remaining
Clear Ice Cycle Delay
Evap Pump Control
Evap Recirculate Timer
Evap Nominal Delta T
Evap Pump 1 Run Hours
Evap Pump 2 Run Hours
Remote Service Enable
Continued next page.
50
From Screen U-4
No password
Operator
Operator
R
R
R
R
R
R
R
R
R
R
R
R/W
R
R
Links to screen
U-21
U-22
U-24
U-30
U-31
U-8
U-34
Cx-3
Cx-3
Links to screen
Links to screen
R
R
R
AGZ 025D through 190D
OMM 1166
Screen U-14
Set-Up
Available Modes
Start Up DT
Shut Down DT
Max Pulldown Rate
Stage Up Delay
Stage Down Delay
Start To Start Delay
Stop To Start Delay
Ice Cycle Delay
External Fault Config
Display Units
From Screen U-4, U11
No password
Operator
R
R
R
R
R
R
Screen U-15
Temperatures
Evap Leaving Water Temp
Evap Entering Water Temp
Evaporator Delta T
Active Set Point
Start Up Temperature
Shut Down Temperature
Stage Up Temperature
Stage Down Temperature
Pulldown Rate
Outside Air Temperature
Cool LWT Setpoint 1
Cool LWT Setpoint 2
Ice LWT Setpoint
From Screen U-4
No password
Screen U-16
Date/Time/Schedules
Actual Time
Actual Date
UTC Difference
DLS Enable
DLS Start Month
DLS Start Week
DLS End Month
DLS End Week
From Screen U-4, U-11
No password
Operator
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
Screen U-17
Power Conservation
Unit Capacity
Demand Limit Enable
Demand Limit Value
LWT Reset Enable
Continued next page.
From Screen U-4, U-11
No password
Operator
R
R/W
R
R/W
OMM 1166
Links to screen
R
Operator
R
R
R
R
R
R
R
R
Links to screen
R
R/W
R/W
R/W
AGZ 025D through 190D
Links to screen
Links to screen
51
52
Screen U-18
LON Setup
Neuron ID
Max Send Time
Min Send Time
Receive Heartbeat
LON BSP
LON App Version
Screen U-19
BACnet IP Setup
Apply Changes
Name
Dev Instance
UDP Port
DHCP
Actual IP Address
Actual Mask
Actual Gateway
Given IP Address
Given Mask
Given Gateway
Unit Support
NC Dev 1
NC Dev 2
BACnet BSP
From Screen U-4, U-11
No password
Operator
R
R/W
R/W
R/W
R
R
From Screen U-4, U-11
No password
Operator
R/W
R/W
R/W
R/W
R/W
R
R
R
R/W
R/W
R/W
R/W
R/W
R/W
R
Screen U-20
BACnet MSTP Setup
Apply Changes
Name
Dev Instance
MSTP Address
Baud Rate
Max Master
Max Info Frm
Unit Support
Term Resistor
NC Dev 1
NC Dev 2
BACnet BSP
From Screen U-4, U-11
No password
Operator
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R
Screen U-21
Modbus Setup
Apply Changes
Address
Parity
Two Stop Bits
Baud Rate
Load Resistor
Continued next page.
From Screen U-4, U-11
No password
Operator
R/W
R/W
R/W
R/W
R/W
R/W
AGZ 025D through 190D
Links to screen
Links to screen
Links to screen
Links to screen
OMM 1166
Screen U-21
Modbus Setup
Response Delay
Comm LED Time Out
Modbus BSP
From Screen U-4, U-11
No password
Operator
R/W
R/W
R
Screen U-22
AWM Setup
Apply Changes
DHCP
Actual IP Address
Actual Mask
Actual Gateway
Given IP Address
Given Mask
Given Gateway
AWM BSP
From Screen U-4, U-11
No password
Operator
R/W
R/W
R
R
R
R/W
R/W
R/W
R
Screen U-23
Configuration
Apply Changes
Number Of Compressors
Expansion Valve Type
Number Of Fans
Fan VFD Enable
Power Configuration
Comm Module 1 Type
Comm Module 2 Type
Comm Module 3 Type
From Screen U-4, U-11
No password
Operator
Screen U-24
Ctrlr IP Setup
Apply Changes
DHCP
Actual IP Address
Actual Mask
Actual Gateway
Given IP Address
Given Mask
Given Gateway
From Screen U-4, U-11
No password
Operator
R/W
R/W
R
R
R
R/W
R/W
R/W
Screen U-25
Design Conditions
Evap Entering Water Temp @
Design
Evap Leaving Water Temp @
Design
Evap Design Water Flow
Evap Design Approach
Cond Design Ambient
Continued next page.
OMM 1166
From Screen U-4
No password
Operator
Links to screen
Links to screen
Links to screen
Links to screen
Links to screen
R
R
*
AGZ 025D through 190D
53
Screen U-25
Design Conditions
Screen U-25
Design Conditions
Cond Design Approach
Unit Full Load Efficiency
Unit Integrated Part Load Value
Rated Capacity
From Screen U-4
No password
From Screen U-4
No password
Screen U-26
Alarm Limits
Low Pressure Hold Setpoint
Low Pressure Unload Setpoint
High Pressure Unload Setpoint
High Pressure Shutdown Setpoint
Low Ambient Start Time
Evaporator Water Freeze
Evaporator Flow Proof
Evap Recirculate Timeout
From Screen U-4, U-11
No password
Operator
R
R
Screen U-27
Calibrate Sensors
Evap Leaving Water Temp
Evap LWT Offset
Evap Entering Water Temp
Evap EWT Offset
Outside Air Temp
OAT Offset
From Screen U-4, U-11
No password
Operator
Links to screen
Screen U-28
Settings Change History
Change 1
Time/Date 1
Change 2
Time/Date 2
Change 3
Time/Date 3
Change 4
Time/Date 4
Change 5
Time/Date 5
Change 6
Time/Date 6
From Screen U-4
No password
Operator
Links to screen
Operator
R
Links to screen
Screen U-29
Menu Password
Password Disable
Continued next page.
54
Operator
Links to screen
Operator
Links to screen
*
R
From Screen U-4
No password
AGZ 025D through 190D
Links to screen
OMM 1166
Screen U-30
Alarm Active
Active Count
Alarm Clear
Active Alarm 1
…
Active Alarm n
From Screen U-7, U-9, U-11
No password
Operator
R
R
R/W
R/W
R
R
R
R
R
R
Screen U-31
Alarm Log
Log Count
Log Clear
Active Alarm 1
…
Active Alarm n
From Screen U-7, U-9, U-11
No password
Operator
R
R
R
R
R
R
R
R
R
R
Screen U-32
Event Log
Unit Power Restore
Circuit #1
Circuit #2
Screen U-33
Unit Status/Settings
Actual Time
Actual Date
Unit Status
Unit Mode
Unit Capacity
Evap Leaving Water Temp
Evap Entering Water Temp
Active Set Point
Pulldown Rate
Outside Air Temperature
Screen U-34
Unit Manual Control
Test Unit Alarm Out
Test Evap Pump 1 Out
Test Evap Pump 2 Out
Input/Output Values
Unit Switch Input State
PVM Input State
Evaporator Flow Switch State
Remote Switch Input State
External Alarm Input State
Double Set Point Input State
Evaporator LWT Input Resistance
Evaporator EWT Input Resistance
OAT Input Resistance
Continued next page.
OMM 1166
From Screen U-7
No password
Links to screen
Links to screen
Operator
R
R
R
Links to screen
U-36
U-37
U-38
Operator
Links to screen
From Screen U-10, U-11
No password
Operator
Links to screen
From Screen U-9
No password
AGZ 025D through 190D
55
56
Screen U-34
Unit Manual Control
LWT Reset Signal Current
Demand Limit Signal Current
Unit Alarm Output State
Evaporator Pump 1 Output State
Evaporator Pump 2 Output State
From Screen U-10, U-11
No password
Operator
Screen U-35
Calibrate Circuit Sensors
Circuit #1
Circuit #2
From Screen U-11
No password
Screen U-36
Unit Power Restore Event Log
Day Selection
Count
Last Occurrence
From Screen U-32
No password
Screen U-37
Circuit 1 Event Log
Event Selection
Day Selection
Count
Last Occurrence
From Screen U-32
No password
Screen U-38
Circuit 1 Event Log
Event Selection
Day Selection
Count
Last Occurrence
From Screen U-32
No password
Screen Cx-1
View/Set Cirx
Data
Status/Settings
Comp 1/2
Comp 3/4
Comp 5/6
Condenser
EXV
Calibrate Sensors
From Screen U-5
No password
Screen Cx-2
Circuit x Status/Settings
Circuit Status
Circuit Mode
Circuit Capacity
Continued next page.
From Screen U-9
No password
Links to screen
Operator
Links to screen
Cx-8
Cx-8
Operator
R/W
R
R
Links to screen
Operator
R/W
R/W
R
R
Links to screen
Operator
R/W
R/W
R
R
Links to screen
Operator
Links to screen
Cx-4
Cx-5
Cmpx-1
Cmpx-1
Cmpx-1
Cx-6
Cx-7
Cx-8
R
R
R
R
Operator
AGZ 025D through 190D
Links to screen
*
*
*
OMM 1166
Screen Cx-2
Circuit x Status/Settings
Evap Leaving Water Temp
Evap Entering Water Temp
Evap Approach
Evap Approach @ Design
Evaporator Pressure
Evaporator Saturated Temperature
Condenser Pressure
Condenser Saturated Temperature
Suction Temperature
Suction Superheat
Compressor 1/2
Run Hours
Number Of Starts
Last Compressor Start
Last Compressor Stop
Compressor 3/4
Run Hours
Number Of Starts
Last Compressor Start
Last Compressor Stop
Compressor 5/6
Run Hours
Number Of Starts
Last Compressor Start
Last Compressor Stop
Condenser
Number of Fans Running
Stage Up Error
Stage Down Error
Condenser Target
VFD Target
VFD Speed
EXV
EXV State
EXV Position
Superheat Target
Suction Superheat
EXV Control Mode
Screen Cx-3
Circuit x Manual Control
Test Comp 1/2 Output
Test Comp 3/4 Output
Test Comp 5/6 Output
Test Liquid Line Output
Test Hot Gas Output
Test EXV Position
Test Fan Output 1
Continued next page.
OMM 1166
From Screen U-9
No password
Operator
Links to screen
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
From Screen U-10, U-11
No password
Operator
AGZ 025D through 190D
Links to screen
57
Screen Cx-3
Circuit x Manual Control
Test Fan Output 2
Test Fan Output 3
Test Fan Output 4
Test Fan Output 5
Test Fan VFD Speed
Input/Output Values
Circuit Switch Input State
MHP Switch Input State
Motor Protector Input State
PVM/GFP Input State
Evaporator Pressure Input Voltage
Condenser Pressure Input Voltage
Suction Temp Input Resistance
Compressor 1/2 Output State
Compressor 3/4 Output State
Compressor 5/6 Output State
Liquid Line Solenoid Output State
Hot Gas Bypass Output State
Fan Output 1 State
Fan Output 2 State
Fan Output 3 State
Fan Output 4 State
Fan Output 5 State
Fan VFD Speed
Screen Cx-4
Data
Evaporator Pressure
Condenser Pressure
Saturated Evap Temperature
Saturated Cond Temperature
Suction Temperature
Suction Superheat
Evaporator Approach
Evaporator Design Approach
Condenser Approach
Condenser Design Approach
EXV Position
Evap Leaving Water Temp
Evap Entering Water Temp
Screen Cx-5
Status/Settings Cirx
Circuit Status
Circuit Mode
Circuit Capacity
From Screen U-10, U-11
No password
Operator
From Screen Cx-1
No password
From Screen Cx-1
No password
Links to screen
Operator
Links to screen
*
*
*
*
*
*
*
*
*
*
*
Operator
R
R
R
Links to screen
*
*
*
Continued next page.
58
AGZ 025D through 190D
OMM 1166
Screen Cx-6
Condenser
Number of Fans Running
Number of Fans
Stage Up Error
Stage Down Error
Condenser Sat Temp
Condenser Target
VFD Target
VFD Speed
Stage On Dead Band 1
Stage On Dead Band 2
Stage On Dead Band 3
Stage On Dead Band 4
Stage Off Dead Band 1
Stage Off Dead Band 2
Stage Off Dead Band 3
Stage Off Dead Band 4
VFD Max Speed
VFD Min Speed
Cond Target @ 100%
Cond Target @ 67%
Cond Target @ 50%
Cond Target @ 33%
From Screen Cx-1
No password
Operator
Links to screen
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Screen Cx-7
EXV
EXV State
Suction Superheat
Superheat Target
EXV Control Mode
EXV Position
Evaporator Pressure
Max Evaporator Pressure
From Screen Cx-1
No password
Operator
Links to screen
*
*
*
*
*
*
*
Screen Cx-8
Calibrate Sensors
Evaporator Pressure
Evap Pressure Offset
Condenser Pressure
Cond Pressure Offset
Suction Temp
Suction Temp Offset
Screen Cmpx-1
Circuit x Comp x
Compressor State
Last Compressor Start
Last Compressor Stop
Run Hours
Number Of Starts
From Screen Cx-1, U-35
No password
Operator
OMM 1166
From Screen Cx-1
No password
Operator
R
R
AGZ 025D through 190D
Links to screen
Links to screen
*
*
*
*
*
59
Optional Low Ambient Fan VFD
The optional VFD fan control is used for unit operation below 35°F (2°C) down to a minimum of -10°F
(-23°C). The control looks at the saturated discharge temperature and varies the fan speed to hold the
temperature (pressure) at the “target” temperature.
Low ambient air temperature control is accomplished by using the Optional Low Ambient VFD to
control the speed of the first fan on each circuit. This VFD control uses a proportional integral function
to drive the saturated condenser temperature to a target value by changing the fan speed. The target
value is normally the same as the saturated condenser temperature target setpoint.
The fan VFD always starts when the saturated condenser temperature rises higher than the target.
What is an Inverter?
The term inverter and variable-frequency drive are related and somewhat interchangeable. An
electronic motor drive, for an AC motor, controls the motor’s speed by varying the frequency of the
power sent to the motor.
In general, an inverter is a device that converts DC power to AC power. The figure below shows how
the variable-frequency drive employs an internal inverter. The drive first converts incoming AC power
to DC through a rectifier bridge, creating an internal DC bus voltage. Then the inverter circuit converts
the DC back to AC again to power the motor. The special inverter can vary its output frequency and
voltage according to the desired motor speed.
Inverter Output to the Motor
!
WARNING
Avoid swapping any 2 of the 3 motor lead connections, which will cause reversal of the motor
direction. In applications where reversed rotation could cause equipment damage or personnel
injury, be sure to verify direction of rotation before attempting full-speed operation. For safety
to personnel, the motor chassis ground must be connected to the ground connection at the
bottom of the inverter housing.
The AC motor must be connected only to the inverter’s output terminals.
The output terminals are uniquely labeled (to differentiate them from the
input terminals) with the designations U/T1, V/T2, and W/T3. This
corresponds to typical motor lead connection designations T1, T2, and
T3. The consequence of swapping any two of the three connections is the
reversal of the motor direction. This must not be done. In applications
where reversed rotation could cause equipment damage or personnel
injury, be sure to verify direction of rotation before attempting full-speed
operation. For safety to personnel, the motor chassis ground must be
connected to the ground connection at the bottom of the inverter housing.
Notice the three connections to the motor do not include one marked “Neutral” or “Return.” The motor
represents a balanced “Y” impedance to the inverter, so there is no need for a separate return. In other
words, each of the three “Hot” connections serves also as a return for the other connections because of
their phase relationship.
Do not to switch off power to the inverter while the motor is running (unless it is an emergency stop) to
avoid equipment damage. Also, do not install or use disconnect switches in the wiring from the inverter to
the motor (except thermal disconnect).
60
AGZ 025D through 190D
OMM 1166
VFD Interface (HMI)
The HMI is located in the lower left-hand
corner of the unit control panel. It is used to
view data including fault and alarm
information. No operator intervention on
this control is required for normal unit
operation.
Table 14, Display Key Functions
Table 15, Display Key Functions
No.
Display
Name
Function
1
Function
Key(F1, F2)
The functions assigned to F1 and F2 vary depending on the currently displayed menu.
The name of each function appears in the lower half of the display window.
23
ESC Key
RESET Key
• Returns to the previous display.
• Moves the cursor one space to the left.
• Pressing and holding this button will return to the Frequency Reference display.
• Moves the cursor to the right.
• Resets the drive to clear a fault situation.
3
4
RUN Key
5
Up Arrow Key
6
Down Arrow
Key
7
STOP Key
8
ENTER Key
9
LO/RE
Selection Key
10
RUN Light
11
LO/RE Light
12
ALM LED Light
OMM 1166
Starts the drive in LOCAL mode.
Scrolls up to display the next item, select parameter numbers, and increment setting
values.
Scrolls down to display the next item, select parameter numbers, and increment
setting values.
Stops drive operation.
• Enters parameter values and settings.
• Selects a menu item to move between displays
Switches drive control between the operator (LOCAL) and an external source
(REMOTE)for the Run command and frequency reference.
Lit while the drive is operating the motor.
Lit while the operator is selected to run the drive (LOCAL mode).
Refer to ALARM (ALM) LED Displays on page 63
AGZ 025D through 190D
61
LCD Display
Table 16, Display Data
No
Name
1
Operation
Mode Menus
2
DriveWorksEZ
Function
Selection
3
Mode Display
Area
4
5
Ready
Data Display
Display
MODE
MONITR
VERIFY
PRMSET
A.TUNE
6
Displayed when in Setup Mode.
DWEZ
Displayed when DriveWorksEZ is set to enable. (A1-07 = 1 or 2)
DRV
PRG
Rdy
—
AI
COM
OP
7
LO/RE Display
<2>
8
Function Key
1(F1)
9
FWD/REV
10
Function Key 2
(F2)
RP
RSEQ
LSEQ
RREF
LREF
JOG
HELP
←
HOME
ESC
FWD
REV
FWD/REV
DATA
RESET
62
Indicates the Verify Menu
Displayed when in Parameter Setting Mode.
Displayed during Auto-Tuning.
SETUP
OPR
FrequencyRef
erence
Assignment
<1>
Content
Displayed when in Mode Selection.
Displayed when in Monitor Mode.
Displayed when in Drive Mode.
Displayed when in Programming Mode
Indicates the drive is ready to run.
Displays specific data and operation data.
Displayed when the frequency reference is assigned to the LCD Operator
Option.
Displayed when the frequency reference is assigned to the Analog Input of the
drive
Displayed when the frequency reference is assigned to the MEMOBUS/Modbus
CommunicationInputs of the drive
Displayed when the frequency reference is assigned to an Option Unit of the
drive.
Displayed when the frequency reference is assigned to the Pulse Train Input of
th d i
Displayed
when the run command is supplied from a remote source.
Displayed when the run command is supplied from the operator keypad.
Displayed when the run command is supplied from a remote source.
Displayed when the run command is supplied from the operator keypad
Pressing [F1} executes the Jog function.
Pressing [F1] displays the Help menu.
Pressing [F1] scrolls the cursor to the left.
Pressing [F1] returns to the top menu (Frequency Reference).
Pressing [F1] returns to the previous display
Indicates forward motor operation.
Indicates reverse motor operation.
Pressing [F2] switches between forward and reverse
Pressing [F2] scrolls to the next display
Pressing [F2] scrolls the cursor to the right
Pressing [F2] resets the existing drive fault error
AGZ 025D through 190D
OMM 1166
Table 17, Alarm Content
State
Illuminated
Content
Display
When the drive detects an alarm or error
When an alarm occurs
Flashing
When an oPE is detected
When a fault or error occurs during Auto-Tuning
Off
Normal operation (no fault or alarm)
Table 18, LO/RE LED and RUN LED Indictors
LED
Lit
When the operator
is selected for Run
command and
frequency
reference control
(LOCAL)
During run
Flashing Slowly
Flashing Quickly
--
--
• During
deceleration to
stop
• When a Run
command is input
and frequency
reference is 0 Hz
• While the drive was set to
LOCAL, a Run command
was entered to the input
terminals then the drive was
switched to REMOTE.
• A Run command was
entered via the input
terminals while the drive was
not in the Drive Mode.
• During deceleration when a
Fast Stop command was
entered.
• The drive output is shut of by
the Safe Disable function.
• The STOP key was pressed
while drive was running in
REMOTE.
• The drive was powered up
with b1-17 = 0 (default) while
the Run command was
active.
Off
When a device other
than the operator is
selected for Run
command and
frequency reference
control (REMOTE)
During stop
Examples
OMM 1166
AGZ 025D through 190D
63
Table 19, Types of Alarms, Faults, and Errors
Type
Drive Response
When the drive detects a fault:
• The digital operator displays text indicating the specific fault and the ALM indicator LED remains lit until the fault is
reset.
• The fault interrupts drive output and the motor coasts to a stop. • Some faults allow the user to select the stopping
method when the fault occurs.
• Fault output terminals MA-MC will close, and MB-MC will open.
Faults
The drive will remain inoperable until the fault is cleared.
When the drive detects an alarm or a minor fault:
• The digital operator displays text indicating the specific alarm or minor fault, and the ALM indicator LED flashes.
• The drive continues running the motor, although some alarms allow the user to select a stopping method when the alarm
Minor Faults
and
Alarms
occurs.
• A multi-function contact output set to be tripped by a minor fault (H2-  = 10) closes. If the output is set to be
tripped by an alarm, the contact will not close.
• The digital operator displays text indicating a specific alarm and the ALM indicator LED flashes.
Remove the cause of the problem to reset a minor fault or alarm.
Operation
Errors
Tuning
Errors
An operation error occurs when parameter settings conflict or do not match hardware settings (such as with an option
card).When the drive detects an operation error:
• The digital operator displays text indicating the specific error. • Multi-function contact outputs do not operate.
The drive will not operate the motor until the error has been reset. Correct the settings that caused the operation error to
clear the error.
Tuning errors occur while performing Auto-Tuning. When the drive detects a tuning error:
• The digital operator displays text indicating the specific error. • Multi-function contact outputs do not operate.
• Motor coasts to stop.
Remove the cause of the error and repeat the Auto-Tuning process.
Copy
Function
Errors
Copy Function Errors occur when using the digital operator or the USB Copy Unit to copy, read, or verify parameter
settings.
• The digital operator displays text indicating the specific error.
• Multi-function contact outputs do not operate.
Pressing any key on the digital operator will clear the fault. Investigate the cause of the problem (such as model
incompatibility)and try again.
Table 20 Fault Reset Methods
NOTE: When a fault occurs, the cause of the fault must be removed and the drive must be restarted. The following
tables list the various ways to restart the drive. Remove the Run command before attempting to clear a fault. If the Run
command is present, the control will disregard any attempt to reset the fault
After the Fault Occurs
Fix the cause of the fault, restart
the drive, and reset the fault
Resetting via Fault Reset Digital
Input S4
Procedure
Press
on the HMI.
Close then open the fault signal
digital input via terminal S4. S4 is
set for “Fault Reset” as default
(H1-04 = 14)
Turn off the main power supply if the above methods do not reset the
fault. Reapply power after the HMI display has turned off.
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AGZ 025D through 190D
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Recommended Periodic Inspection
!
WARNING
Electrical Shock Hazard. Before servicing or inspection equipment, disconnect power to the unit.The
internal capacitor remains charged after power is turned off. Wait at least the amount of time specified
on the drive before touching any components.
Table 21, Periodic Inspection Checklist
Inspection Area
General
Relays and Contactors
Inspection Points
Inspect equipment including wiring, terminals,
resistors, capacitors, diode and IGBT for
discoloration from overheating or deterioration.
Inspect for dirt or foreign particles
Inspect contactors and relays for excessive
noise.
Inspect for signs of overheating such as
melted or cracked insulation
Corrective Action
Replace damaged components.
Use dry air to clear away.
Check for over or undervoltage
Replace damaged parts.
Optional BAS Interface
The AGZ chiller controller is configured for stand-alone operation or integration with BAS through
an optional communication module.
The following installation manuals for optional BAS interface modules are shipped with the chiller.
They can also be found and downloaded on www.DaikinApplied.com under Product
Information > Air cooled Chillers> Scroll Type >Literature>Installation & Operation
Manuals:
•
•
•
•
•
•
IM 966-1, BACnet® IP Communication Module
IM 967-1, BACnet® Communication Module (MS/TP)
IM 968-1, LONWORKS Communication Module
IM 969-2, Modbus® Communication Module
ED 15120, Protocol Information for MicroTech III chiller, BACnet and LONWORKS
ED 15121, Protocol Information for MicroTech III chiller, Modbus
,
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AGZ 025D through 190D
65
Startup
Pre Start-up
The chiller must be inspected to ensure no components became loose or damaged during shipping or
installation.
Start-Up
Refer to the MicroTech III Controller section beginning on page 13 to become familiar with its
operation before starting chiller.
There should be adequate building load (at least 50 percent of the unit full load capacity) to properly
check the operation of the chiller refrigerant circuits.
Be prepared to record all operating parameters required by the “Compressorized Equipment
Warranty Form”. Return this information within 10 working days to Daikin Applied as instructed on
the form to obtain full warranty benefits.
1. Verify chilled water flow.
2. Verify remote start / stop or time clock has requested the chiller to start.
3. Set the chilled water setpoint to the required temperature. (The system water temperature must be
greater than the total of the leaving water temperature setpoint plus one-half the control band
before the MicroTech III controller will stage on cooling).
4. Set the Evap Delta T and the Start Delta T as a starting point.
5. Put both pumpdown switches (PS1 and PS2) to the ON position.
6. Put system switch (S1) to ON position.
Switch Position
Switch
PS1, PS2,
Pumpdown
Switches
S1,
System Switch
ON
Circuits will operate in the
normal automatic mode
Unit will operate in the
normal automatic mode
OFF
Circuit will go through the
normal pumpdown cycle and
shut off
Unit will shut off immediately
without pumping down
(emergency stop)
7. After the chiller has been operating for a period of time and has become stable, check the
following:
•
Compressor oil level. (Some scroll compressors do not have oil sight glasses).
•
Refrigerant sight glass for flashing
•
Rotation of condenser fans
•
Complete the “Compressorized Equipment Warranty Form.”
Shutdown
Temporary
1. Put both circuit switches (PS1 and PS2) to the OFF position (Pumpdown and Stop).
2. After compressors have stopped, put System Switch (SW1) to OFF (emergency stop).
3. Turn off chilled water pump. Chilled water pump to operate while compressors are pumping
down.
To start the chiller after a temporary shutdown, follow the start-up instructions.
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AGZ 025D through 190D
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Extended
1. Front seat (close) both condenser liquid line service valves.
2. Put both circuit switches (PS1 and PS2) to the OFF position (Pumpdown and Stop position).
3. After the compressors have stopped, put System Switch (SW1) to the OFF position (emergency
stop).
4. Front seat both refrigerant circuit discharge valves (if applicable).
5. If chilled water system is not drained, maintain power to the evaporator heater to prevent freezing.
Maintain heat tracing on the chilled water lines.
6. Drain evaporator and water piping to prevent freezing.
7. If electrical power to the unit is on, the compressor crankcase heaters will keep the liquid
refrigerant out of the compressor oil. This will minimize start-up time when putting the unit back
into service. The evaporator heater will be able to function.
8. If electrical power is off, make provisions to power the evaporator heater (if chilled water system
is not drained or filled with correct anti-freeze). Tag all opened electrical disconnect switches to
warn against start-up before the refrigerant valves are in the correct operating position.
To start the chiller after an extended shutdown, follow the prestart-up and start-up instructions.
Pre Startup Water Piping Checkout
1. Check the pump operation and vent all air from the system.
2. Circulate evaporator water, checking for proper system pressure and evaporator pressure drop.
Compare the pressure drop to the evaporator water pressure drop curve.
3. Clean all water strainers before placing the chiller into service.
Pre Startup Refrigerant Piping Checkout
1. Check all exposed brazed joints for evidence of leaks. Joints may have been damaged during
shipping or when the unit was installed.
2. Check that all refrigerant valves are either opened or closed as required for proper operation of the
chiller.
3. A thorough leak test must be done using an approved electronic leak detector. Check all valve
stem packing for leaks. Replace all refrigerant valve caps and tighten.
4. Check all refrigerant lines to insure that they will not vibrate against each other or against other
chiller components and are properly supported.
5. Look for any signs of refrigerant leaks around the condenser coils and for damage during shipping
or installation.
6. Leak detector fluid may be applied externally to refrigerant joints at the factory. Do not confuse
this residue with an oil leak.
7. Connect refrigerant service gauges to each refrigerant circuit before starting unit.
Pre Startup Electrical Check Out
! CAUTION
Electrical power must be applied to the compressor crankcase heaters 8 hours before
starting unit to drive off refrigerant from the oil and prevent damage to the unit.
1. Open all electrical disconnects and check all power wiring connections. Start at the power block
and check all connections through all components to and including the compressor terminals.
These should be checked again after 3 months of operation and at least yearly thereafter.
2. Check all control wiring by pulling on the wire at the spade connections and tighten all screw
connections. Check plug-in relays for proper seating and to insure retaining clips are installed.
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AGZ 025D through 190D
67
3. Put System Switch (S1) to the Emergency Stop position.
4. Put both circuit #1 & #2 switches to the Pumpdown and Stop position.
5. Apply power to the unit. The panel Alarm Light will stay on until S1 is closed. Ignore the Alarm
Light for the check out period. If you have the optional Alarm Bell, you may wish to disconnect
it.
6. Check at the power block or disconnect for the proper voltage and proper voltage between phases.
Check power for proper phasing using a phase sequence meter before starting unit.
7. Check for 120Vac at the optional control transformer and at TB-2 terminal #1 and the neutral
block (NB).
8. Check between TB-2 terminal #7 and NB for 120 vac supply for transformer #2.
9. Check between TB-2 terminal #2 and NB for 120 vac control voltage. This supplies the
compressor crank case heaters.
10. Check between TB-3 terminal #17 and #27 for 24 vac control voltage.
Operation
Hot Gas Bypass (Optional)
This option allows the system to operate at lower loads without excessive on/off compressor cycling.
The hot gas bypass option is required to be on both refrigerant circuits because of the lead/lag feature
of the controller.
This option allows passage of discharge gas into the evaporator inlet (between the TX valve and the
evaporator) which generates a false load to supplement the actual chilled water or air handler load.
Note: The hot gas bypass valve cannot generate a 100% false load.
The pressure regulating valves are a Sporlan HGBE-8-75/150-7/8 ODF on models AGZ 025 to 065
and Sporlan HGBE-8-75/150-1 1/8 ODF on AGZ 070 to 190. They are factory set to begin opening at
100 psig (R-410A) and can be changed by changing the pressure setting. The adjustment range is 75
to 150 psig. To raise the pressure setting, remove the cap on the bulb and turn the adjustment screw
clockwise. To lower the setting, turn the screw counterclockwise. Do not force the adjustment beyond
the range it is designed for, as this will damage the adjustment assembly. The regulating valve
opening point can be determined by slowly reducing the system load while observing the suction
pressure. When the bypass valve starts to open, the refrigerant line on the evaporator side of the valve
will begin to feel warm to the touch.
The bypass piping also includes a solenoid valve that is controlled by the MicroTech III controller. It
is active when the first stage of cooling on a circuit is active.
!
WARNING
The hot gas line may become hot enough to cause injury. Be careful during valve checkout.
VFD Low Ambient Control (Optional)
The optional VFD fan control is used for unit operation below 35°F (2°C) down to a minimum of
-10°F (-23.3°C). The control looks at the saturated discharge temperature and varies the fan speed to
hold the temperature (pressure) at the “target” temperature. This temperature is established as an input
to a setpoint screen labeled “Sat Condenser Temp Target”.
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AGZ 025D through 190D
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Compressor Communications
The communication module, installed in the 20 to 40 ton compressor electrical box, provides advanced
diagnostics, protection, and communications that enhance compressor performance and reliability.
Features include motor temperature protection, scroll temperature protection, missing phase
protection, reverse phase protection, low control circuit voltage protection, short cycling detection and
alert, modbus communication to system controller, operational and fault history storage, and LED
status display.
Green/Red LEDs
OPERATION
Warnings and Alerts
A solid green LED indicates the module is powered and operation is normal.
A solid red LED indicates an internal problem with the module.
A flashing green LED communicates Warning codes. Warning codes do not result in a trip or lockout
condition.
A flashing red LED communicates Alert codes. Alert codes will result in a trip condition and
possibly a lockout condition
Warning Codes (Flashing Green LED )
Code 1 – Loss of Communication: The module will flash the green Warning LED one time indicating
the module has not communicated with the master controller for longer than 5 minutes.
Code 2 – Reserved For Future Use
Code 3 – Short Cycling: The module will flash the green Warning LED three times indicating the
compressor has short cycled more than 48 times in 24 hours.
Code 4 – Open/Shorted Scroll Thermistor: The module will flash the green Warning LED four times
indicating an open/shorted
Alert/Lockout Codes (Flashing Red LED)
Code 1 – Motor High Temperature: The module will flash the red Alert LED one time indicating the
motor is onerheating . A code 1 Alert will open the M2-M1 contacts. The Alert will reset after 30
minutes. Five consecutive Code 1 Alerts will lockout the compressor. Once the module has locked out
the compressor, a power cycle or Modbus reset command will be required for the lockout to be
cleared.
Code 2 – Open/Shorted Motor Thermistor The module will flash the red Alert LED two times
indicating the motor PTC thermistor circuit has an open/shorted thermistor chain (see Table 2). A
Code 2 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2-M1
contacts will close if the resistance of the motor PTC circuit is back in the normal range. The module
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AGZ 025D through 190D
69
will lockout the compressor and a power cycle or Modbus reset command will be required to clear the
lockout.
Code 3 – Short Cycling: The module will flash the red Alert LED three times indicating the
compressor is locked out due to short cycling. Once locked out the compressor, a power cycle or
Modbus reset command will be required to clear the lockout.
Code 4 – Scroll High Temperature; The module will flash the red Alert LED four times indicating the
over-temperature condition. A Code 4 Alert will open the M2-M1 contacts.The Alert will reset after
30 minutes. Once the module has locked out the compressor, a power cycle or Modbus reset command
will be required to clear the lockout.
Code 5 – Reserved for Future Use
Code 6 – Missing Phase: The module will flash the red Alert LED six times indicating a missing
phase. The Alert will reset after 5 minutes and the module will lockout the compressor after 10
consecutive Code 6 Alerts. Once locked out, a power cycle or Modbus reset is required.
Code 7 – Reverse Phase: The module will flash the red Alert LED seven times indicating a reverse
phase in two of the three compressor leads. The modules will lockout the compressor after one Code
7 Alert. A power cycle or Modbus reset command will be required to clear the lockout.
Code 8 – Reserved For Future Use
Code 9 – Module Low Voltage; The module will flash the red Alert LED nine times indicating low
module voltage for more than 5 seconds. . The Alert will reset after 5 minutes and the M2-M1
contacts will close if the T2-T1 voltage is above the reset value.
NOTE:If a compressor with CoreSense Communications fails in the field, the CoreSense module
should remain with the failed compressor so the manufacturer’s technicians can download the
CoreSense data to assist with determining the root cause of compressor failure.
Filter-Driers
Each refrigerant circuit is furnished with a full flow filter drier (AGZ 030D – 100D) or a replaceable
core type filter-drier (AGZ 140D – 180D). The core assembly of the replaceable core drier consists of
a filter core held tightly in the shell in a manner that allows full flow without bypass.
Pressure drop across the filter drier at full load conditions must not exceed 10 psig at full load. See
page for maximum pressure drop at other load points. Replace the filter drier if the pressure drop
exceeds maximum.
!
WARNING
Pump out refrigerant before removing end flange for replacement of core(s) to remove liquid
refrigerant and lower pressure to prevent accidental blow off of cover. EPA recovery
regulations apply to this procedure.
A condenser liquid line service valve is provided for isolating the charge in the condenser, but also
serves as the point from which the liquid line can be pumped out. With the line free of refrigerant, the
filter-drier core(s) can be easily replaced.
System Adjustment
To maintain peak performance at full load operation, the system superheat and liquid subcooling may
require adjustment. Read the following subsections closely to determine if adjustment is required.
Liquid Line Sight Glass
The color of the moisture indicator is an indication of the dryness of the system and is extremely
important when the system has been serviced. Immediately after the system has been opened for
service, the element may indicate a wet condition. It is recommended that the equipment operate for
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AGZ 025D through 190D
OMM 1166
about 12 hours to allow the system to reach equilibrium before deciding if the system requires a
change of drier cores.
Bubbles in the sight glass at constant full load indicates a shortage of refrigerant, a plugged filter-drier,
or a restriction in the liquid line. However, it is not unusual to see bubbles in the sight glass during
changing load conditions.
Refrigerant Charging
Liquid line subcooling at the liquid shut-off valve should be between 15 and 20 degrees F at full load.
If the unit is at steady full load operation and bubbles are visible in the sight glass, then check liquid
subcooling.
Thermostatic Expansion Valve
The expansion valve performs one specific function. It keeps the evaporator supplied with the proper
amount of refrigerant to satisfy the load conditions.
NOTE: Before adjusting superheat, check that unit charge is correct and liquid line sight glass is full
with no bubbles and that the circuit is operating under stable, full load conditions.
The suction superheat for the suction leaving the evaporator is set at the factory for 8 to 12 degrees F
at full load. To have full rated unit performance, the superheat must be about 8 degrees F at 95°F
outdoor ambient temperature.
Crankcase Heaters
The scroll compressors are equipped with externally mounted band heaters located at the oil sump
level. The function of the heater is to keep the temperature in the crankcase high enough to prevent
refrigerant from migrating to the crankcase and condensing in the oil during off-cycle.
Power must be supplied to the heaters 8 hours before starting the compressors.
Evaporator
Models AGZ 025D through 130D
The evaporator is a compact, high efficiency, dual circuit, brazed, plate-to-plate type heat exchanger
consisting of parallel stainless steel plates.
The evaporator is protected with an electric resistance heater and insulated with 3/4" (19mm) thick
closed-cell polyurethane insulation. This combination provides freeze protection down to -20°F (29°C) ambient air temperature.
The water side working pressure is 363 psig (2503 kPa). Evaporators are designed and constructed
according to, and listed by, Underwriters Laboratories (UL).
NOTE: This product is equipped with a copper-brazed series 304 stainless steel plate evaporator. The
water or other fluid used in these evaporators must be clean and non-corrosive to the materials used in
the evaporator. The use of non-compatible fluids can void the equipment warranty. If the compatibility
of the fluid with the evaporator is in question, a professional water quality consultant should
administer the proper testing and evaluate compatibility.
Models AGZ 140D through 180D
The evaporator is direct expansion, shell-and-tube type with water flowing in the baffled shell side and
refrigerant flowing through the tubes. Two independent refrigerant circuits within the evaporator
serve the unit's dual refrigerant circuits.
The evaporator is wrapped with an electric resistance heater cable and insulated with 3/4" (19mm)
thick vinyl nitrate polymer sheet insulation, protecting against water freeze-up at ambient air
temperatures to -20°F (-29°C). An ambient air thermostat controls the heater cable. The fitted and
glued-in-place insulation has a K factor of 0.28 Btu in/hr ft2 °F at 75°F.
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AGZ 025D through 190D
71
The refrigerant (tube) side maximum working pressure is 300 psig (2068 kPa). The water side
working pressure is 152 psig (1048 kPa). Each evaporator is designed, constructed, inspected, and
stamped according to the requirements of the ASME Boiler and Pressure Vessel Code. Double
thickness insulation is available as an option.
Phase Voltage Monitor (Optional)
Factory settings are as follows:
•• Trip Delay Time, 2 seconds
•• Voltage Setting, set at nameplate voltage.
•• Restart Delay Time, 60 seconds
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AGZ 025D through 190D
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Unit Maintenance
General
On initial start-up and periodically during
operation, it will be necessary to perform
certain routine service checks. Among these
are checking the liquid line sight glasses,
taking condensing and suction pressure
readings, and checking to see that the unit has
normal superheat and subcooling readings. A
recommended maintenance schedule is located
at the end of this section.
Compressor Maintenance
The scroll compressors are fully hermetic and
require no maintenance other than checking oil
level.
Lubrication
No routine lubrication is required on AGZ
units. The fan motor bearings are permanently
lubricated and no further lubrication is
required. Excessive fan motor bearing noise is
an indication of a potential bearing failure.
The compressors in this unit use POE
lubricant. POE lubricant is required with
refrigerant R-410A. Do not use mineral oil.
Electrical Terminals
!
DANGER
Electric shock hazard. Turn off all power
before continuing with following service.
Condensers
The condensers are air-cooled and constructed
of 3/8" (9.5mm) O.D. internally finned copper
tubes bonded in a staggered pattern into
louvered aluminum fins. Maintenance consists
primarily of the routine removal of dirt and
debris from the outside surface of the fins and
repairing any fin damage. Daikin Applied
recommends the use of foaming coil cleaners
available at most air conditioning supply
outlets. Use caution when applying such
cleaners as they can contain potentially
harmful chemicals. Care should be taken not to
OMM 1166
damage the fins during cleaning. The coils
should be thoroughly rinsed to remove any
cleaner residue.
If the service technician determines that the
refrigerant circuit contains noncondensables,
recovery can be required, strictly following
Clean Air Act regulations governing refrigerant
discharge to the atmosphere. The Schrader
purge valve is located on the vertical coil
headers on both sides of the unit at the end
opposite the control box. Decorative panels
cover the condenser coils and must be removed
for servicing. Recover with the unit off, after a
shutdown of 15 minutes or longer, to allow air
to collect at the top of the coil. Restart and run
the unit for a brief period. If necessary, shut the
unit off and repeat the procedure. Follow
national and local regulations regarding
refrigerant venting and reclamation when
removing refrigerant from the unit.
Condensers with Electrofin® Coating
Documented routine quarterly coil cleaning of
Electrofin coils is required to maintain the
coating warranty. The cleaning procedure can
be downloaded from the Electrofin web site
www.luvata.com/electrofin ,click on
Procedures for Cleaning
Optional High Ambient Control
Panel
Consists of exhaust fan with rain hood, two
inlet screens with filters, necessary controls
and wiring to allow operation to 125°F (52°C).
The option can be factory or field installed as a
kit.
• It must be supplied on units operating at
ambient temperatures of 105°F (40.6°C) and
above.
• It is automatically included on units with
fan VFD (low ambient option).
• Check inlet filters periodically and clean as
required. Verify that the fan is operational.
AGZ 025D through 190D
73
Liquid Line Sight Glass
The refrigerant sight glasses should be
observed periodically (a weekly observation
should be adequate.) A clear glass of liquid
indicates that there is subcooled refrigerant
charge in the system. Bubbling refrigerant in
the sight glass, during stable run conditions,
indicates that the system can be short of
refrigerant charge. Refrigerant gas flashing in
the sight glass could also indicate an excessive
pressure drop in the liquid line, possibly due to
a clogged filter-drier or a restriction elsewhere
in the liquid line.
See Table 22 on page 78 for maximum
allowable pressure drops. If subcooling is low,
add charge to clear the sight glass. If
subcooling is normal (15 to 20 degrees F) and
flashing is visible in the sight glass, check the
pressure drop across the filter-drier.
Subcooling should be checked at full load with
70°F (21.1°C) ambient temperature, stable
conditions, and all fans running.
An element inside the sight glass indicates the
moisture condition corresponding to a given
element color. If the sight glass does not
indicate a dry condition after about 12 hours of
operation, the circuit should be pumped down
and the filter-drier changed or verify moisture
content by performing an acid test on the
compressor oil.
Planned Maintenance Schedule
OPERATION
WEEKLY
General
Complete unit log and review (Note 3)
Visually inspect unit for loose or damaged components
Inspect thermal insulation for integrity
Clean and paint as required
ANNUAL
(Note 2)
X
X
X
X
Electrical
Check terminals for tightness, tighten as necessary
Clean control panel interior
Visually inspect components for signs of overheating
Verify compressor heater operation
Test and calibrate equipment protection and operating
controls
Megger compressor motor *
Refrigeration
Leak test
Check sight glasses for clear flow
Check filter-drier pressure drop (see manual for spec)
Perform compressor vibration test
Acid test oil sample
MONTHLY
(Note 1)
X
X
X
X
X
X
X
X
Condenser (air-cooled)
Clean condenser coils (Note 4)
Check fan blades for tightness on shaft (Note 5)
Check fans for loose rivets and cracks
Check coil fins for damage
X
X
X
X
X
X
X
Notes:
1. Monthly operations include all weekly operations.
2. Annual (or spring start-up) operations includes all weekly and monthly operations.
3. Log readings can be taken daily for a higher level of unit observation.
4. Coil cleaning can be required more frequently in areas with a high level of airborne particles.
5. Be sure fan motors are electrically locked out.
* Never Megger motors while they are in a vacuum to avoid damage to the motor.
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AGZ 025D through 190D
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Service
R-410A
Refrigerant Terminology
Bubble Point: The temperature/pressure
where bubbles first appear when heat is added
to a liquid refrigerant. Used to measure subcooling.
Dew Point: The temperature/pressure where
droplets first appear when heat is removed
from a refrigerant gas. Used to measure
superheat.
Fractionalization: A change in refrigerant
composition due to the tendency of the higher
pressure refrigerant to leak at a faster rate,
should a system have leakage from a static
two-phase region.
Glide: The total difference of Dew and Bubble
Point at a specific condition. Mid-Point or
Mean: Measurement half way between Dew
and Bubble Points.
Miscibility: The ability of a refrigerant and oil
to mix and flow together.
Solubility: The effect of refrigerant on the
viscosity of a lubricant.
Safety
Comparable to R-22; ANSI/ASHRAE safety
group A1.
Always carry and be familiar with MSDS
information for R-410a.
Store refrigerant in clean, dry area out of direct
sunlight.
Never heat or store cylinders above 125° F.
Note vehicle precautions!
Never tamper with cylinder valves or pressure
relief valves. (Typical relief for R-410A is 525
psig).
Never refill disposable cylinders.
Verify cylinder hook-up.
Verify cylinder label and color code match. R410A is rose/light maroon. Must be DOT
approved, R-410A with 400 psig rating. Open
cylinders slowly.
OMM 1166
Avoid rough handling of cylinders and secure
as appropriate. Cap when not in use.
Do not overfill recovery cylinders or
overcharge units.
Check gauge calibration before every use and
manifold set for leaks regularly.
Be aware of pneumatic and possible
hydrostatic pressure potentials.
Never pressurize systems with oxygen or
ref/air mix. R-410A, R-407C, R-134A, & R-22
are flammable with low air mix.
Wear protective clothing. Impervious gloves
and splash goggles should be worn.
Avoid contact with liquid refrigerant (R-410A 60.8°F @ atms.) due to corrosion and freezing
hazards.
Avoid exposure to vapors. 1000 ppm/8 hr.
Evacuate areas in cases of large releases. R410A is heavier than air and can cause
asphyxiation, narcotic and cardiac sensation
effects.
Evacuate systems and break vacuum (0 psig)
with nitrogen before welding or brazing.
Always ventilate work areas before using open
flames. Exposure to open flames or glowing
metal will form toxic hydrofluoric acid &
carbonyl fluoride. No smoking!
Make sure all tools, equipment, and
replacement components are rated for the
refrigerant used.
Lubrication
POE oil is extremely hydroscopic, is polar in
nature (picks up dirt, etc.), and will hydrolyze
(produce acids) in the presence of water.
NOTE:POE lubricants must be handled
carefully and the proper protective equipment
(gloves, eye protection, etc.) must be used
when handling POE lubricant. POE must not
come into contact with any surface or material
that might be harmed by POE, including
AGZ 025D through 190D
75
certain polymers (e.g. PVC/CPVC and
polycarbonate piping)
Use only the manufacturer’s recommended oil.
Use only new sealed metal containers of oil to
insure quality.
Buy smaller containers to prevent waste and
contamination.
Use only filter driers designed for POE and
check pressure drops frequently.
Test for acid and color at least annually.
Change filter driers if acid or high moisture (>
200 ppm) is indicated (< 100 ppm typical).
Do not use oil additives or refrigerant
additives.
Evacuate to 500 microns and hold test to
insure systems are dry.
The units are factory-charged with lubricant
and one of the following lubricants must be
used if lubricant is to be added to the system:
••
Copeland Ultra 22 CC
••
Mobil EAL Arctic 22 CC
••
ICI EMKARATE RL RL 32CF
Since POEs are very hygroscopic, they will
quickly absorb moisture if exposed to air.
Pump the lubricant into the unit through a
closed transfer system. Avoid overcharging the
unit.Control and Alarm Settings
The software that controls the operation of the
unit is factory-set for operation with R-410A,
taking into account that the
pressure/temperature relationship differs from
R-22. The software functionality is the same
for either refrigerant.
Refrigerant Charging
The AGZ units have a condenser coil design
with approximately 15% of the coil tubes
located in a subcooler section of the coil to
achieve liquid cooling to within 5°F (3°C) of
the outdoor air temperature when all condenser
fans are operating.
Once the subcooler is filled, extra charge will
not lower the liquid temperature and does not
help system capacity or efficiency.
If a unit is low on refrigerant, you must first
determine the cause before attempting to
recharge the unit. Locate and repair any
76
refrigerant leaks. Soap works well to show
bubbles at medium size leaks but electronic
leak detectors are needed to locate small leaks.
Charging or check valves should always be
used on charging hoses to limit refrigerant loss
and prevent frostbite. Ball valve type
recommended.
Charge to 80-85% of normal charge before
starting the compressors.
Charging procedure. The units are factorycharged with R-410A. Use the following
procedure if recharging in the field is
necessary:
To prevent fractionalization, liquid must be
charged from the refrigerant cylinder, unless
charging the entire cylinder contents.
The charge can be added at any load condition
between 25 to 100 percent load per circuit, but
at least two fans per refrigerant circuit should
be operating if possible.
Start the system and observe operation.
1. Trim the charge to the recommended liquid
line sub-cooling (approximately 14-20
degrees F typical).
2. Verify the suction superheat (10 degrees F
for EEVs and 10 – 12 degrees F for TXVs)
at full load conditions.
Use standard charging procedures (liquid only)
to top off the charge.
Check the sight glass to be sure there is no
refrigerant flashing.
With outdoor temperatures above 60°F
(15.6°C), all condenser fans should be
operating and the liquid line temperature
should be within 5°F to 10°F (2.8°C to 5.6°C)
of the outdoor air temperature. At 25-50%
load, the liquid line temperature should be
within 5°F (2.8°C) of outdoor air temperature
with all fans on. At 75-100% load the liquid
line temperature should be within 10°F (5.6°C)
of outdoor air temperature with all fans on.
It may be necessary to add refrigerant through
the compressor suction. Because the
refrigerant leaving the cylinder must be a
liquid, exercise care to avoid damage to the
compressor by using a flow restrictor. A sight
glass can be connected between the charging
hose and the compressor. It can be adjusted to
AGZ 025D through 190D
OMM 1166
have liquid leave the cylinder and vapor enter
the compressor.
Overcharging of refrigerant will raise the
compressor discharge pressure due to filling of
the condenser tubes with excess refrigerant.
Service
With R-410A, fractionalization, if due to leaks
and recharge has a minimal effect on
performance or operation.
Special tools will be required due to higher
refrigerant pressures with R-410A. Oil-less/hp
recovery units, hp recovery cylinders (DOT
approved w/525# relief), gauge manifold 30”250 psi low/0-800 psi high, hoses w/800 psi
working & 4,000 psi burst.
All filter driers and replacement components
must be rated POE oils and for the refrigerant
pressure (R-410A 600psig typical).
!
R-410A compressor internal relief is 600-650
psid.
Brazed connections only. No StayBrite or
solder connections (solder should never be
used with any refrigerant). K or L type
refrigeration tubing only. Use nitrogen purge.
Higher R-410A pressures and smaller molecule
size make workmanship more critical.
R-410A must be charged from cylinder as a
liquid unless entire cylinder is used. Use a
Refrigerant flow restrictor if charging liquid to
suction or to a system at pressure below a
saturated temperature of 32° F.
EPA recovery and handling requirements for
R-410A are the same as R-22.
Cooling the recovery cylinder will speed
recovery and lessen stress on recovery
equipment.
WARNING
Service on this equipment is to be performed by qualified refrigeration personnel
familiar with equipment operation, maintenance, correct servicing procedures, and the
safety hazards inherent in this work. Causes for repeated tripping of equipment
protection controls must be investigated and corrected.
Disconnect all power before doing any service inside the unit.
Servicing this equipment must comply with the requirements set forth by the EPA in
regards to refrigerant reclamation and venting.
Filter-Driers
Replace the filter-drier any time excessive
pressure drop is read across the filter-drier
and/or when bubbles occur in the sight glass
with normal subcooling. The maximum
recommended pressure drops across the filterdrier are shown below.
Table 22, Filter-Drier Pressure Drop
PERCENT CIRCUIT
LOADING (%)
100%
75%
50%
25%
OMM 1166
MAXIMUM RECOMMENDED
PRESSUREDROP ACROSS
FILTER DRIER PSIG (KPA)
10 (69)
8 (55.2)
5 (34.5)
4 (27.6)
The filter-drier should also be changed if the
moisture indicating liquid line sight glass
indicates excess moisture in the system.
During the first few months of operation the
filter-drier replacement can be necessary if the
pressure drop across the filter-drier exceeds the
values listed in the paragraph above. Any
residual particles from the condenser tubing,
compressor and miscellaneous components are
swept by the refrigerant into the liquid line and
are caught by the filter-drier.
AGZ 025D through 190D
77
Liquid Line Solenoid Valve
The liquid line solenoid valves that shut off
refrigerant flow in the event of a power failure
do not normally require any maintenance. The
solenoids can, however, require replacement of
the solenoid coil or of the entire valve
assembly.
The solenoid coil can be checked to see that
the stem is magnetized when energized by
touching a screwdriver to the top of the stem.
If there is no magnetization, either the coil is
bad or there is no power to the coil.
The solenoid coil can be removed from the
valve body without opening the refrigerant
piping after pumpdown. For personal safety,
shut off and lock out the unit power.
The coil can then be removed from the valve
body by simply removing a nut or snap-ring
located at the top of the coil. The coil can then
be slipped off its mounting stud for
replacement.
To replace the entire solenoid valve follow the
steps involved when changing a filter-drier.
Evaporator
The evaporators on AGZ-C models 030 - 130 are
brazed plate type, and on models 140, 160, and
180 they are shell-and-tube type. Other than
78
cleaning and testing, no service work should be
required on the evaporator.
AGZ 025D through 190D
OMM 1166
AGZ-D Troubleshooting Chart
PROBLEM
Compressor Will
Not Run
Compressor
Noisy Or Vibrating
High Discharge
Pressure
Low Discharge
Pressure
High Suction
Pressure
Low Suction
Pressure
Compressor Will
Not Stage Up
Compressor
Staging Intervals
Too Short
IMM 1078
POSSIBLE CAUSES
POSSIBLE CORRECTIVE STEPS
1.
Main switch.
2.
Fuse blown. circuit breakers open
3.
Thermal overloads tripped
4.
Defective contactor or coil.
5.
System shutdown by equipment protection devices
6.
7.
8.
9.
No cooling required
Liquid line solenoid will not open
Motor electrical trouble
Loose wiring
1.
2.
3.
4.
5.
Low or no refrigerant charge
Compressor running in reverse
Improper piping support on suction or discharge
Worn compressor isolator bushing
Worn Compressor
1.
Noncondensables in system
2.
3.
4.
5.
6.
7.
System overcharged with refrigerant
Optional discharge shutoff valve partially closed
FanTrol wiring not correct
Fan not running
Dirty condenser coil
Air recirculation
1.
Refrigerant flood back
2.
Wind blowing into coil at low ambient
3.
4.
5.
Faulty condenser temperature regulation
Insufficient refrigerant in system
Low suction pressure
6.
Only one compressor operating
1.
2.
3.
4.
Excessive water temperature
Excessive load
Expansion valve overfeeding
Compressors running in reverse
1.
2.
3.
4.
1.
Rapid load swings
2.
Lack of refrigerant
3.
4.
Clogged liquid line filter drier
Expansion valve malfunctioning
5.
Condensing temperature too low
6.
Compressor will not unload
7.
Insufficient water flow
8.
Evaporator head ring gasket slippage
9.
Evaporator dirty
10. Rapid load swings
1.
Stabilize load.
2.
Check for leaks, repair, add charge. Check liquid
sight glass.
3.
Check pressure drop across filter drier. Replace.
4.
Check and reset for proper superheat.
5.
Check means for regulating condenser
temperature.
6.
See corrective steps for Compressor Staging
Intervals Too Low.
7.
Adjust flow.
8.
Take pressure drop across vessel and contact
factory to obtain design pressure drop for that vessel.
9.
Clean chemically.
10. Stabilize load.
1.
2.
1.
2.
Defective capacity control
Faulty thermostat stage or broken wire
1.
Close switch.
2.
Check electrical circuits and motor windings for
shorts or grounds. Investigate for possible overloading.
Replace fuse or reset breakers after fault is corrected.
Check for loose or corroded connections.
3.
Overloads are auto-reset. Check unit closely when
unit comes back on line. Allow time for auto-reset.
4.
Repair or replace
5.
Determine type and cause of shutdown and correct
it before resetting equipment protection switch.
6.
None. Wait until unit calls for cooling.
7.
Repair or replace solenoid coil. Check wiring.
8.
Check motor for opens, shorts, or burnout.
9.
Check all wire junctions. Tighten all terminal screws.
1.
Repair and recharge
2.
Check unit and compressor for correct phasing
3.
Relocate, add, or remove hangers
4.
Replace
5.
Replace
1.
Extract the noncondensables with approved
procedures.
2.
Remove excess, check liquid subcooling.
3.
Open valve.
4.
Check FanTrol wiring.
5.
Check electrical circuit, Check fan motor.
6.
Clean coil.
7.
Correct.
1.
Correct.
2.
Shield coil from direct wind, Wind guards are
available.
3.
Check condenser control operation.
4.
Check for leaks. Repair and add charge.
5.
See corrective steps for Low Suction Pressure.
6.
See corrective steps for Compressor Will Not Stage
Up.
Check control settings.
Reduce load or add additional equipment.
Check remote bulb. Regulate superheat.
Check for proper phasing.
Replace.
Replace.
3.
Stages not set for application
3.
Reset thermostat setting for application.
1.
2.
Thermostat control band not set properly
Faulty water temperature sensor
1.
2.
Set control band wider.
Replace.
3.
4.
Insufficient water flow
Rapid load swings
3.
4.
Adjust flow.
Stabilize load.
AGZ 030C through 190C
79
PROBLEM
Compressor Oil
Level Too High
Or Too Low
Compressor
Loses Oil
Motor Overload
Relays or Circuit
Breakers Open
Compressor
Thermal
Protection Switch
Open
POSSIBLE CAUSES
1.
2.
3.
4.
5.
6.
Oil hang-up in piping
Low oil level
Loose fitting on oil line
Level too high
Insufficient water flow - Level too high
Excessive liquid in crankcase - Level too high
POSSIBLE CORRECTIVE STEPS
7.
Short cycling
1.
Review refrigerant piping and correct.
2.
Check and add oil.
3.
Check and tighten system.
4.
Adjust thermal expansion valve.
5.
Adjust flow.
6.
Check crankcase heater. Reset expansion valve
for higher superheat. Check liquid line solenoid valve
operation.
7.
Stabilize load or increase staging interval.
1.
2.
Lack of refrigerant
Suction superheat too high
1.
2.
Check for leaks and repair. Add refrigerant
Adjust superheat.
3.
Crankcase heater burnout
3.
Replace crankcase heater.
1.
2.
Low voltage during high load conditions
Defective or grounded wiring in motor
1.
2.
Check supply voltage for excessive line drop.
Replace compressor motor.
3.
4.
5.
Loose power wiring or burnt contactors
High condenser temperature
Power line fault causing unbalanced voltage
1.
Operating beyond design conditions
2.
3.
4.
5.
6.
Discharge valve partially shut
Blown compressor internal gasket
Voltage range or imbalance
High superheat
Compressor bearing failure
3.
Check all connections and tighten.
4.
See corrective steps for High Discharge Pressure.
5.
Check supply voltage. Notify power company. Do
not start until fault is corrected..
1.
Add facilities so conditions are within allowable
limits.
2.
Open valve.
3.
Replace gasket.
4.
Check and correct.
5.
Adjust to correct superheat.
6.
Replace compressor .
Warranty Statement
Limited Warranty
All Daikin equipment is sold pursuant to standard Daikin Applied Terms and Conditions of
Sale and Limited Product Warranty. Consult your local Daikin Applied Representative
for warranty details. Refer to form 933-430285Y-00-A (09/08). To find your local
representative, go to www.DaikinApplied.com
Daikin Applied Training and Development
Now that you have made an investment in modern, efficient Daikin equipment, its care should be a
high priority. For training information on all Daikin HVAC products, please visit us at
www.DaikinApplied.com/training, or call 540-248-9646 to speak with the Training Department.
Warranty
All Daikin equipment is sold pursuant to Daikin Applied standard terms and conditions of sale,
including Limited Product Warranty. Consult your local Daikin Applied Representative for warranty
details. To find your local Daikin Applied Representative, go to www.DaikinApplied.com.
This document contains the most current product information as of this printing. For the most up-todate product information, please go to www.DaikinApplied.com.
(800) 432-1342 • www.DaikinApplied.com
OMM 1166 (4/13)
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