Installation, Operation, and Maintenance Manual Magnitude Magnetic Bearing Centrifugal Chillers IOM 1210-1
Installation, Operation, and Maintenance Manual Magnitude Magnetic Bearing Centrifugal Chillers IOM 1210-1
Installation, Operation, and Maintenance Manual Magnitude Magnetic Bearing Centrifugal Chillers IOM 1210-1
Magnitude®
Magnetic Bearing Centrifugal Chillers
Model WMC, C Vintage
125 to 400 Tons (440 to 1400 kW)
HFC-134a Refrigerant
50/60 Hz
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . 20
The Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator Schools . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sequence of Unit Operation . . . . . . . . . . . . . . . . . . . 20
Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . 6 Unit Enabling/Disabling . . . . . . . . . . . . . . . . . . . . . . 20
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator Interface Touch Screen (OITS) . . . . . . . . . 21
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 The Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Building Automation Systems (BAS) . . . . . . . . . . . . 58
Unit Dimensions and Shipping Weight . . . . . . . . . . . . 7 Use with On-Site Generators . . . . . . . . . . . . . . . . . . 58
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Service Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Vessel Drains at Startup . . . . . . . . . . . . . . . . . . . . . . . 8 Chiller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 59
Condenser Water Temperature Control . . . . . . . . . . . 9 Seasonal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 59
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Seasonal Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Field Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 60
Field Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Communication Setup for Multiple Chillers . . . . . . . 18 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Temperature / Pressure Chart . . . . . . . . . . . . . . . . . 64
Pre-Start Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 19
©2014 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 any time without notice.
Notes: The most common problems delaying start-up and affecting unit reliability are:
1. Field installed compressor motor power supply leads too small. Questions: Contact the local McQuay International sales representative. State size, number and
type of conductors and conduits installed:
a. From Power supply to starter
b. From starter to chiller unit (remote mounted)
2. Centrifugal chillers with water cooled oil coolers must have a 115 volt normally closed water solenoid valve installed in the oil cooler water supply line. Daikin
Applied recommends ASCO Type 8210B27 solenoid valve or approved equal and 40-mesh strainer. Daikin Applied does not supply these components.
3. A 115-volt field-supplied relay (CP1,2) must be used to start/stop condenser water pump on most applications. Cold condenser water must not flow through
condenser during compressor off cycle. Provisions have been made in control center for connecting CP relay, but must not have a rating in excess of 100 VA.
4. Refer to NEC Article 430-22 (a) *Does Not Apply to Magnetic Bearing Chillers (WMC/WME)
Introduction
This manual provides installation, operation, and maintenance information for McQuay WMC Magnitude® centrifugal chillers with
the MicroTech® II controller.
WARNING
Electric shock hazard. Improper handling of this equipment can cause personal injury or equipment damage. This equipment must
be properly grounded. Connections to and service of the MicroTech® II control panel must be performed only by personnel that are
knowledgeable in the operation of the equipment being controlled.
CAUTION
Static sensitive components. A static discharge while handling electronic circuit boards can cause damage to the components.
Discharge any static electrical charge by touching the bare metal inside the control panel before performing any service work.
Never unplug any cables, circuit board terminal blocks, or power plugs while power is applied to the panel.
NOTICE
This equipment generates, uses, and can radiate radio frequency energy. If not installed and used in accordance with this instruction
manual, it may cause interference with radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the owner will be required to correct the interference at the owner’s own expense.
Daikin Applied disclaims any liability resulting from any interference or for the correction thereof.
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.
General Description
McQuay Magnitude® Centrifugal Chillers are complete, self- thereby simplifying installation and increasing reliability.
contained, automatically controlled, fluid-chilling units featuring Necessary equipment protection and operating controls are
oil-free, magnetic bearing compressors. All Magnitude® chillers included.
are equipped with a single evaporator and a single condenser All McQuay International centrifugal chillers must be
along with either one or two compressors depending on the commissioned by a factory-trained McQuay International
model. service technician. Failure to follow this startup procedure can
Magnitude® chillers are designed for indoor, non-freezing affect the equipment warranty.
installation only. The chillers use refrigerant HFC-134a that The standard limited warranty on this equipment covers parts
operates at a positive pressure over the entire operation range, that prove defective in material or workmanship. Specific
so no purge system is required. details of this warranty can be found in the warranty statement
Only normal field connections such as water piping, relief valve furnished with the equipment.
piping, electric power, and control interlocks are required,
NOMENCLATURE
W M C 290 D CS
Water-Cooled Vintage/Single Circuit
Power Panel
Compressor #1
Compressor #2
Control Panel
Evaporator Vessel
Operator
Interface Touch
Screen (OITS)
Tube Sheet
NOTE: Unit shown with right-hand water connections. Water connection orientation is based on facing the unit power panel.
Unit Controller 1
The purpose of the MicroTech® II unit controller is to acquire
and process data relating to chiller operation, issue instructions
to various components of the chiller, and maintain controlled
operation of the chiller. As a part of operating the chiller
successfully, the unit controller offers necessary condenser
water control. See “Condenser Water Temperature Control” on 2
page 9 for more information.
The controller is located in the control panel, as shown in
Figure 3. It has a 4x20 LCD display and keys for accessing
data and changing setpoints. The controller sends information
to the operator interface touch screen (OITS) for graphic
display. If the OITS should become inoperable, the controller
LCD can display most of the same information as the OITS and
can be used to operate the chiller independently of the OITS.
See “The Controller” section on page 48 for information.
The unit should be inspected immediately after receipt for There are several identification nameplates on the chiller:
possible damage. All McQuay International centrifugal water • The unit nameplate is located on the Unit Control Panel.
chillers are shipped FOB factory and all claims for handling and Both the Model No. and Serial No. are unique to the unit
shipping damage are the responsibility of the consignee. and will identify it. These numbers should be used to
On units with factory-installed insulation, the insulation identify the unit for service, parts, or warranty questions.
is removed from the vessel lifting hole (also used for This plate also has the unit refrigerant charge and
transportation tie-downs) locations and is shipped loose. It electrical ratings.
should be secured in place after the unit is finally placed. • Vessel nameplates are located on the evaporator and
Neoprene vibration isolation pads are shipped loose in the condenser. They have a National Board Number (NB)
power panel. If the unit is equipped with a shipping skid, leave and a serial number, either of which identify the vessel
the skid in place until the unit is in its final position. This will aid (but not the entire unit).
in handling the equipment.
CAUTION Location
Extreme care must be used when rigging the unit to prevent WMC chillers are intended only for installation in an indoor or
damage to the control panels and refrigerant piping. See the weather protected area consistent with the NEMA 1 rating on
certified dimension drawings included in the job submittal for the chiller, controls, and electrical panels. Equipment room
the weights and center of gravity of the unit. If the drawings temperature for operating and standby conditions is 40°F to
are not available, consult the local McQuay International sales 104°F (4.4°C to 40°C).
office for assistance.
The unit can be lifted by fastening the rigging hooks to the
four corners of the unit where the rigging eyes are located. A Clearance
spreader bar must be used between the rigging lines to prevent The unit must be placed in an area that allows for adequate
damage to the control panels, piping, and electrical panels. clearance around the unit. See Figure 5 for clearance
The spreader-bar length should be equal to, or no more than requirements around the sides of the chiller. Doors and
1-foot shorter than, the distance between the lifting holes removable wall sections can be utilized to meet these
located at opposite ends of the chiller. The unit will require a clearance requirements. There must be a minimum 3-feet
single spreader-bar of this length capable of supporting 1.5 clearance above the top of the chiller. The U.S. National
times the shipping weight of the unit. Separately, all cables and Electric Code (NEC) or local codes can require more clearance
hooks by themselves must also be capable of supporting 1.5 in and around electrical components and must be checked for
times the shipping weight of the unit. compliance.
If a knockdown option was ordered on the unit, reference the
Knockdown Installation Manual for more information.
Minimum 3’ Clearance
Minimum 4’ Clearance
in front of control boxes and electrical panels
NOTE: Hinged type waterboxes may require more clearance. Consult a McQuay International sales representative for details.
Condenser Water pressure is reached. As heat builds, the valve will open
slowly until a full flow condition from the cooling tower
Temperature Control is established. A separate power source is required to
provide power to the valve actuator.
Condenser water control is an important consideration in chiller
3. VFD Operating with a Condenser Water Pump
plant design since condenser water temperature will directly
impact chiller operation and efficiency. When the ambient A third method of condenser control for startup is
wet bulb temperature is lower than peak design, the entering utilizing a variable frequency drive with the condenser
condenser water temperature from the cooling tower can water pump. The speed will change as directed by the
be allowed to fall, improving chiller performance. However, MicroTech® II output signal until design flow is reached.
operational issues may occur when the condenser water Speed adjustments may be required during the initial
temperatures are either too high or too low. The WMC chiller chiller startup as determined by the service technician.
provides several options to assist the chiller plant designer in NOTE: Not using the MicroTech® II logic to control valves
providing the optimum control of condenser water temperature. and variable frequency drives may result in system
instability, capacity reduction, and issues starting the
Cooling Tower Control chiller with cold condenser water temperature.
Control of the cooling tower is required to maintain stability and
avoid operational issues. This can be achieved through a BAS Condenser Pump Sequencing
or by using the MicroTech® II controller. For systems utilizing a It is recommended to utilize the logic built into the MicroTech® II
common condenser water loop for multiple purposes, the BAS controller to start the condenser pump and maintain condenser
contractor must provide the control but use of the MicroTech® II head pressure control. MicroTech® II has the capability to
output signal is still recommended. operate a primary pump and a secondary standby pump. The
The preferred cooling tower control utilizes a variable speed condenser water flow should be stopped when the chiller shuts
fan. MicroTech® II will provide a control signal to determine the off. This will conserve energy and prevent refrigerant from
proper fan speed. It can also control up to four stages of fan migrating to the condenser.
cycling. Note that fan cycling can cause cooling tower water
temperature to fluctuate as fans stage on/off, potentially adding Lenient Flow Operation
instability to the system. For chiller startup, the condenser control systems can reduce
Special consideration must be given to starting the chiller when the flow to very low rates, which can make operation of a flow
cold condenser water is present, such as with inverted starts or sensing device questionable. The MicroTech® II controller has
changeover from free (tower) cooling to mechanical cooling. It a “lenient flow” feature that acts as an override of the flow
is required that some method be used to control the condenser sensor while protecting the chiller by monitoring a condenser
water to maintain proper head pressure as indicated by the pressure setting that is below the high pressure cutout.
MicroTech® II controller.
Acceptable methods include the following (Each of these
Water Side Economizer Cycle Operation
options can be controlled by the MicroTech® II or through Water side economizers are commonly used for ASHRAE 90.1
a BAS utilizing the MicroTech® II output signals.): compliance and energy savings. This system utilizes a heat
exchanger external to the chiller when cold cooling tower water
1. Three-Way Bypass Valve Operation
is available to provide cooling. The most common system
A traditional method for building condenser pressure at has a heat exchanger used in conjunction with the chiller’s
startup with colder condenser water is with the use of evaporator.
a three-way bypass valve. The device blends warmer
The BAS contractor will need to provide controls for the heat
water leaving the condenser with cooler water from the
exchanger including isolation valves and temperature control.
cooling tower at the condenser inlet. The bypass valve
The BAS contractor will also need to control the isolation
position will change until full flow from the tower to the
valves for the chiller. It is important to use slow-acting type
condenser is obtained. The MicroTech® II provides only
valves to prevent rapid changes in system flows. Changeover
the valve position control signal. Main power to drive the
from economizer cooling to mechanical cooling requires one
valve’s actuator must be provided by the installer. The
of the methods previously mentioned to maintain suitable
three-way valve should be located close to the chiller
condenser head pressure.
within the equipment room to minimize the volume of
water. Contact your local McQuay International representative for
more information on this application.
2. Two-Way Valve Operation
Another condenser control method is to use a modulating
two-way control valve located on the outlet connection of
the condenser. The valve will be nearly closed at startup
to restrict water flow, which keeps generated heat in
the condenser until an acceptable minimum condenser
Relief Valves the three-way valve is pulled back completely, the valve is in
“Back Seated Position” and all refrigerant will flow through the
As a safety precaution and to meet code requirements, each front outlet port as shown in Figure 10.
chiller is equipped with pressure relief valves located on
the condenser and evaporator for the purpose of relieving Figure 9: Three-Way Valve, Front Seated Position
excessive refrigerant pressure (caused by equipment
malfunction, fire, etc.) to the atmosphere.
• Condensers have two 200 psi, 1.0-inch female NPT relief
valves as a set with a three-way valve separating the two
valves. (See Figure 8.) One valve remains active at all
times and the second valve acts as a standby.
• Evaporators have a single 200 psi valve. Each valve has
a 1.0-inch female NPT connection.
• When purchased with a suction isolation valve, each
suction line has a single 200 psi relief valve rated at 6.9
lb/min air with a 3/8-inch flare connection.
• Vessel valve capacity is 75 lb/min air.
CAUTION
Units are shipped with refrigerant valves closed to isolate the Figure 10: Three-Way Valve, Back Seated Position
refrigerant in the unit condenser. Valves must remain closed
until startup by the factory service technician.
Most codes require that relief valves be vented to the outside
of a building. Relief piping connections to the relief valves must
have flexible connectors.
Remove plastic shipping plugs (if installed) from the inside of
the valves prior to making pipe connections. Whenever vent
piping is installed, the lines must be in accordance with local
code requirements; where local codes do not apply, the latest
issue of ANSI/ASHRAE Standard 15 code recommendations
must be followed.
Relief Valves
Figure 12: Wiring Index
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Installation
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Figure 13: Controller Box Wiring
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NOTES:
UNIT CONTROL BOX FACTORY ASSEMBLY:
JUMPERS WJ1 AND WJ2 MUST ONLY BE CONNECTED TO TERMINAL BLOCK 33.
CHILLER FACTORY ASSEMBLY:
IF OPTIONAL GFP1 IS USED THEN REMOVE JUMPER WJ1. OTHERWISE COMPLETE CONNECTION WJ1 TO TERMINAL BOLOCK 38.
IF OPTIONAL GFP2 IS USED THEN REMOVE JUMPER WJ2. OTHERWISE COMPLETE CONNECTION WJ2 TO TERMINAL BOLOCK 39.
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Pre-Start Checklist
It is important that the operator become familiar with the As load decreases, the compressors will unload to
equipment and the system before attempting operation. During sustain the water temperature set point by reducing
the initial startup of the chiller, the McQuay International speed until the minimum speed limit has been reached.
technician will be available to answer any questions and If further unloading is required, the IGV assemblies will
instruct the proper operating procedures. It is recommended close as required to satisfy the load.
that the operator maintain an operating log for each individual 7. Staging down to one compressor running
chiller unit. In addition, a separate maintenance log should be
kept of the periodic maintenance and servicing activities. With the chiller running two compressors on condition
and the building load reducing to the point that one
compressor can carry the load, compressor wear
Operator Schools balancing logic will again determine which compressor to
shutdown.
Training courses for Magnitude® Centrifugal Maintenance and
8. Chiller shutdown
Operation are held through the year at the Daikin Learning
Institute in Staunton, Virginia. The school duration is three and The remaining compressor will adjust capacity to
one-half days and includes instruction on basic refrigeration, manage the chiller load until the load increases to the
MicroTech® II controllers, enhancing chiller efficiency and point where another compressor is needed, or the load
reliability, MicroTech® II troubleshooting, system components, reduces below the minimum capacity of one compressor
and other related subjects. For more information, visit us and the leaving water temperature goes below set point
at www.DaikinApplied.com and click on Training or call the and reaches the stop delta temperature. Anytime the
Training Department. Refer to the back cover of this document chiller is disabled, it will perform an orderly unload and
for contact information. shutdown both compressors.
Figure 15: OITS Screen Layout Figure 16: Home View Screen
HOME
SCREEN
SETPOINTS HISTORY
TIMERS
VALVE TREND
OR
SERVICE TOWER ALARM
HISTORY
MOTOR
MODES
WATER
BAR GRAPHS
• Any type of alarm will cause the ALARM button to appear.
UNIT I/O
Pressing the ALARM button will bring up the Active
CHILLER
Alarms Screen (Figure 52 on page 43) to view the
COMPRESSOR STATE
alarm details. For more information on alarms, see page
COMPRESSOR I/O
42 through page 47.
UNIT I/O
(II) Information
EVAPORATOR
CONDENSER
• Chilled water setpoint (ACTIVE LWT SETPOINT)
• Entering and leaving evaporator water temperatures
• Entering and leaving condenser water temperatures
• Percent unit RLA
VIEW Screens • UNIT STATUS, which is MODE followed by STATE
View screens are used for looking at unit status and conditions. followed by the SOURCE that is the device or signal
that created the STATE. The possible combinations are
Home View Screen shown in Table 3.
The Home View Screen (Figure 16) shows the basic operating Table 3: UNIT STATUS Possibilities
condition of the chiller and is the screen that is normally left
on. Note that the chiller displayed on this screen, as well as on MODE STATE SOURCE
all other screens that display an image of the chiller, will show COOL OFF Manual Switch
either one or two compressors depending on the chiller model. SHUTDOWN Remote Switch
AUTO Local
BAS Network
RUN Load
RUN Hold Normal operation
RUN Unload
Unloading during the shutdown
SHUTDOWN Unload sequence
The Compressor State Information is basically a compilation Pressing the EVAP or COND buttons on Detail View Screen
of the events that the chiller sequences through at startup. A will display pertinent vessel temperatures and pressures. The
green light indicates that a particular sequence requirement Evaporator Information and Condenser Information are shown
has been satisfied. It is recommended that this information in Figure 21 and Figure 22, respectively.
be viewed during the startup sequence. One can see the
requirements light up as they are met and quickly see why a Figure 21: Evaporator Information
non-start may have occurred. For instance, the “Evap Flow
OK” item will light when the evaporator flow switch is closed
by flow. The bottom sections (from “RUN” down) of the
Compressor State Information are in effect during the shut
down process. The sequence transitions back to OFF at this
point and the OFF light will be illuminated.
Pressing the I/O button on the Detail View Screen displays the
status of the compressor digital inputs and outputs, as shown
in Figure 19, on the right side of the Detail View Screen. Use
the COMP button to toggle between the two compressors’
data. Many of the inputs and outputs shown in the Compressor
Inputs/Outputs Information will also appear under the
Compressor State Information (Figure 18) since they are part
of the startup sequence and define the compressor state at
any given time.
Figure 23: Unit Inputs/Outputs Information The Bar Graphs Screen (Figure 25) is accessed by pressing
the BAR GRAPHS button from the View Menu Screen (Figure
24). If information is present on the right side of the View
Menu Screen before pressing the BAR GRAPHS button, that
information will appear to the right of the Bar Graphs Screen
as well. In Figure 25, for example, the Compressor State
Information is shown to the right of the screen. Bar graphs with
labels can be viewed by pressing the LABELED BAR GRAPHS
button on the View Menu Screen.
SET Screens
The Setpoint Screens on the Operator Interface Touch Screen required to meet job conditions. Certain settings involving
(OITS) are used to input the many setpoints associated pumps and tower operation are field set.
with equipment of this type. MicroTech® II provides a Pressing the SET button found on almost every screen
simple method for accomplishing this. (Note that if the accesses the last Setpoint Screen used or the Service Screen,
OITS is unavailable, the controller can be used to change whichever of the two was used last. When in any Setpoint
setpoints.) Appropriate setpoints are factory set and checked Screen, pressing the SET button again will toggle to the
by a McQuay International service representative during Service Screen, shown in Figure 47 on page 40. A typical
commissioning; however, adjustments and changes are often Setpoint Screen is displayed in Figure 26 below.
Unit Status
Compressor
Status
Setpoint
Description
Range of
Settings
Numeric
Keypad
Figure 26 shows the WATER Setpoint Screen. The various The numbered Setpoint Selection buttons are pressed to
setpoint groups are in a column on the right side of the screen. select a particular setpoint. The selected setpoint will appear
Each button contains a number of setpoints grouped together in blue on the screen and a description of it (with the range of
by similar content. The WATER button, for example, contains available settings) will appear in the upper left-hand box.
various setpoints relating to water temperature setpoints.
NOTE: Some setpoints that do not apply to a particular unit
application may still be listed on the screen but will be
grayed out. They will be inactive and can be ignored.
Procedure for Changing a Setpoint 7. Setpoints with numeric values can be changed in two
ways:
A list of setpoints along with their default value, available
setting range, and password authority can be found in the • Select the desired value by pressing the numbered
tables under each Setpoint Screen, starting on page 28. buttons on the Numeric Keypad. Press ENTER
Follow the steps listed below in order to change a setpoint. to enter the value or CANCEL to cancel the
transaction.
CAUTION • Press the UP or DOWN button to increase or
Many setpoints are interactive. Changes may have an adverse decrease the value displayed. Press ENTER
effect on chiller operation. Only trained operators should be to enter the value or CANCEL to cancel the
allowed to change chiller setpoints. transaction.
1. Press the applicable Setpoint Group. (A complete Some setpoints are text rather than numeric values.
explanation of setpoint content of each group follows this For example, LWT Reset Type on the WATER Setpoint
section.) Screen (Figure 45 on page 39) can be “None” or “4-20
ma.” The selection can be made by toggling between
2. Select the desired setpoint by pressing the numbered choices using the UP or DOWN button. If dashed lines
Setpoint Selection button. appear in the setpoint window it means that toggling in
3. Press the CHANGE button to change a setpoint value. that direction can go no further, so reverse direction.
The Keyboard Screen, as shown in Figure 27, will Press ENTER to enter the choice or CANCEL to cancel
be turned on automatically to facilitate entering the the transaction.
password. Once CHANGE is selected, the CANCEL or ENTER
buttons must be pressed before another setpoint can be
Figure 27: Keyboard Screen selected.
8. Additional setpoints can be changed by selecting another
setpoint on the screen using the Setpoint Selection
buttons or by selecting an entirely new group of setpoints
using the Setpoint Group buttons.
Explanation of Setpoints
There are seven setpoint groups shown on the Setpoint
Screens:
1. TIMERS, sets timers such as start-to-start, etc.
2. ALARMS, sets the limit and shutdown alarms.
3. VALVE, sets the parameters for operation of an optional
field-installed tower bypass valve.
4. TOWER, selects the method of controlling the cooling
tower and sets the parameters for fan staging/VFD.
5. MOTOR, selects motor related setpoints such as amp
limits. Also has maximum and minimum rate of change of
4. Input the appropriate password number. (Use 100 for
chilled water temperature.
operator level or 2001 for manager level. The technician
level password is only provided to Daikin Applied 6. MODES, selects various modes of operation such as
technicians) There is a small delay between pressing the control source, multiple compressor staging, pump
keypad and recording the entry. Be sure that an asterisk staging, BAS protocol, etc.
appears in the window before pressing the next number. 7. WATER, sets leaving water temperature setpoint, start
5. After inputting the password on the Keyboard Screen, and stop delta-T, resets, etc.
press ENTER to return to the Setpoint Screen. The Each of the seven setpoint groups are detailed in the following
password will remain open for 15 minutes after initiation pages.
and does not need to be re-entered during this period.
6. Press CHANGE again on the Setpoint Screen. The right
side of the screen will become inactive (the background
will turn blue). The Numeric Keypad and Action buttons
in the lower left-hand corner of the screen will become
active (the background will turn green).
TIMERS Setpoints
NOTE: In Table 5 and in the rest of the Setpoint tables on the following pages, the letters in the Password column refer to the
following:
• O = Operator Level (the password number for operator level is 100)
• M = Manager Level (the password number for manager level is 2001)
• T = Technician Level (the password number for technician level is only provided to McQuay International technicians)
ALARMS Setpoints
NOTE: The setpoints listed in Table 6 should only be changed by a McQuay International technician. Contact a
McQuay International service representative for more information.
Table 7: Tower Bypass VALVE Setpoint Settings (See page 32 for complete explanation.)
NOTE: Table 7 relies on Setpoints 1 and 2 in Table 8 on page 31. The setpoints listed in Table 7 should only be changed by a
McQuay International technician. Contact a McQuay International service representative for more information.
Table 8: Tower Fan Setpoint Settings (See page 32 for complete explanation.)
Explanation of Tower Control Settings Figure 34: TOWER Setpoint - SP2 - (II) VALVE SP
There are five possible tower control strategies: (I) NONE, Cooling Tower
(II) VALVE SP, (III) VALVE STAGE, (IV) VFD STAGE, and Fan Staging
(Up to 4 fans)
(V) VALVE SP / VFD STAGE. These control strategies are Tower
selected from the TOWER Setpoint Screen (see Figure 31 Control
on page 31) using Setpoint 2. (In the following pages, “SP” Panel
means “Setpoint.”) An explanation of each control strategy
follows this paragraph. Along with each explanation is a Bypass Line Bypass
diagram and graph to help illustrate the control strategy. Note MicroTech® II Valve
that these graphs illustrate the default conditions for each Controller 0-10 VDC Signal
strategy. See "Setting Tower Control Using the OITS Panel"
on page 34 for details on how to set these tower control Condenser
strategies.
(I) NONE: This control strategy is tower fan staging only.
This is not a recommended strategy. In this mode the Figure 35: (II) VALVE SP - Valve Opening vs. Temperature
tower fan staging (up to four stages) is controlled by
either the condenser Entering Water Temperature (EWT) 100
or LIFT pressure (difference between the condenser and
Cooling Tower 20
Fan Staging
(Up to 4 fans)
Tower 0
Control 60 65 70 75 80 85 90
Panel Temperature (°F)
Fan Staging
85 (Up to 4 fans)
Tower
80
Control
75 Panel
70
Bypass Line Bypass
65 MicroTech® II Valve
0 1 2 3 4 5 Controller 0-10 VDC Signal
Fan Stages
Condenser
Figure 37: (III) VALVE STAGE - As shown in Figure 39, the default minimum and maximum
Valve Opening vs. Temperature VFD speeds are 20% and 100%, respectively. These minimum
and maximum values are adjustable anywhere between 0%
100
and 100%. Additional fans stage on when the VFD speed
80 reaches the maximum value that was set.
Valve Opening (%)
(IV) VFD STAGE: In this mode, a VFD controls the first fan.
Up to three more fans are staged on and off and there is
no bypass valve. See Figure 38 and Figure 39. Figure 41: (V) VALVE SP / VFD STAGE
Percent vs. Temperature
Figure 38: TOWER Setpoint - SP2 - (IV) VFD STAGE 100
Cooling Tower
Fan Staging 80
(Up to 4 fans) Tower
Percent (%)
Control 60
0-10 VDC Panel
Signal w/ Fan 40
VFD
20
MicroTech® II 0
Controller
60 65 70 75 80 85 90
Temperature (°F)
Condenser
% VFD Speed (4 Fan Stages) % VFD Speed (1 Fan Stage)
% Valve Opening
Figure 39: (IV) VFD STAGE - VFD Speed vs. Temperature
As shown in Figure 41, the default minimum and maximum
100
VFD speeds are 20% and 100%, respectively. These minimum
80 and maximum values are adjustable anywhere between 0%
and 100%. Additional fans stage on when the VFD speed
VFD Speed (%)
0
65 70 75 80 85 90
Temperature (°F)
4 Fan Stages 1 Fan Stage
BAS Alternate each of the five tower control strategies are provided next.
In control strategies (I) through (V), the chiller MicroTech® II (I) NONE: Tower Fan Staging Only (This is the default
is directly controlling the cooling tower fan staging, variable setting but it is NOT a recommended control strategy.)
frequency drives, and bypass valves. As an alternative, a BAS The following settings are used for the Tower Fan Staging Only
can control these components based on a signal from the mode, (SP = setpoint)
MicroTech® II controller. See Figure 42.
A. TOWER Setpoint Screen
Figure 42: BAS Alternate 1. SP1. Select TEMP if control is based on condenser
EWT or LIFT if based on compressor lift expressed in
pressure.
Tower
BAS 2. SP2. Select NONE for no bypass valve or fan VFD
Control
Panel control.
w/ Fan
VFD
3. SP3. Select one to four fan outputs depending on the
number of fan stages to be used. More than one fan
Bypass Line can be used per stage through the use of relays.
MicroTech® II
0-10 VDC Signal 4. SP4. Select STAGE UP TIME from 1 to 60 minutes.
Controller
The default value of 2 minutes is probably a good
Condenser
starting point. The value may need to be adjusted later
depending on actual system operation.
5. SP5. Select STAGE DOWN TIME from 1 to 60
Setting Tower Control Using the OITS Panel minutes. The default value of 5 minutes is probably
a good starting point. The value may need to be
MicroTech® II may assist in the head control either directly adjusted later depending on actual system operation.
or through inputs to a BAS to optimize performance and
efficiency. Using the MicroTech® II, up to four Digital Outputs of 6. If TEMP is selected in SP1, use
Tower Staging along with three Analog Outputs (0-10 VDC) are a. SP6. Select STAGE DIFFERENTIAL in degrees F.
available. The three Analog Outputs are as follows: Start with default of 3°F.
1. Bypass Valve signal b. SP8-11. Set the STAGE ON temperatures
2. Tower Fan VFD signal consistent with the temperature range over which
the condenser EWT is desired to operate. The
3. Tower Reset signal: Defined by a voltage to offset the default values of 70°F, 75°F, 80°F and 85°F are a
tower control setting. If the MicroTech® II is controlling good place to start in climates with moderate wet
the tower, this signal is not used. bulb temperatures. The number of STAGE ON
Setup for any tower control will be accomplished on the OITS setpoints used must be the same as SP3.
using the TOWER Setpoint Screen (see Figure 31 on page 7. If LIFT is selected in SP1, use
31) and the VALVE Setpoint Screen (see Figure 30 on page
30). a. SP7. Select STAGE DIFFERENTIAL in PSI. Start
with default of 6.0 PSI.
Setpoint 1 (Cooling Tower Control) on the TOWER Setpoint
Screen sets the type of control. NONE is selected as default. b. SP12-15. Start with default setpoints. The number
Choose TEMP for entering condenser water control or LIFT to of STAGE ON setpoints used must be the same as
define the lift pressure between the Evaporator Pressure and SP3.
the Condenser Pressure. (II) VALVE SP: Tower Fan Staging With Bypass Valve
Setpoint 3 (Cooling Tower Stages) on the TOWER Setpoint Controlling Minimum EWT
Screen sets the number of tower stages that the tower has. A. TOWER Setpoint Screen
Setpoint 2 (Tower Bypass Valve / Fan VFD) on the TOWER 1. Use all of the same setpoint settings as those outlined
Setpoint Screen defines if and how the first two MicroTech® in section I.A [the TOWER Setpoint Screen section for
II Analog Outputs (Bypass Valve signal and Tower Fan VFD control strategy (I) NONE] except for SP2. For SP2,
signal) will be used with the Staging selected for the tower. A select VALVE SP for control of the bypass valve based
BAS or other control may monitor these outputs to understand on temperature or lift.
when or how much the MicroTech® II would recommend for
B. VALVE Setpoint Screen
proper head control on the WMC unit. The third Analog Output
(Tower Reset) is only configurable from the MicroTech® II 1. SP1. Select NC or NO depending if valve is normally
controller. Commissioning setup of this 0-10 VDC signal, that closed to the tower with no control power or normally
will represent the MicroTech® II recommending increased open to the tower with no control power.
head pressure by a reset voltage, is typically done by the 2. If TEMP was selected for SP1 on the TOWER
McQuay International startup technician. Setup instructions for
Setpoint Screen, use the following on the VALVE (III) VALVE STAGE: Tower staging with bypass valve
Setpoint Screen: controlled by fan stage
a. SP2. Set the VALVE TARGET. This setpoint is A. TOWER Setpoint Screen
usually 5°F below the minimum fan stage setpoint 1. Use all of the same setpoint settings as those outlined
established in SP8 of the TOWER Setpoint Screen. in section I.A [the TOWER Setpoint Screen section for
This keeps full flow through the tower until the last control strategy (I) NONE] except for SP2. For SP2,
fan is staged off. The default for SP2 is 65°F. select VALVE STAGE. .
b. SP4. Set VALVE DEADBAND. The default of 1.0°F B. VALVE Setpoint Screen
is a good place to start.
1. Use all of the same setpoint settings as those outlined
c. SP12. Set the minimum position to which the valve in section II.B [the VALVE Setpoint Screen section for
can go. The default is 10%. control strategy (II) VALVE SP]. In addition, set the
d. SP13. Set the maximum position to which the following:
valve can go. The default is 100%. a. SP6. Set STAGE UP (valve position % open)
e. SP14. Set the control gain for error. The default is above which the first fan can stage on. Fan
20. STAGE#X ON temperature from SP8-11 on the
TOWER Setpoint Screen and FAN STAGE UP
f. SP15. Set the control gain for slope. The default
is 1. TIME from SP4 on the TOWER Setpoint Screen
must also be satisfied. The default for SP6 is 80%.
CAUTION b. SP7. Set STAGE DOWN (valve position % closed)
Setpoints 14 and 15 on the VALVE Setpoint Screen are site below which the first fan can stage off. Fan
specific, dealing with system fluid mass, component size, and STAGE#X ON temperature form SP8-11 on the
other factors affecting the reaction of the system to control TOWER Setpoint Screen and FAN STAGE DOWN
inputs. To avoid possible equipment damage, these setpoints TIME from SP5 on the TOWER Setpoint Screen
should be set by personnel experienced with setting up this must also be satisfied). The default for SP7 is 20%.
type of control. (IV) VFD STAGE: Fan VFD, no bypass valve
A. TOWER Setpoint Screen
3. If LIFT was selected for fan control, use:
1. Use all of the same setpoint settings as those outlined
a. SP3. Set the VALVE TARGET. This setpoint is
in section I.A [the TOWER Setpoint Screen section
usually 5 psi below the minimum fan stage setpoint
for control strategy (I) NONE] except for SP2. For
established in SP12 of the TOWER Setpoint
SP2, select VFD STAGE for control of the VFD speed
Screen. This keeps full flow through the tower until
based on temperature or lift.
the last fan is staged off. The default for SP3 is 30
psi. (V) VALVE SP/VFD STAGE: Fan VFD, no bypass valve
b. SP5. Set VALVE DEADBAND, the default of 1.0 A. TOWER Setpoint Screen
psi is a recommended initial setting. 1. Use all of the same setpoint settings as those outlined
c. SP12. Set the minimum position to which the valve in section I.A [the TOWER Setpoint Screen section for
can go. The default is 10%. control strategy (I) NONE] except for SP2. For SP2,
select VALVE SP/VFD STAGE.
d. SP13. Set the maximum position to which the
valve can go. The default is 100%. B. VALVE Setpoint Screen
e. SP14. Set the control gain for error. The default is 1. Use all of the same setpoint settings as those outlined
20. in section II.B [the VALVE Setpoint Screen section for
control strategy (II) VALVE SP].
f. SP15. Set the control gain for slope. The default
is 1.
CAUTION
Setpoints 14 and 15 on the VALVE Setpoint Screen are site
specific, dealing with system fluid mass, component size, and
other factors affecting the reaction of the system to control
inputs. To avoid possible equipment damage, these setpoints
should be set by personnel experienced with setting up this
type of control.
NOTE: Setpoints that have a technician level password (T) should only be changed by a McQuay International technician.
Contact a McQuay International service representative for more information.
CAUTION
* Chiller Nameplate RLA MUST match chiller dataplate per compressor.
MODES Setpoints
NOTES:
1. If both compressors have the same sequence number, they will automatically balance starts and run-hours.
2. Setpoints 11 through 14 display compressor staging strategy.
WATER Setpoints
Alarm History Screen Although the Alarm History Screen only displays the eight most
current alarms, a record of ALL alarms is stored in the OITS
The Alarm History Screen (Figure 50) is accessed from the
PC. Note that this record may include alarms that occurred
Trend History Screen by pressing the HISTORY button again.
when the chiller was in the factory. This record is maintained
even if the OITS PC is powered off. When the OITS is powered
Figure 50: Alarm History Screen back on, the last eight alarms will show back up on the Alarm
History Screen and all alarm history will still be available for
download. (The download process is described next.) If an
alarm occurs and is cleared when the OITS PC is powered off,
it will not be recorded in the alarm history.
The Alarm History Screen can be used to download the trend
history (Figure 49) or the alarm history (Figure 50) via USB. In
order to download the trend or alarm history, first insert a USB
drive into the left side of the OITS PC (see Figure 3 on page
5 if help is needed to identify the OITS PC). The OITS PC
will have two USB ports. Insert the USB drive into the USB port
closer to the front of the OITS PC.
NOTE: In order to prevent viruses from being transferred
from the USB drive to the OITS, it is important that
a clean USB drive is used. Do NOT use a USB drive
that contains any auto-executable files.
If a directory screen opens when the USB drive is inserted,
close out of that screen and continue with the directions
There are three types of alarms: instructed below.
1. Fault (Red)- This is an equipment protection alarm that To Download Trend History:
shuts a unit or compressor off. • Make sure that the “History File” text field on the right
2. Problem (Yellow)- This is a limit alarm that limits side of the Alarm History Screen shows a date. If it shows
compressor loading in response to an out-of-normal “ALARMS” rather than a date, press either the PREV
condition. If the condition that caused a limit alarm is or NEXT button. (Pressing the PREV button when the
corrected, the alarm light will be cleared automatically. “History File” text field shows “ALARMS” will bring up
yesterday’s date. Pressing the NEXT button when the
3. Warning (Dark Blue)- This is a notification only. The “History File” text field shows “ALARMS” will bring up
controller takes no action in response to this alarm. today’s date.)
The Alarm History Screen displays a maximum of eight alarms • Use the PREV or NEXT button to change the date in the
with the most current alarm listed on top. Each alarm displays “History File” text field to the desired date. The dates will
the date stamp, action taken, and the cause of the alarm. As stop scrolling when the last file in that direction has been
shown in Figure 51, clicking on a listed alarm will bring up more reached. (The OITS PC will store 30 days of history at a
details about that particular alarm at the top of the screen. minimum. More days might be stored depending on the
trend history file sizes. The OITS PC will automatically
Figure 51: Alarm History Screen with Alarm Detail delete old trend history files as needed to make room for
new trend history files.)
• Take note of the file size of that date’s history by viewing
the “Size” text field. Press the COPY to USB button and
watch the file size in the “Size” text field count up to the
noted file size. Once this text field has stopped counting
and has reached its actual file size, the download of that
file to the USB is complete.
• Repeat this process for each desired day of trend history.
Each day must be downloaded individually. It is not
possible to download multiple days of trend history at
once.
To Download Alarm History: The current active alarms (there may be more than one) will be
displayed on the Active Alarms Screen. Alarms are arranged
• Make sure that the “History File” text field on the right side
in order of occurrence, with the most recent on top. The date/
of the Alarm History Screen shows “ALARMS.” If it shows
time and cause of the alarm are displayed. See the "Possible
a date instead, press the ALARMS button.
Alarms and Events" section starting on page 44 for specifics
• Take note of the file size of the alarm history by viewing on alarms that may occur.
the “Size” text field. Press the COPY to USB button and
watch the file size in the “Size” text field count up to the After eliminating the cause of the alarm, clear the alarm by
noted file size. Once this text field has stopped counting pressing the CLEAR button. This will clear the alarm from
and has reached its actual file size, the download of the the register and allow the unit to restart after going through
alarm history to the USB is complete. (Note that unlike the start sequence. The alarm notice will be deleted from the
the trend history files, alarm history only has one file.) screen.
Viewing/Using Trend History and Alarm History Files: If the cause of the alarm is not remedied, the alarm is still
active and the alarm message will remain open. The unit will
• Trend history file names will be displayed as
not begin its starting sequence.
“HCXXXXXX”, where the first two X’s will be numbers to
indicate the year, the second two X’s will be numbers to
indicate the month, and the last two X’s will be numbers
to indicate the day. For example, if there is a file called
HC140510, it indicates that the file contains trend history
from 5/10/2014.
• The alarm history file name will be displayed as “alarms.”
• All trend history and alarm history files are saved from
the OITS PC as .csv files. These files can be opened on
a normal PC and manipulated using Microsoft Excel for
personal use. If tech support is requested, the original
(un-manipulated) .csv files must be sent to Daikin
Applied. Any other file formats are NOT accepted.
Fault Alarms
Equipment protection faults cause rapid compressor shutdown. The compressor is stopped immediately (if the compressor was
running).
Auto-clears
High Condenser Pressure Circuit 1 COMPR STOP - Condenser Pressure High Locked off if Tripped 3x in 50 min
Auto-clears
High Condenser Pressure Circuit 2 COMPR STOP - Condenser Pressure High Locked off if Tripped 3x in 50 min
Auto-clears
High Discharge Temperature Circuit 1 COMPR STOP - Discharge Temperature High Locked off if Tripped 3x in 50 min
Auto-clears
High Discharge Temperature Circuit 2 COMPR STOP - Discharge Temperature High Locked off if Tripped 3x in 50 min
COMPR STOP - Compressor Fault
Starter Fault Compressor 1 Reset is dependent on specific alarm
(previously used for WMC general compressor fault)
COMPR STOP - Compressor Fault
Starter Fault Compressor 2 Reset is dependent on specific alarm
(previously used for WMC general compressor fault)
COMPR STOP - Compressor Comm Loss
No Starter Transition Comp 1 Auto-clears
(previously used for compressor communication error)
COMPR STOP - Compressor Comm Loss
No Starter Transition Comp 2 Auto-clears
(previously used for compressor communication error)
General Compressor Fault 1 COMPR STOP - Compressor Fault Reset is dependent on specific alarm
General Compressor Fault 2 COMPR STOP - Compressor Fault Reset is dependent on specific alarm
Communication Fault 1 COMPR STOP - Compressor Comm Loss Auto-clears
Communication Fault 2 COMPR STOP - Compressor Comm Loss Auto-clears
Interlock Fault NO START - Interlock Fault Auto-clears
Interlock Fault 2 NO START - Interlock Fault Auto-clears
Problem Alarms
Problems do not cause compressor shutdown but do limit operation of the chiller.
Warning Alarms
Warnings only generate a warning message to the operator. Chiller operation is not affected.
Events
Events do not generate a warning message to the operator but they may notify the BAS, if used. Chiller operation may be affected
by events.
The four arrow keys (UP, DOWN, LEFT, RIGHT) have three Top Level Menu Selection 2nd Level Menu Screen
modes of use:
< ALARM ALARM < ACTIVE
1. Select a specific data screen in the menu matrix using
→
< VIEW < LOG
dynamic labels such as ALARM, VIEW, SET, etc. This < SET <
mode is entered by pressing the MENU key. For ease < COMMISSION <
of use, a pathway connects the appropriate button to
its respective label on the screen. See "Menu Structure < ALARM VIEW < COMPRESSOR
(Hierarchical)" on page 48 for more information.
→
< VIEW < UNIT
2. Scroll between data screens in the direction indicated < SET < EVAPORATOR
by the arrows. See "Menu Structure (Scrolled)" on page < COMMISSION < CONDENSER
49 for more information.
< ALARM SET < ALARM LIMITS
3. Change field values in the setpoint programming mode.
→
< VIEW < UNIT SPs
See "Editing Fields on the Controller" on page 52 for < SET < COMPRESSOR SPs
more information. < COMMISSION < TOWER SPs
2nd Level Menu Selection Data Screen In order to toggle between these two screens:
1. Use the DOWN arrow key to scroll to the “VIEW COMP
VIEW < COMPRESSOR VIEW EVAPORATOR (7)” screen.
→
< UNIT Suct SH = 000.0°F
< EVAPORATOR Approach = 00.0°F VIEW COMP (7)
< CONDENSER Hours = 00000 x10
Starts = 00000 .
→
< UNIT UNIT < WATER State = Run
< EVAPORATOR < REFRIGERANT % RLA = 095%
< CONDENSER < TOWER Evap LWT = 054.0°F
NOTE: The notation “blank mask page” indicates that the screen does not apply to this unit.
VIEW
VIEW UNIT VIEW COMPRESSOR EVAPORATOR
VIEW UNIT STATUS(1) VIEW UNIT WATER(1)°F VIEW UNIT REFRG (1) VIEW UNIT TOWER (1) VIEW COMP (1) VIEW COMP#2 (1) VIEW EVAPORATOR
UNIT= Off GasVal 2 In Out Delta psi °F Feedback Sig=(type?) State = Off State = Run Suct SH = 000.0°F
COMP#1 Off #2Run Evap 00.0 00.0 00.0 Sat Evap 000.0 000.0 Fans ON= 0 of 2 % RLA = 000% % RLA = 095% Approach = 00.0°F
Ev/Cn Pmps= Off /Off Cond 00.0 00.0 00.0 Sat Cond 000.0 000.0 Setpoint= (type?) Evap LWT = 054.0°F Evap LWT = 054.0°F
VIEW UNIT STATUS(2) VIEW UNIT WATER(2)°F VIEW UNIT REFRG (2) VIEW UNIT TOWER (2) VIEW COMP (2) psi VIEW COMP#2 (2) psi
Comp#1 Off In Out Delta Suct Line = 000.0°F Fan Speed = None Cond Press = 000.0 Cond Press = 000.0
Start-Start Tmr Clr HtRc 00.0 00.0 00.0 Liquuid Line= 000.0°F Bypass Valve= None Evap Press = 000.0 Evap Press = 000.0
Inhibits None Cond 00.0 00.0 00.0 Lift Press = 000.0psi B-Val Sp = (type?) Lift Press = 000.0 Lift Press = 000.0
VIEW UNIT STATUS(3) VIEW UNIT WATER(3)°F VIEW COMP (3)TC Tmp VIEW COMP#2(3)TCTmp
Comp#2 Run Water Flow Rates BMCC PCB =XXX.xF BMCC PCB =XXX.xF
Start-Start Tmr Clr Evap = xxxxx GPM Backplane=XXX.xF Backplane=XXX.xF
Inhibits PulDn Cond = xxxxx GPM VFD Assembly=XXX.xF VFD Assembly=XXX.xF”
VIEWCOMP(8)HWLok VIEWCOMP#2(8)HWLok
Interlock Open Interlock Open
Mode3 Units0 Float0 Mode3 Units0 Float0
Auto Demand 000.0% Auto Demand 000.0%
VIEWCOMP(15)Motor VIEWCOMP#2(15)Motor
MaxFlow 0 Lo-Spd-Ld MaxFlow 0 Lo-Spd-Ld
Cool #2 Inv=000.0°F Cool #2 Inv=000.0°F
S_SP+0000 SPdly0000S S_SP+0000 SPdly0000S
NOTE: Screens listed in this table that have a gray background require a technician level password to manipulate.
VIEW ALARM SET UNIT SET ALARM SET TOWER SET
SET COMPRESSOR SETPOINTS
CONDENSER LOG SETPOINTS LIMITS SETPOINTS PASSWORD
VIEW CONDENSER Alarm Log: 01 SET UNIT SPs (1) SET COMP SPs (1) SET COMP#2 SPs (1) SET ALARM LMTs (1) SET TOWER SPs (1) SET PASSWORD
Disch SH = 000.0°F description Unit Enable = Off Demand Limit=Off Demand Limit=Off LowEvPrHold=27psi TowerControl=(type?) Enter
Approach = 00.0 F HH:MM:SS Unit Mode = Cool Minimum Amps=010% Minimum Amps=010% LowEvPrUnld=26psi Tower Stages=1 Password:00000
Subcooling= 00.0 F MM/DD/YY Source = Switches MaximumAmps=100% Maximum Amps=100% LowEvPrStop=25psi StageUP/Dn=080/020% No Access Given
Alarm Log: 02 SET UNIT SPs (2) SET COMP SPs (2) SET COMP#2 SPs (2) SET ALARM LMTs (2) SET TOWER SPs (2) SET PASSWORD (2)
description Available Modes StageMode =Normal StageMode =Normal HighCondPr =140psi Stage ON Tech Password
HH:MM:SS = Cool StageSequence# = 01 StageSequence# = 01 HiDschT-Load=170°F #1 #2 #3 #4 00000 00000
MM/DD/YY Select w/Unit Off Max Compr On = 02 Max Compr On = 01 HiDschT-Stop=190°F” xxx xxx xxx xxx No Access Given
Alarm Log: 03 SET UNIT SPs (3) SET COMP SPs (3) SET COMP#2 SPs (3) SET ALARM LMTs (3) SET TOWER SPs(3)Fans
description Cool LWT = 44.0°F StageDeltaT = 1.0°F StageDeltaT = 1.0°F WMC Compressor VFD Min Spd = 20.0%
HH:MM:SS Ice LWT = 25.0°F Stop-Start = 03 min Stop-Start = 03 min Oilless Design StageDiff= (type? Psi/F)
MM/DD/YY Heat LWT = 135.0°F Start-Start = 05 min Start-Start = 05 min (blank mask page) Stg Up=02 Dn=05 min
^ I SET UNIT SPs (4) SET COMP SPs (4) SET COMP#2 SPs (4) SET ALARM LMTs (4) SET TOWER SPs (4)
I v Leaving Water Temp UL Surg Ofs=200RPM Surge Slp Str=20°F Valve/VFD Control=
StartDelta= 03.0°F Name Plate RLA 140 Name Plate RLA 140 Surge Tmp Run=20°F None
StopDelta = 3.0°F MtrCurThrshld=05% Valve Type=NC
^ I SET UNIT SPs (5) SET COMP SPs (5) SET COMP#2 SPs (5) SET ALARM LMTs (5) SET TOWER SPs (5)
I v Rest Type = NONE Lead Staging = 030% Evap Freeze= 34.0°F Valve Sp= 065°F
MaxResetDT =00.0°F Nom Capacity=0100T Nom Capacity=0100T Cond Freeze= 34.0°F Reset = 20.0psi
StrtResetDT = 10.0°F HG-Bypass=30% RLA HG-Bypass =30% Sensor = ECWT-B3
^ I SET UNIT SPs (6) SET COMP SPs (6) SET COMP#2 SPs (6) SET TOWER SPs (6)
I v Soft Load = OFF IntrLokTmr=010sec Same as Comp #1 ValveStartPosition
InitialSLAmps= 020% UnloadTimer=120sec Min=010% @ 060°F
SoftLoadRamp=05min Max Str LWT=10.0°F Max=100% @ 090°F”
Alarm Log: 25 SET UNIT SPs (7) SET COMP SPs (7) SET COMP#2 SPs (7) SET TOWER SPs (7)
description Max/Min LWT Rates Vane Control WMC Automatic Valve Control Range
HH:MM:SS Max = 1.0°F/min Lead Start = 012% Vane Control Min= 010% Max= 100%
MM/DD/YY Min = 0.4°F/min Lag Start = 040% (blank mask page) Tower Loop = 1.7min
SET UNIT SPs (8) SET COMP SPs (8) SET COMP#2 SPs (8) SET TOWER (8) ByP xxx%
EvapRecTmr = 0.5min Start Speed WMC Automatic FB +075.4 Intg Derv
EvapPump = #1 ONLY Lead Str Spd = 015% VFD Control Trg+075.0 006s 01g
CondPump = #1 ONLY Lag Str Spd = 003% (blank mask page) Gain 20 D-Band01.0
SET UNIT SPs (9) SET COMP SPs (9) SET COMP#2 SPs (9) SET TOWER (9) VFD xxx%
Templifier Src Water Protocol=M-Bus MSTR Starter Set Up FB +075.4 Intg Derv
No Start = 070°F Id ent Number= 001 Same as Comp #1 Trg+075.0 600s 001s
Delta Reset = 055°F Baud Rate = 19200 K08.0 Db0.0 Tc0500mS
SET UNIT SPs (10) SET COMP SPs (10) SET COMP#2 SPs(10) Db Tower R06.5 F0653
VFD = Yes Refrg Sat Pressure Refrg Sat Pressure CAF*+013 +012 UT250
Harmonic Filter Evp Offset =+00.0 psi Evp Offset =+00.0 psi Spd 120 000% S0200
Engages > 06 RLA% Cnd Offset =+00.0psi Cnd Offset =+00.0psi RLA-05 CsP+002 m1000
SET UNIT SPs (11) SET COMP SPs (11) SET COMP#2 SPs (11)
Max Wtr Flow Rates ELWT Offset = +0.0 °F Uses Comp#1 Sensor
Evap WF=02400GPM Orbit Limit = A Orbit Limit = C
CondWF=03000GPM
NOTE: “Sensor Range” in Table 20 indicates the range of the input, NOT the operating range of the chiller.
NOTE: “Sensor Range” in Table 22 indicates the range of the output, NOT the operating range of the chiller.
Controller Setpoints
Table 24 groups setpoints that relate to the entire unit operation and are stored in the controller. Standard settings are made
through the OITS. The Password (PW) column indicates the password that must be active in order to change the setpoint. The
letters in the Password column refer to the following:
O = Operator (the password number for operator level is 100)
M = Manager (the password number for manager level is 2001)
T = Technician (the password number for technician level is only provided to McQuay International technicians)
Generator Sizing
Gas and diesel generators are sensitive to the compressor’s
locked-rotor characteristics when the chillers start up. Use the
electrical data supplied with the performance output sheet,
obtained from the McQuay International sales office, for
generator sizing purposes. The chiller data sheet will show the
RLA, which is for each compressor. Refer to Electrical Data to
determine the LRA, which is based on the RLA. It is important
It is important that an air conditioning system receive adequate Special care must be taken when utilizing open system water
maintenance if the full equipment life and full system benefits that is usually not treated (such as lakes, rivers, and ponds).
are to be realized. Maintenance should be an ongoing program The use of untreated water will result in corrosion, erosion,
from the time the system is initially started. A full inspection slime buildup, scaling, or algae formation. Water treatment
should be made after 3 to 4 weeks of normal operation on a service must be used. Special tube and water head material
new installation and on a regular basis thereafter. may be required to reduce damage from corrosion. Daikin
Applied is not responsible for damage or faulty operation from
Daikin Applied offers a variety of maintenance services through untreated or improperly treated water.
the local McQuay International service office and can tailor
these services to suit the needs of the building owner. Most
popular among these services is the McQuay International
Comprehensive Maintenance Contract. For further information
Seasonal Shutdown
concerning the many services available, contact your local CAUTION
McQuay International service office.
The condenser and evaporator are not self-draining. Where the
chiller can be subject to freezing temperatures, the condenser
Chiller Maintenance and evaporator must be drained of all water. Water permitted
to remain in the piping and vessels can rupture these parts if
DANGER subjected to freezing temperatures. Dry air blown through the
vessels will aid in forcing all water out.
Wait 20 minutes after disconnecting power from unit before
opening any compressor access covers. The DC link
capacitors store enough energy to cause electrocution. Except for freezing conditions, it is desirable to leave water in
the vessels to avoid long term exposure to air.
Electrical System Continuous forced circulation of antifreeze through the
vessels is one method of avoiding freeze up.
Maintenance of the electrical system involves the general
requirement of keeping connections clean and tight. Pump
interlocks and flow switches should be checked to be sure they
interrupt the control circuit when tripped.
Seasonal Startup
Seasonal startup procedures are as follows:
Cleaning and Preserving 1. Leak test the unit.
A common cause of service calls and equipment malfunction 2. Check and tighten all electrical connections.
is dirt. This can be prevented with normal maintenance. The
3. Replace the drain plugs (including cooling tower pump
system components most subject to dirt are:
and tower drain) if they were removed at shutdown the
1. Strainers: Remove and clean strainers in the chilled previous season.
water system and condenser water system at every
inspection.
2. Condenser Tubes: Inspect the condenser tubes
annually for fouling and clean if required. The standard
waterboxes should be removed with care due to their
weight. One method for handling standard waterboxes
follows (only qualified service personnel should perform
these tasks):
• After draining water, remove all but two head bolts
at roughly 10 and 2 o’clock.
• Loosen the remaining two bolts to enable the head
to be separated from the tube sheet sufficiently for
a clevis pin or hook to be inserted into an open bolt
hole at the top of the head.
• Attach a hoist to the pin or hook, lift the head
to remove weight from the two remaining bolts,
remove the bolts, and carefully remove the head.
• Do not try to install a machine thread eyebolt into
the head vent fitting, which has pipe threads.
• Reverse this procedure to mount the head, using a
new gasket.
Maintenance Schedule
Table 25 provides an overview of recommended maintenance procedures along with how frequently these procedures should be
performed.
Performance
As Required
Shutdown
Seasonal
Seasonal
Quarterly
Annually
Annually
Monthly
Startup
During
During
Semi-
By
I. Compressor
A. Analyze Compressor Fault Log X
B. Check IGV operation X
D. Check and tighten compressor electrical connections X
II. MicroTech® II Controls
A. Check for proper settings X
B. Verify transducers and sensors for accuracy X
C. Retrieve and archive OITS Trend Logs O
D. Perform MicroTech® II check, log, and last fault analysis X
III. Condenser
A. Confirm correct water flow and pressure drop O X
B. Confirm appropriate water treatment O
C. Clean and Leak Test condenser tubes X X X
D. Eddy Current Test - tube wall thickness X
E. Seasonal Protection X
IV. Evaporator
A. Confirm correct water flow and pressure drop O X
B. Confirm appropriate water treatment O
C. Clean and Leak Test evaporator tubes X
D. Eddy Current Test - tube wall thickness X
E. Seasonal Protection X
V. Chiller Unit
A. Run Test / Performance Evaluation X
B. Leak Test entire unit X X X
C. General Appearance:
1. Paint / Corrosion X
2. Insulation X
VII. Electrical
A. Check and record line voltage X
B. Inspect power components for signs of overheating X
C. Check and tighten unit electrical components X X
Definitions Appendix
Active Amp Limit temperature every few seconds and subtracting them from the
previous value over a rolling one-minute interval.
Active amp limit is the actual amp limit imposed by an outside
signal such as the load limit function. Error
Active Capacity Limit In the context of this manual, “Error” is the difference between
the actual value of a variable and the target setting or setpoint.
The active capacity setpoint is the setting in effect at any
given moment. Any one of several external inputs can limit a Evaporator/Condenser Approach
compressor’s capacity below its maximum value.
The evaporator/condenser approach is calculated for each
Active Setpoint circuit. The equation is as follows:
The active setpoint is the parameter setting in effect at any Approach = LWT – Saturated Temperature
given moment. This variation can occur on setpoints that can
be altered during normal operation. Resetting the chilled water Evap Hold-loading
leaving temperature setpoint by one of several methods such This is a setpoint that establishes the minimum evaporator
as return water temperature is an example. pressure to which the chiller is allowed to go. It signals that the
unit is at full load so the no further loading will occur that would
Condenser Recirc (Recirculation) Timer lower the pressure even further.
A timing function, with a 30-second default after start, that
holds off tower fan control for the duration of the timing setting. Evap Recirc (Evaporation Recirculation)
Timer
Dead Band A timing function, with a 30-second default, that holds off any
The dead band is a set of values associated with a setpoint reading of chilled water for the duration of the timing setting.
such that a change in the variable occurring within the dead This delay allows the chilled water sensors to take a more
band causes no action from the controller. For example, if a accurate reading of the chilled water temperature.
temperature setpoint is 44°F and it has a dead band of ± 2.0°F,
nothing will happen until the measured temperature is less than EXV
42°F or more than 46°F.
Electronic expansion valve, used to control the flow of
refrigerant to the evaporator, controlled by the circuit
Demand microprocessor.
Signal between 0 & 1000 sent from the compressor controller
to the compressor. This directs where the compressor needs to Lenient Flow Logic
be with capacity: increasing, stable, or decreasing.
This option affords the chiller the maximum tolerance to
intermittent water flow loss detection, and reduces nuisance
Discharge Superheat chiller trips. Momentary loss of flow detection can be a result
Discharge superheat is calculated using the following equation: of valve changes in the primary loop, as when staging another
chiller, or sudden changes in water temperature around the
Discharge Superheat = Discharge Temperature – Condenser
flow sensor. Variable speed pumps operating at minimum flow
Saturated Temperature
rates can exacerbate these flow issues.
ELWT Enabled, this logic detects a loss of flow signal (>5 Sec)
in either the condenser or evaporator and sets an internal
Evaporator leaving water temperature. The “water” is any fluid logic flag. Chiller operation is allowed to continue as long
used in the chiller circuit. as the vessel pressures and surge detection remain valid. If
condenser flow is lost and the pressure rises to within 5psi of
ELWT Error the condenser pressure trip point the chiller will shut down on
Error in the controller context is the difference between the condenser flow loss alarm. If evaporator flow is lost and the
value of a variable and the setpoint. For example, if the ELWT evap pressure drops to the EP-Unload set point the chiller will
setpoint is 44°F and the actual temperature of the water at a shut down on evaporator flow loss alarm. If either flow signal is
given moment is 46°F, the ELWT error is +2 degrees. lost and the surge logic is tripped, the chiller will shut down and
generate a flow loss alarm for whichever flow was missing.
ELWT Slope The default setting for Lenient Flow logic in the WMC code is
The ELWT slope is an indication of the trend of the chilled On. Turning it off converts the flow loss alarms, to timer based.
water temperature. It is calculated by taking readings of the Evap flow loss is adjustable from 12 down to 3s (default 12s),
and the condenser flow loss is adjustable from 20 to 3s (default power is returned to the compressors it checks the status of
20s). this function, and if enabled it then checks if the chiller was
running when power was lost. If so, it clears timers, enables the
Load Balance pumps, and clears power loss alarms. Evaporator water flow
must be detected before the compressor is allowed to start,
Load balance is a technique that equally distributes the total the re-circulation timer will be cleared. As the compressors
unit load between two or more running compressors. start in quick session the maximum pull down rate is relaxed to
promote a fast return to set point. The function ends when the
Load Limit ELWT has dropped below the Stage-Delta temperature, or a
An external signal from the keypad, the BAS, or a 4-20 ma compressor shuts down (for any reason).
signal that limits the compressor loading to a designated If other alarms are pending (such as a bearing fault) the
percent of full load. Used to limit unit power input. RapidRestore® function will be canceled.
RapidRestore® Function
This logic has been introduced to reduce the time the chiller
needs to recover from a power loss event. The chiller’s run
status is continuously stored in battery backed RAM. When
Suction Superheat
Suction superheat is calculated for each circuit using the
following equation:
Suction Superheat = Suction Temperature –
Evaporator Saturated Temperature
VDC
Volts, Direct Current; sometimes noted as vdc.
VFD
Variable Frequency Drive, a device located on the compressor
used to vary the compressor speed.
Warranty
All McQuay International equipment is sold pursuant to its standard terms and conditions of sale,
including Limited Product Warranty. Consult your local McQuay International representative for warranty
details. To find your local McQuay International representative, go to www.DaikinApplied.com.
Aftermarket Services
To find your local parts office, visit www.DaikinApplied.com or call 800-37PARTS (800-377-2787).
To find your local service office, visit www.DaikinApplied.com or call 800-432-1342.
This document contains the most current product information as of this printing. For the most up-to-date
product information, please go to www.DaikinApplied.com.