optimizer manual

Chiller OptimizerBy

Energy OptimizationInstruction Manual

Controller Face

Energy Optimization

Chiller Optimizer

Table of ContentsController Face I. General Description................................................................................. Soft Start............................................................................................. Soft/Variable load ............................................................................... Temperature Reset............................................................................. Low Load Shut-Down Sequence ........................................................ Air Temperature Lockout .................................................................... Lag Chiller Operation.......................................................................... Load Shedding ................................................................................... Additional Cooling Capacity................................................................ Control Safeties .................................................................................. Reciprocating Control ......................................................................... II. Operational Modes................................................................................. Base Water Return Temperature........................................................ Base Outside Air Temperature ........................................................... Air/Return Water Reset Ratio ............................................................. Scan Time........................................................................................... Min. Capacity Time ............................................................................. Lead/Lag Options ............................................................................... Chiller Optimizer Face Plate ............................................................... III. Mode: Display Function ...................................................................... MCU Data ........................................................................................... CCU Data ........................................................................................... Sys Data ............................................................................................. Arch Data............................................................................................ IV. Mode: Start/Stop Chillers................................................................... Starting the Lead Chiller ..................................................................... Stopping All Chillers ........................................................................... V. Mode: Data Entry................................................................................. Basic Setup ........................................................................................ System Setup ..................................................................................... MCU Setup ................................................................................ Basic Setup.......................................................................... Extended Set-Up.................................................................. Choice for Start-up Mode..................................................... Lead/Lag Options Setup ...................................................... KW Demand Setup .............................................................. MCU Calibrate (Temperature Sensors) ............................... CCU Setup ................................................................................ CCU Configure..................................................................... CCU Calibrate...................................................................... Time & Date Setup..................................................................... Comm. Setup ............................................................................. Diagnostics ................................................................................ Set Passcode............................................................................. VI. Chiller Bypass Function ...................................................................... Appendix A Installation Instructions Appendix B Operating Instructions 1 Page 2 2 2 2 3 3 3 4 4 4 4 6 6 6 7 7 7 7 8 9 11 14 16 18 21 21 22 23 23 26 27 28 29 31 32 33 35 36 37 39 40 41 42 43 44

Instruction Manual

Energy Optimization

Chiller Optimizer

I. General DescriptionThe Chiller Optimizer (CO) is a third generation control instrument continuously marketed by Energy Optimization since 1980. It is a selff-contained solid state dedicated microprocessor system, specifically designed to reduce the energy consumption of centrifugal, screw, reciprocating or absorption chiller systems. It is capable of operating a single chiller or multiple (up to eight) chillers in switchable leadlag sequence. The CO may be used as a stand-alone control or it can be interfaced with timers, load controllers, or central computer systems through the remote contact points. The main features of the CO are: SOFT START The controller soft starts the chiller compressor(s) at the lowest practical capacity level. This "soft" start saves money in two ways: (1) it significantly reduces the electrical peak demand produced each time a compressor is started, overshooting the correct capacity level at start-up. Soft start does not impact supply and return inrush, which is frequently not charged, to the customer by the utility company. SOFT/VARIABLE LOAD After the soft start , the CO uses a variable soft load. This means that the chiller is gradually brought up to match the building load, faster during the warmer months and after shutdowns and slower during cooler months. This is accomplished by having a variable step size that automatically adjusts from 2% to 10% of FLA depending on the requirements of the system. TEMPERATURE RESET Most chillers produce a constant temperature chilled water supply temperature year-round. While a user may occasionally reset this temperature, it does require extra effort and is not generally done. Our ELECTRA program monitors outside air temperature and chilled water return temperature, using these parameters to adjust chiller loading at optimum setting. Allowing an increase of 1F in chilled water temperature results in about a 2% to 4% savings in energy costs. During cooler weather, an increase of 6 degrees will result in a 12% to 24% cost savings. That's significant! And that's why the Chiller Optimizer has been designed to continuously and precisely adjust the water temperature to match current demand conditions.

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Instruction Manual

Energy Optimization

Chiller Optimizer

I. General Description, contdLOW LOAD SHUT-DOWN SEQUENCE During periods when the demand for cooling is low, as at night, a chiller system will reduce its capacity to a point where its operation is very inefficient (from 3 or 4 times the power per ton in constant speed systems). Additionally, operation at low loads frequently causes higher motor winding and bearing temperatures, and possibly compressor surging. To avoid this problem, when the chiller reaches its programmed minimum capacity level and the chilled water temperature is below the target by more than the programmed offset, the CO controller initiates this sequence: The low load timer starts, allowing the chiller to operate at minimum for that time. If the time expires, and the water temperature is still below the target temperature, the chiller is shut down, and will remain off for at least as long as the "TIME @ MIN" setting. If the demand for cooling does return within the time period allowed, then the "TIME @ MIN" is reset, and the sequence is ready to start again if minimum load is perceived. If the chiller does get shut down, a subsequent increase in demand will re-start the chiller, it will soft-start and soft-load in the normal manner. The net result is that the CO low load cycle saves energy by operating the compressor at more favorable efficiency levels and by reducing unnecessary compressor cycling. AIR TEMPERATURE LOCKOUT The CO can be programmed to monitor outside air temperature and hold the chiller system off as long as the outside air temperature is colder than certain user programmable set points. LAG CHILLER OPERATION When the CO determines that a chiller should be started, it always calls the first chiller (lead chiller) in the preprogrammed sequence. When the lead chiller is not sufficient to satisfy the load, the lag chiller(s) are called. The CO controller starts the lag chiller(s) when the lead chiller reaches a user programmed threshold set point, between 75% and 100% capacity. to satisfy cooling requirements. The lag chiller is soft started, when the RTL signal is received, the CO regulates the capacities of both chillers, reducing the loading of the lead chiller by the amount of loading on the lag chiller. The chiller loading is proportional to their full scale capacities.

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Instruction Manual

Energy Optimization

Chiller Optimizer

I. General Description, contdWhen the lead chiller can once again satisfy cooling requirements and lag chiller operation is no longer efficient, the controller shuts down the lag chiller and Increases the capacity of the lead chiller to replace the lag chiller capacity that was removed. The lag chiller shut down is initiated by the "LOW LOAD OFFCYCLE" sequence described above. If the chillers have approximately the same capacity, they are loaded evenly. If they have different capacities, they are loaded proportionally. (The full load capacity of each chiller is entered in the CCU Configuration tables). LOAD SHEDDING The CO has the capability to receive an external load shedding signal from a load controller to reduce the electric energy usage of the chiller. The CO will decrease chiller capacity by 10% per minute until the signal is terminated or until the "minimum operation %" level is reached. Routine capacity adjustments resume when the load shed signal is terminated. Some operations may require lag chiller lockout rather than load shedding, the same terminals are used for either, the programmed entry in the MCU Setup determines which operation occurs at contact closure. (It is not necessary to use either.) ADDITIONAL COOLING CAPACITY Humidity monitors, critical temperature thermostats, or similar devices can be used to request the CO to increase cooling capacity. When an additional cooling signal is received, the controller will lower the return water set point temperature by 3 F, thereby requiring increased loading on the chiller. The system water temperature will be returned to normal when the signal is terminated. CONTROL SAFETIES The CO will allow the control panel of the chiller to protect the system if any of the safeties are violated. RECIPROCATING CONTROL (SERIES R) Capacity controls of reciprocating compressors may be accomplished in several ways, but all involve some method of bypassing a stage. This may be accomplished by holding the inlet valve open, or opening a "side pocket" that considerably increases the volume of the cylinder as well as dumping the slightly compressed gas back into the cylinder on the intake stroke.

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Instruction Manual

Energy Optimization

Chiller Optimizer

I. General Description, contdAny of these methods are initiated by relays in the controller. The Chiller Optimizer offers up to 12 Solid State Relays (SSRs) for unloader control. A dedicated Chiller Control Interface Board (CCU) replaces the centrifugal CCU and all other features of the ELECTRA software are incorporated in the Series-R reciprocating chiller CO when so configured. Note: In later model recip or screw chillers, interface cards to accept 4-20 mA or PWM remote signals are available. The CCU is setup to output these signals for capacity control.

The front control panel of the CO consists of a numeric touch pad with UP/DOWN buttons along with four special function buttons: Mode, Display, Enter & Bypass. A dual line backlighted LCD display is also featured. The Mode button is used to START/STOP the lead chiller, enter the Basic Set-up variables and (with a passcode) to enter the Extended Set-up. The Extended Set-up tables are usually accessed by a qualified technician when the system is first set up. There are certain parameters that the operator may enter without a passcode. These are called the Basic Set-up and are accessed by pressing the Mode button twice. A selection is made with the UP/DOWN buttons. Explanation of these entries follows with a complete listing of all entries.

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Instruction Manual

Energy Optimization

Chiller Optimizer

II. Operational ModesThere are three basic operational modes of the Chiller Optimizer:

A. The Display Function entered by pressing the Display button. B. The Data Entry Function entered by pressing the

Mode

button

C. The Optimizer Bypass Function entered by pressing the Bypass button button .

Pressing Mode once brings a prompt to Press Enter to Start or Stop Chiller. Pressing Mode again ignores this prompt and proceeds to the next prompt of Basic Setup on the top line and the variable to edit on the bottom line. A different variable may be selected with the UP/DOWN buttons. Pressing Enter shows the numeric value of the variable. The operator choices are: BASE RETURN WATER TEMPERATURE The desirable return water temperature is set by this control. This water temperature will be maintained only when the outside air temperature is equal to the base outside air temperature set point. When the outside air temperature exceeds the base, return water base temperature is reduced by a preset ratio (see below). Conversely, when air temperature goes down, the water temperature set-point is increased. Return water settings usually range between 50F to 60F. For system diagnostic or service purposes, the water temperature set point may temporarily be set higher or lower to cause capacity to increase or decrease depending on the needs of the service personnel. BASE OUTSIDE AIR TEMPERATURE This is the set point at which the CO will maintain the base return water temperature. The coldest water temperature will be provided when the actual outside temperature exceeds this point. In general, this setting should be within a few degrees of the highest summer temperature. Typical settings are from 90F to 100F.

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Instruction Manual

Energy Optimization

Chiller Optimizer

II. Operational Modes, contdThere are three basic operational modes of the Chiller Optimizer:

AIR/RETURN WATER RESET RATIO (CONSERVATION RATIO) This control sets the degrees per degree change in the return water temperature set point with regard to outside air temperature. For a ratio of 10, a 10 change in outside air temperature from the base will result in 1.0F change in water temperature. A more aggressive setting will be 20.0 where a 10 degF change in outside air will change the water target temperature by 2.0 degF. If water temperature reset from outside air variations is not desired, the conservation ratio should be set to 0.0. SCAN TIME The Scan time is set to match the reaction time of the system. It governs the rate at which chiller capacity changes are made when needed. The time should be set to the number of minutes that it takes for water to leave the chiller, be pumped through the building, and return to the chiller. The adjustment rate setting is typically 4 to 6 minutes on average systems, 8 to 12 minutes on large central plants. MIN. CAPACITY TIME This control prevents the chiller system from short-cycling during low demand conditions. The chiller system will be held at the minimum load for this time, preventing it from cycling on and off. LEAD/LAG OPTIONS There are five choices of lead/lag selections explained in detail in the Data Entry section

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Instruction Manual

Energy Optimization

Chiller Optimizer

The Chiller Optimizer Face PlateChiller Optimizer1 4 7 2 5 8 0Enter Mode DisplayBypassed

10

4In Control

3 6 9

5 6 7 8 9

Setting MF

Override

1 2 3

Chiller MF

Bypass

Membrane Switch Keypad and Annunciator Panel:This panel, on a hinged swing-out plate inside the door of the Optimizer, has tactile numeric buttons for data entry and UP/DOWN buttons for navigating through different tables and variables. In addition, the following special functions are included: 1. Enter button.................................Enter displayed parameter into memory

2. 3. 4. 5. 6.

Mode button ........................... Used to start/stop chillers, enter Basic or Advanced Setup Bypass button ........................ Used to bypass optimizer control of chiller(s) In Control LED (green) ........... Lights up when control is within 1 degF of target temperature Setting MF LED (amber) ........ Lights up when a chiller is not tracking the target capacity Override LED (amber)............ Lights up when normal set-point control is overridden Examples: Additional Cooling, Loadshedding, Supply Temp. High Limit, Outside Air Cutoff 7. Chiller MF LED (amber) ......... Lights up when a chiller is called to run and it fails to do so 8. Display button ........................ Used to abort entries in process and go to Display mode 9. Bypassed LED (red)............... When any one of chillers within the MCU is being bypassed 10. LCD Dual line, back lighted alphanumeric disply

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display FunctionThe keypad Display, UP/DOWN and Enter buttons are used to display variables, settings and miscellaneous data values of the Chiller Optimizer

CHWR T. F CHWS T. F

54.3 48.3

Home Display: The dual line LCD display is typically displaying the header water temperatures, Supply and Return. Other variables may be selected as explained below.

Display When the button is momentarily depressed, the top line of the display will start blinking with a message reflecting the previous selection made for that line, such as MCU Data:. If pressed again, the second line of the display will start blinking. The blinking line will be selected if

Enter

is pressed. The choices for display in

either line may be scrolled by using the arrow UP/DOWN buttons while the display is blinking. The display.

Enter

button selects the blinking variable and returns to a steady

Display

MCU Data: CHWS T. F

Press Display button: 48.3 Display shows a blinking MCU Data: message on top line with CHWST on the bottom line (previously selected).

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display FunctionThe keypad Display, UP/DOWN and Enter buttons are used to display variables, settings and miscellaneous data values of the Chiller Optimizer

DisplayCHWR T. F MCU Data:

54.3

Press Display again and the display will show the CHWRT on the top line with Master Control Unit MCU Data: blinking on the bottom line

Each time an arrow key button is pressed the display will toggle through the following: MCU Data --- Master Control Unit Data CCU Data: --- Chiller Control Unit Data Sys Data: --- System Data Arch View: --- Viewing Collected Archives

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - MCU DataThe Master Control Unit (MCU) Display Table contains most variables associated with the system rather than individual chillers. Refer to the CCU Table for individual chiller parameters and/or variables. Press the Enter key when MCU Data is blinking to start the selection of variables to display from the MCU data :table.

EnterEach time an arrow key

or

is pressed the

MCU Data is displayed in the following sequence:

CHWR T. CHWR T.

F F

64.3 64.3

Press an Enter key and the display will sequence to CHWRT. F Value: Chiller Return Water Temperature

CHWR T. CHWS T.

F F

64.3 48.0

Press an Arrow key and the display will sequence to CHWS T. F Value: Chilled Water Header Supply Temperature.

CHWR T. OAT.

F F

64.3 48.0

Press an Arrow key and the display will sequence to OSA T. F Value: (Outside Air Temperature)

CHWR T. Target

F F

64.3 48.0

Press an Arrow key and the display will sequence to Target F Value: (Target Temperature for Return Water)

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - MCU Data, contdThe Master Control Unit (MCU) Display Table contains most variables associated with the system rather than individual chillers. Refer to the CCU Table for individual chiller parameters and/or variables.

CHWR T. F %Cap. Chg

64.3 14.7

Press an Arrow key and the display will sequence to %Cap. Chg Value (The Present System %Target Capacity Change)

CHWR T. Avail Cap

F

64.3 0

Press an Arrow key and display will sequence to Avail Cap Value (The Available Capacity in tons for the system)

CHWR T. Curr Cap

F

64.3 0

Press an Arrow key and the display will sequence to Curr Cap Value (The Current Capacity in tons being used)

CHWR T. Sys Cap %

F

64.3 00

Press an Arrow key and the display will sequence to Sys Cap Value (The Capacity of the system being used in percent)

CHWR T. Scan Tmr.

F

64.3 0

Press an Arrow key and the display will sequence to Scan Tmr. Value (Time remaining in the load update Scan Timer in Seconds)

CHWR T. F MinCap Tmr.

64.3 0

Press an Arrow key and the display will sequence to MinCap Tmr. Value (minimum capacity timer in seconds). If not changing, system is not at Minimum Capacity.

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - MCU Data, contdThe Master Control Unit (MCU) Display Table contains most variables associated with the system rather than individual chillers. Refer to the CCU Table for individual chiller parameters and/or variables.

CHWR T. Lo Ld Tmr.

F

64.3 0

Press an Arrow key and the display will sequence to Lo Ld Tmr. Value (off state timer in seconds). If not changing, system is not in OFF state.

CHWR T. Seq:

F

64.3 123xxxxxx

Press an Arrow key and the display will sequence to Seq. Value (Chiller operating sequence currently being used)

CHWR T. mcu:

F IDLE

64.3

Press an Arrow key and the display will sequence to mcu Value (Active/Idle Status of Master Control Unit).

CHWR T. mcu:

F 64.3 MCU Clear

Press an Arrow key and the display will sequence to mcu Override/Clear status of Master Control Unit.

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - CCU DataThese are all the parameters and variables associated with each chiller in the system.

CHWR T. F CCU Data:

64.3

Press Display and Arrow key until the display shows Chiller Control Unit CCU Data: blinking.

EnterCHWR T. F Chiller 1 64.3 Press Enter key and the display will show Chiller 1 blinking in the display. Press ENTER to select, or DOWN arrow to rotate to another chiller.

CHWR T.

F Chiller 2

64.3

Press an Arrow key and the display will show Chiller 2 , Chiller 3 etc. blinking in the display. The up or down arrows determine whether Chiller 2, 3 is chosen (depending how many chillers are in the system).

CHWR T.

F Chiller 3

64.3

When the display is, lets say, at chiller 1, the following information may be displayed by pressing the

Enter

key and arrow key

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Chiller Optimizer

III. Mode: Display Function - CCU Data, contdThese are all the parameters and variables associated with each chiller in the system. Any one chiller may be selected, chiller 1 is shown as an example.

CHWR T. F CT1 Load %

64.3 0.0

Press Arrow key and the display will show the CT1 Load % (Percent FLA Reading for Chiller1). This is the signal from the chiller 1 KW transmitter.

CHWR T. F CT1 Targ %

64.3 0.0

Press Arrow key and the display will show the CT1 Targ % . The CO is calling for this percent of total capacity from chiller 1.

CHWR T. RTL1 Tmr.

F

64.3 0

Press Arrow key and the display will show the RTL1 Tmr value (Ready-to-Load Timer for Chiller 1, seconds). If not changing, chiller 1 is not waiting for a Ready-to-Load signal.

CHWR T. F Run Time1:

64.3 29:48

Press Arrow key and the display will show the Run Time1 value (Total Run Time for Chiller 1 in hours and minutes)

CHWR T. ccu1:

F

64.3 CONTROL

Press Arrow key and the display will show the control state of ccu1. ACTIVE or IDLE.

CHWR T. ccu1:

F

64.3 No Fault

Press Arrow key and the display will show the Fail State of ccu1.

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Instruction Manual

Energy Optimization

Chiller Optimizer

IV. Mode: Display Function - Sys DataThe keypad buttons are used to display the System data values of the Chiller Optimizer

CHWR T. F Sys Data:

64.3

Press Display and Arrow key until the display shows Sys Data: blinking.

EnterCHWR T. Time: F 64.3 18:33:34

Press Enter key and the display will show the Time: Value (Present clock time in military time).

CHWR T. Reset Cnt.

F

64.3 10

Press the Arrow key and the display will show the Reset:Cnt. (Total number of Archive Resets)

CHWR T. Arch. Max:

F

64.3 1945

Press the Arrow key and the display will show the Arch. Max: Value (Maximum number of Archives the internal memory can hold before it starts overwriting)

CHWR T. Arch. Cnt:

F

64.3 68

Press Enter key and the display will show the Arch. Cnt: Value (Number of Archives Stored)

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - Sys Data, contdThe keypad buttons are used to display the System data values of the Chiller Optimizer

CHWR T. Ver

F 64.3 1.50000.0000

Press Enter key and the display will show the Ver. Value The Software code version of the Optimizer)

CHWR T. S/N

F 64.3 001e36440000

Press Enter key and the display will show the S/N. Value (The Embedded Controller Serial Number)

CHWR T. F KwHr Rmp:

64.3 000

Press Enter key and the display will show the KwHr. Rmp. Value (Scheduled KWH Demand for current period)

CHWR T. F KwHr Dmd:

64.3 0

Press Enter key and the display will show the KwHr. Dmd. Value (Power Demand in KWH for current period)

CHWR T. KwH Tot:

F

64.3 0

Press Enter key and the display will show the KwHr. Tot. Value (Total KWH since last reset)

CHWR T. Date:

F 64.3 mm/dd/yyyy

Press Enter key and the display will show the Date. Value (present date in real time)

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - Arch DataThe keypad buttons are used to display the stored Archive data values of the Chiller Optimizer. Archives are collected and stored in non-volatile memory once every Demand Period. They are typically collected by the PC Monitor program. They can also be viewed in this Display mode.

CHWR T. F Arch View:

64.3

Press Enter key and the display will show the CHWRT on the top line with Archive View Arch View: blinking on the bottom line

EnterCHWR T. ? arch # F 64.3 0000_ Press Enter key and the display will ask for the ?arch # displayed asking for the number of the archive that you want to display..

Archives are numbered from 0001 to 1950. When an archive is selected the following may be displayed by using the arrow keys:

CHWR T. ? arch #

F

64.3 00001

Enter the number 1 for Archive number

EnterCHWR T. 15:00 F 64.3 MM/dd/YYYY Time and Date of the Archive is displayed

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - Arch Data, contdThe keypad buttons are used to display the stored Archive data values of the Chiller Optimizer. Archives are collected and stored in non-volatile memory once every Demand Period. They are typically collected by the PC Monitor program. They can also be viewed in this Display mode.

CHWR T. KWH1

F

64.3 0

Press the Arrow key and KW-Hr reading for Chiller 1 at the time and date of the archive is displayed

Continuing to press the same Arrow key will senquence through all connected chillers. CHWR T. F Load Tons: 64.3 0 Press the Arrow key and Tonnage Load for all running chillers at the time and date of the archive is displayed,

CHWR T. Load %

F

64.3 0

Press the Arrow key and Percent Load on all chillers (% of total capacity) at the time and date of the archive is displayed.

CHWR T. Target:

F

64.3 00.0

Press the Arrow key and The Target Temperature for Return Water at the time and date of the archive is displayed.

CHWR T. OutA:

F

64.3 00.0

Press the Arrow key and The Outside Air Temperature at the time and date of the archive is displayed.

CHWR T. SupW:

F

64.3 00.0

Press the Arrow key and the header Supply Water Temperature at the time and date of the archive is displayed.

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Instruction Manual

Energy Optimization

Chiller Optimizer

III. Mode: Display Function - Arch Data, contdThe keypad buttons are used to display the stored Archive data values of the Chiller Optimizer. Archives are collected and stored in non-volatile memory once every Demand Period. They are typically collected by the PC Monitor program. They can also be viewed in this Display mode.

CHWR T. RetW:

F

64.3 00.0

Press the Arrow key and The Return Water Temperature at the time and date of the archive is displayed.

CHWR T. MD:

F

64.3 00.0

Press the Arrow key and Maximum Demand for this Period at the time and date of the archive is displayed.

CHWR T. Kw_Hr:

F

64.3 00234

Press the Arrow key and Total Kw-Hr in this demand period at the time and date of the archive is displayed.

CHWR T. KwDmd:

F

64.3 000

Press the Arrow key and Total Kw-Hr since the last reset at the time and date of the archive is displayed.

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Instruction Manual

Energy Optimization

Chiller Optimizer

IV. Mode: Start/Stop ChillersThe keypad buttons are used to input the data values of the Chiller Optimizer

Starting the Lead ChillerModePress Mode The Lead Chiller may be started

Press ENTER to Start Chiller

Note: To avoid starting chillers presseither the MODE or DISPLAY buttons to exit start-up.

Enter

Press ENTER This Starts the Lead Chiller. Display returns Home.

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Chiller Optimizer

IV. Mode: Start/Stop Chillers, contdThe keypad buttons are used to input the data values of the Chiller Optimizer

Stopping All ChillersMode

Press ENTER to Stop Chiller

If chiller(s) are not running, the display will prompt Press ENTER to Start Chiller.

Note: To avoid shutting down chillerspress either the MODE or DISPLAY buttons.

Press ENTER

Enter

This STOPS all Chillers. Display returns to Home Display.

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V.

Mode: Data Entry-Basic Setup

The keypad buttons are used to input the data values of the Chiller Optimizer

BASIC SETUPBasic SetupPress MODE twice. This allows you to alter the basic setup for Base Water Temperature and other settings from the Basic Menu. The Arrow keys allow you to scroll up or down for other basic setup parameters.

Mode Mode

Basic Setup: Base RetW

Note: This Basic Setup is entered without a passcode. It is intended for operating people to change basic parameters. There is also a password protected Basic Setup with more detailed Lead/Lag configuration options and certain other detailed parameters.

Base RetW

F 059.0

By pressing the ENTER at any of the Basic Setup screens you will be taken directly to that parameters input screen. Example: Pressing ENTER on Base RetW. By pressing the 0 then 5 then 6 then 0 buttons the value of 056.0 will be entered into the display. Press Enter again to input the value into the controller. Now the Base RetW is 056.0 F.

? Base RetW

F 056.0

Enter

By pressing Enter, the Base Return Water Temp. was stored and the display returns to Home. Mode must be pressed twice again to change another parameter in the Basic Setup. 23

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V.

Mode: Data Entry-Basic Setup, contd


Basic Setup: Base RetW

Pressing Mode twice again you re-enter the Basic Setup. Press Arrow to select another variable. Press Enter when the variable is displayed.

Basic Setup: Base OutAir

This is the Base Outside Air Temp. (OSAT) where no adjustment is made to the Base Water Temp.

Basic Setup: Air/Water Ratio Mode

Mode

If the OSAT deviates from the Base above, a change is made to the Base RetW. A ratio of 10 makes a change of 1.0 for every 10 degF change in OSAT. A setting of 20 makes a 2.0 degF change.

Basic Setup: outAir Cutoff

Below this Outside Air Temp., chillers will not startup (once turned off).

Basic Setup: Scan Time

This is how frequently the CO makes a chiller load capacity change (in seconds).

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V.

Mode: Data Entry-Basic Setup, contd


Basic Setup: Ld/Lag Options

Pressing Enter here will call for a selection of the different Lead/Lag Options. The Arrow key is used to browse through and then Enter is pressed. The User Sequence is scheduled under passcode. Chillers 1,2,3,4

? Ld/Lag Options: Local_Addr Ld/Lag Options: Least_Hours Ld/Lag Options: Tons_Lo_Hi Ld/Lag Options: Tons_Hi_Lo Ld/Lag Options: User_Sequence

Chiller with least hours first Chiller with Lowest Ton rating first Chiller with highest Ton rating first Chillers 4,3,2,1 or any random sequence as set in MCU Extd Setup

Basic Setup: Setback1 Temp

This changes a Setback1 Base Water Temp. but the start and stop times are set under passcode (in MCU Extd Setup).


This changes a Setback2 Base Water Temp. but the start and stop times are set under passcode (in MCU Extd Setup).

Basic Setup: Sup Lim High

When this Supply Water Temp. is exceeded, the Return Water Temp. SP is reduced by 1.0 degF. 25

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V.

Mode: Data Entry-System Setup

The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Most or all these parameters will likely be entered at installation time.

System SetupMode Mode ModeAfter the four digit pass code is input (factory default is 0000) and the ENTER Button is pushed, the Optimizer is in the Setup Mode. Entry to the Configuration Tables is gained by pressing Mode three times .

Enter Passcode 0000

EnterThis is a subset list of inputs for System setup MCU Setup CCU Setup Time/Date Comm. Setup Diagnostic Set Passcode 26 Each of these subsets is browsed by pushing an Arrow button and selected with the Enter button.

Instruction Manual

Energy Optimization

Chiller Optimizer

V. Mode: Data Entry-MCU SetupThe System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Most or all these parameters will likely be done at installation time.

Master Control Unit (MCU) SetupMode Select: MCU Setup

EnterThis is a subset list of inputs for MCU setup Basic Setup Extd Setup RTS Options Ld/Lag Options Kw Dmd Setup Calibrate Each of these subsets is browsed by pushing an Arrow button and selected with the Enter button.

By pressing the ENTER that subset.

Enter

button at any subset you will be taken to the input menu for

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V. Mode: Data Entry-MCU Setup, contdThe System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Most or all these parameters will likely be done at installation time.

Basic SetupThis is the same as the Basic Setup discussed above (without passcode), except for the following additional entries.


This entry is a Setback1 Base Water Temperature. It replaces the normal Base Return Water Temperature Set-point at specific times of day.

Start Hour 00 Start Minute 00 If a non-zero entry is made above, this prompt appears. Enter time to start in military format.

Stop Hour 00 Stopt Minute 00 Enter time to stop and go back to the normal Setpoint.


This is Setback2, a second Setback Base Water Temperature. It replaces the normal Base Return Water Temperature Set-point at different times from Setback1. If not desired, enter 00. If entry is non-zero, the Start and Stop times will be prompted.

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V.

Mode: Data Entry-MCU Setup, contd

The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Most or all these parameters will likely be done at installation time.

Extended SetupThis is the main System Configuration table. It should be done first because it defines the number of chillers in the system and other key system parameters. The Extended set-up configures the entire chiller system.

MCU Setup: Extd Setup

Pressing. Enter, the Extended Setup is entered.

? No. Chillers 03

This is the total number of chillers controlled by the Chiller Optimizer control system. This is the number of chillers controlled by the MCU controller (a maximum of 3). Up to (5) additional slave units may be connected externally.

? # Local CCUs 03

? RetW Offset F 000.0

This is the minimum water temperature offset before the lead chiller can start or stop.

? Min Cap Time (minutes)

At this Minimum Capacity, a timer starts 0001

? Min Capacity % 030.0

Percent minimum capacity when the Minimum Capacity Timer starts.

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V.



? Min Off Time (minutes)

002

Minimum off cycle time in minutes. When the lead chiller is turned off by the optimizer, it will stay off for this no. of minutes.

?

Temp Units Deg. F

Specifies units for all temperature inputs and calculations. Choice between F or C is made with Arrow then Enter.

?

Gain 1% 001.0

Gain control for 0 1 F deviation.

?

Gain 2% 001.0

Gain control for 1 -2 F deviation.

?

Gain 3% 001.0

Gain control per degree for 2 F or higher deviation.

? Air Sensor (1=yes, 0=no)

1

Is an Outside Temperature Sensor used? If No, outside air reset is disabled.

? Ld Shed Lockout (1=yes, 0=no)

0

Is Load Shed or Lockout used? This is the external control contact terminal assignment.

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V.



Ready-to-Start (RTS) Options Choice for Start-up ModeStart-up starts the Lead Chiller

MCU Setup: RTS Options

RTS (Ready-To-Start) option allows the selection of the System start-up mode.

? RTS

Options: Local

Chiller Optimizer runs under Local control.

? RTS

Options: Remote

Start-up is done remotely (with a contact closure) by a BAS or time scheduler.

? RTS

Options: Timer

Start-up is based on time/day of week. If Enter, further prompts apply.Refer to Appendix B for details.

? RTS

Options: M and V

Chiller Optimizer runs under the Measurement and Verification(M and V) Mode (one day in Bypass, next day on optimizer control).

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Lead/Lag OptionsThis is the same as the Basic Setup discussed above (without passcode), except for the following additional entries.

Basic Setup: Ld/Lag Options

When in Lead/Lag Options the User Sequence is selected, here the arbitrary sequence of chillers may be programmed.

Ld/Lag Options User_Sequence

Enter the order of the chillers to be started as demand for cooling increases.

? 1 st chiller: (1..8)

0

Enter the order of the chillers to be started starting with the 1st chiller. Press Enter.

? 2 nd chiller: (1..8)

0

Enter the 2nd chiller to be startedcontinuing to the last chiller.

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V.



KW Demand SetupThis subset of menus is used to setup the KW Demand, or electrical sensing and interpretation electrical sensed inputs for the Chiller Optimizer.

? MCU Setup Kw Dmd Setup

Enter? Demand Period (seconds)

1800

Demand Period is the time period the electric utility uses to define rate of energy use. The KW-HRs accumulated during this period determine the rate at which the user is using electricity. It is defined as KW demand or KVA demand. This period is typically either 15 minutes, 30 minutes or one hour (900, 1800 or 3600 seconds respectively) as defined by the contract with the local utility or energy provider. The contract with the utility calls for a maximum monthly KW demand which, if exceeded during any one demand period during the month, may impose surcharges and/or increased cost per KW-HR in the final bill. A separate KW-HR transducer is recommended producing one pulse per KW-HR and installed in the main feed line metered by the utility.

? Kw_Hr / pulse 01.00

This is the numerical value in KWH for each pulse of a utilitys pulsing demand meter.

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V.



? Kw_Hr ramp offset 00000

In order to schedule the demand over the demand period, a ramp is internally generated from zero to some max. value. An offset is set here instead of starting from 0.0

? Max Kw_Hr Dmd 001000

This is the contractual maximum demand as set by the utility. The ramp reaces this number in one demand period.

? Clear Archives (1=yes, 0=no)

This clears out the Archive memory. 0

? Set KwHr Total 00000020

This is the starting number for the total buildings KWHrs.

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V.


Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly. Most or all these parameters will likely be done at installation time.

MCU Calibrate: Calibration of Temperature SensorsDetailed steps in the calibration process can be found in Appendix B

? MCU Calibrate: Return Water

This is used to calibrate the return water temperature sensor a/d converter. Pressing the ENTER button at this screen takes you to the a/d converter calibration screen

? MCU Calibrate: Outside Air

This is used to calibrate the outside air temperature sensor a/d converter. Pressing the ENTER button at this screen takes you to the a/d converter calibration screen

? MCU Calibrate: Supply Water

This is used to calibrate the Supply Water temperature sensor a/d converter. Pressing the ENTER button at this screen takes you to the a/d converter calibration screen

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V.

Mode: Data Entry-CCU Setup


Chiller Control Unit (CCU) Setup

Mode Select: CCU Setup

Each Chiller Control Unit (CCU) is configured in this Setup Table.

EnterPressing ARROW buttons will scroll through the chillers by number. Once a chiller is selected press the ENTER Button.

CCU Select: Chiller 1

Enter

CCU Options: Calibrate

CCU Options: Configure

Pressing ARROW buttons will toggle between the two available CCU Options of Calibrate or Configure. Once an Option is chosen, press the Enter button to chose that Option

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V.

Mode: Data Entry-CCU Setup, contd


CCU ConfigureCCU Options: Configure

After chiller is selected, the parameters corresponding to that chiller are stored.

Enter? Capacity Tons 1000 Enter rated capacity in Tons.

?

Startup

% 030.0

Enter Start-up minimum Load in % FLA.

?

Minimum

% 030.0

Enter Minimum Capacity in % FLA.

?

Min. Adj.

% 002.0

Enter Minimum Load/Unload Step in %. Enter Deadband for CT Load in %. This applies only when Direct Vane control is used . Select the type of load/unload adjustment between fixed step or variable step. Select with Arrow then Enter. The KW rating at 100% capacity. 0500

?

CT Deadband

% 001.0

Adjust Type: Variable

Max Kw:

Set KWHR

Total 00067039

Initialize the KWH counter for this chiller.

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V.



Available Chiller Types? Chiller Type: Centrifugal Centrifugal Reciprocating ? Chiller Type: Reciprocating MA Output PWM ? Chiller Type: mA Output % at 4mA 000.0 Enter Capacity in % at 4ma. This applies to chillers with remote reset interface cards. Enter Capacity in % at 20ma.

%

at

20mA 100.0

?

Chiller Type: PWM

These are York chillers with PWM remote reset.

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V.



CCU CalibrateThis is a software calibration procedure of the KW transmitter of each chiller to read 0-100% Full Load KW. CT Load % implies the Current Transformer Load as %FLA.

CCU Options: Calibrate

Enter? Apply ct Low % a/d = 652 000.0 .Run the chiller at a known low %FLA, enter the % and press Enter.

? Apply ct Hi % a/d = 2902

.Run the chiller as close to full load as possible, enter the %FLA and press Enter. The reading on the bottom left is the A/D count You may review the raw A/D for the low calibration point and edit it if necessary.. 652

? Edit

ct

Low

? Edit

ct

Hi 2902

You may review the raw A/D for the high calibration point and edit it if necessary...

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V.

Mode: Data Entry-Time/Date Setup

Time and Date are critical system variables because all archives are collected and stored based on this clock.

System Time & Date Setup

Mode Select: Time/Date

This is a passcode protected mode.

Enter

The clock must be reset for daylight time and for leap years.

? Enter Hour 13 ? Enter Minute 45 ? Enter Month 08 ? Enter Day 18 ? Enter Year 05

Use keypad and press Enter. Hours are set in military format. Use keypad and press Enter

Use keypad and press Enter



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V.

Mode: Data Entry-Comm. Setup

Each Chiller must be setup with its own communication ID unless there are only three chillers in the system all controlled within the MCU.

Serial Communication System Setup

Mode Select: Comm. Setup

This is a passcode protected mode.

Enter

The Communication Addresses are assigned when there are slave units present. Typically, there will be slave units when there are more than three chillers in the system.

Enter Slave Address (1-7)

1

Use keypad and press Enter. Addresses start from 0 (only the Master has 0 Address) and slaves start from 1, 2, 3, 4 etc. (non-zero).

CAUTION: If a slave is connected to the local bus it will be assigned this address!!!Enter My Comm. Address (0-7) Use keypad to enter the address of the Master. Press Enter.

0

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V.

Mode: Data Entry-Diagnostic

This is mainly a troubleshooting aid for the technicians.

DiagnosticsDetailed steps in the calibration process can be found in Appendix B

Enter

Dig in: (0=exit)

10010001 00000

Diagnostics for digital inputs and outputs

Enter

a/d in: (0=exit)

xxxx 0

Diagnostics for A/D and D/A Converters

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V.

Mode: Data Entry-Set Passcode

The security to the Data Entry consists of two passcodes: Level 1: Passcode for restricting access to the Extended and System Setup menus. Level 2: Passcode for locking/unlocking the keypad.

Mode Select: Set Passcode

The factory passcode is 0000. Here you can set your own passcode. If not, press the UP or DOWN button to continue selection.

Enter new Passcode

The passcode should be a four digit number and easy to remember. Press Enter. 0000

Enter new keylock

789

This passcode locks out the keypad completely. The keylock passcode should be a three digit number and easy to remember. Press Enter.

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VI. BypassThis is a dedicated button to facilitate quick transfer of chillers from optimizer control to chiller and back.

t

Chiller Bypass FunctionThis function places a chosen chiller under the control of chiller control panel. It is also used to return chiller to optimizer control.

BypassBypass Select: Chiller 1 Use the UP/DOWN buttons to browse through chillers in the system. Press Enter to select.

EnterPress ENTR to Bypass Chiller When Enter is pressed again, the selected chiller will be under the control of its local OEM control system. Note that the Bypass indication LED on the Chiller Optimizer is On.

Enter

Bypassing a chiller does not turn the chiller off.If the chosen chiller was already bypassed, restore it to the control of the Chiller Optimizer, by pressing the BYPASS button again.

Press ENTR to Clear Chiller

This is the prompt if selected chiller is already Bypassed.

When the ENTER button is pushed, the Chiller Optimizer will take control of the loading and unloading of the selected chiller, if the chiller was already running (RTL input active). If the chiller was not running, it will simply be included in the lead/lag sequence to be started when the cooling demand requires additional tonnage. 44

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Chiller Optimizer

CHILLER OPTIMIZER INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSCAUTION!! The wiring and controls for air conditioning systems are varied and frequently reflect the personal preferences of the installing or service contractor. For these reasons, the installation instructions given in this manual are general in nature. Chiller Optimizer should be installed only by a qualified contractor who is able to modify the instructions given here to meet the operational needs of the particular system. Wiring and installation must be done in accordance with all applicable codes, ordinances, and

WARNING VOLTAGES CAPABLE OF CAUSING SEVERE INJURY OR DEATH ARE PRESENT IN AIR CONDITIONING SYSTEMS. THE INSTALLER SHOULD INSURE THAT ELECTRICAL POWER CIRCUITS ARE TURNED OFF WHILE INSTALLING CHILLER OPTIMIZER . TURNING OFF MORE THAN ONE DISCONNECT MAY BE REQUIRED TO REMOVE ALL POWER.

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Energy Optimization Chiller Optimizer

Appendix A TABLE OF CONTENTSPage CHILLER OPTIMIZER INSTALLATION OVERVIEW The Hardware System................................................................................. 3 Direct Vane Relay Control .......................................................................... 4 Analog Control............................................................................................. 4 PWM Control ............................................................................................... 4 Installation Summary ................................................................................... 4 Chiller Preparation....................................................................................... 4 CHILLER OPTIMIZER INSTALLATION DETAILS Controller Mounting ..................................................................................... 5 Field Wiring.................................................................................................. 6 System Power Supply (FX-684) .................................................................. 7 Chiller Control Unit (FX-681) ....................................................................... 8 Controller Power.......................................................................................... 9 120/220 VAC Line Voltage .......................................................................... 9 Chassis Ground........................................................................................... 9 Temperature Sensors.................................................................................. 9 Temperature Sensor Installation ................................................................. 9 Sensor Mounting and Wiring ....................................................................... 9 Air Temperature Sensor .............................................................................. 10 Water Temperature Sensors ....................................................................... 10 Sensor Surface Mounted on Water Pipe ......................................... 10 Sensor Mounted in Thermometer Well ............................................ 10 STATUS INPUT SIGNALS Ready to Load ............................................................................................. 11 KWH Demand Input..................................................................................... 11 USER OPTION SIGNALS Remote Start ............................................................................................... 11 Load Shed/Lag Chiller Lockout ................................................................... 11 Additional Cooling........................................................................................ 11 Remote Bypass ........................................................................................... 11

2

Appendix A



CHILLER OPTIMIZER INSTALLATION OVERVIEWTHE HARDWARE SYSTEM The minimum hardware required for a Chiller Optimizer system is a Master Cabinet (MCU) containing: (1) FX-680 Main Processor Board with keypad and two-line LCD display. (1) FX-681 Master Power Supply Board converting line voltage (110 or 220 vac) to 24 and 5 vdc. In addition, this board conditions the analog inputs (temperatures, etc.) and all the system digital inputs. (1) FX-689 Modem Board. (1) FX-684 Chiller Interface Board. For centrifugal chillers, up to three of these boards may be housed within the MCU cabinet controlling up to three centrifugal chillers. For additional chillers in the system, up to five may be added (remotely mounted) communicating with the MCU via an RS-485 Modbus. Different interface boards are used for reciprocating type chillers (unless they use remote reset interface boards) although the MCU remains the same.

Interwiring Detail Between Boards in the MCU CabinetModem Board Connectors: 6. Serial (TTL) from FX-680 8. Power (8-12vdc) from FX-681

6 +

FX-689 Modem Board

8

DUAL LINE LCD DISPLAYFX-681 Master Power Supply+4

5

RJ-11 Modem Connector

8

FX-680 Master Processor Board

1

10

Chiller 1

9

9

FX-684A Centrifugal

2

13 3 Modem2

RS-485

7

3

Chiller 2

11

Computer (DB9)

1

6

7 4 512

9

9

FX-684A Centrifugal

11

FX-680 MPB CABLES: 1. Digital outputs, 1-8 2. Digital outputs, 9-16 3. Digital inputs, 1-8 4. Analog Inputs/Outputs 5. Power In 8-12vdc 6. Serial Modem TTL 7. Serial Bus, RS-485 8. Power to Modem 9. Power to CCU's 10. CCU1 Signal Cable 11. CCU2 Signal Cable 12. CCU3 Signal Cable 13. Remote Bypass

10

9

Chiller 3

12

9

9

FX-684A Centrifugal

3

Appendix A



DIRECT VANE RELAY CONTROLThe chiller is turned on or off by an interlock relay. The capacity of the chiller is regulated by Chiller Optimizer using two relays, one for increasing capacity and another for decreasing capacity. An AC voltage signal from a current transformer or a 4-20 mA dc signal from a KW transducer are used to monitor chiller capacity. When the capacity increase relay is energized, an actuator motor or another control increases chiller output. When the capacity decrease relay is energized, an actuator motor or other control decreases chiller output. The relay control method is used for centrifugal chiller systems with electric actuator motor controlled vane angle and for screw compressor chiller systems with hydraulic solenoid regulated capacity. ANALOG CONTROL The chiller is turned on or off by an interlock relay. The capacity of the chiller is regulated by Chiller Optimizer with a 4-20 milliamp signal output. The analog signal output may be used in several ways to control the capacity of the chiller: a. The 4-20 mA signal may drive analog input guide vane positioners, electric or pneumatic. If pneumatic, an external I/P or current-to-pneumatic transducer must be used externally to convert the mA to pneumatic pressure. This control method is used for centrifugal chiller systems with pneumatically controlled vane angle and for absorption chillers with pneumatically controlled steam or hot water valves. b. If an interface card is available in the chiller control panel, the 4-20 mA signal may be used to control the load limit and/or the leaving chilled water temperature of the chiller. The appropriate settings must be made on the chiller control panel.

PWM CONTROL Some chillers (specifically those maufactured by York ) will accept a Pulse-Width-Modulated (PWM) remote signal to modulate the current demand limit or offset the leaving water temperature set-point. A special software code is made available in the optimizer to accommodate such an interface. The INCREASE relay is used for the PWM signal output of the optimizer. SUMMARY OF INSTALLATION Chiller Optimizer Millennium Series may be installed using any combination of the two control methods described above. Up to three relay control chillers (chillers 0, 1 & 2) may be controlled by the Master Control Unit (MCU). Up to five additional chillers may be controlled external to the MCU for a total of eight chillers in a system. Control method or type of chiller tied to the MCU bus may be different but they all share the same temperature signals. Each chiller however, has its own interface control module and its own CT or KW load signal terminated to this control module.

4

Appendix A

Installation InstructionsCHILLER PREPARATION


Prior to the installation of Chiller Optimizer, the installer should verify the correct functioning of the chiller system. The check should include chiller controls and safeties. The calibrations of the load limit control circuit and the pilot positioner should be checked and, if required, accurately calibrated as prescribed by the chiller manufacturer.

General Dimensions of the Master Control Unit

5

Appendix A



CHILLER OPTIMIZER INSTALLATION DETAILSCONTROLLER MOUNTING A typical Chiller Optimizer Millennium Series will consist of only one cabinet with up to three centrifugal chiller control cards inside. If more than three chillers are to be optimized, the control cards for the additional chillers will be mounted inside separate boxes and close to their respective chillers. The remote optimizers communicate with the master cabinet via an RS-485 Modbus communication link (two wires and a shield). The Chiller Optimizer MS is suitable for both indoor and outdoor surface mounting although it is typically mounted in a chiller room. The cabinet is rated NEMA 4X however with its fiberglass, corrosion resistant outer shell and a clear acrylic front window. Select a suitable location, such as on a wall or mounting board. The selected location should be dry, lighted, and easily accessible. Locations of extreme vibration, moisture, or heat must be avoided. Mark and drill the pilot holes for mounting screws. (see Dimension Drawing for mounting dimensions). Fasten Chiller Optimizer to the surface area by means of the slot holes in the accessory ears of FIELD WIRING Access to field wiring terminals is gained by unlocking and opening the aluminum control panel. All field wiring terminals are plug-in type and do not require any special lugs or tools. Field wiring is simply terminated by stripping the end of the wire and inserting it into its assigned terminal. There are no holes pre-drilled in the cabinet. The installer may drill the conduit holes in any one of the four sides of the cabinet. The bottom of the cabinet is the side of choice to prevent condensation from entering the cabinet. A minimum of three conduits should be brought to the cabinet: One (or two) conduits should be used to bring in all the low power signal wires from the temperature and KW transmitters. Another conduit should be used for all remote command dry contracts or 24vdc powered signals. A separate conduit should be used for AC power and Chiller RTL, INCR/DECR and INTLK wires. Refer to the external wiring schedule below for correct termination of the field wiring. All field wiring terminates on two boards mounted on the back plate inside the MCU. The FX-684 is the chiller specific board (one per chiller) while the common system signals (all temperatures and remote commands) terminate on the Master Power Supply board (FX-681). Wiring should be done with U.L. approved 600 volt 18-gage or 16-gauge stranded wire. Insulated spade connectors (furnished) should be used for connecting power (110/220 VAC) to the EMI filter directly as marked. All electrical connections to Chiller Optimizer must be from a single-phase electrical power supply with a good earth ground. The FX-684 is a termination board for a centrifugal chiller. It is connected to the P.S./Interface Board from where it receives its power and interfaces to the microprocessor Mother Board.

6

Appendix A



There is an FX-684 board for each centrifugal chiller in the system. Up to (3) FX-684s may be housed inside the Master Control Unit (MCU) each controlling a separate chiller. For more than (3) chillers in the system, additional FX-684s are mounted in separate Chiller Control slave boxes with their own Power Supply and micro-processor boards. These communicate with the MCU via a local Modbus RS-485 network. Each of the FX-684s has provisions for the following input/outputs: 1. (1) AC Input in the 0-10VAC range proportional to CT Load, or dc input in the 4-20 mA range 2. (1) 120/240VAC or 24vdc (jumper selectable) Ready-to-Load input 3. (1) Analog Control Output in the 4-20 mA range 4. (1) Interlock SPST, 5A contact (Chiller START) 5. (1) Increase SPST, 5A contact (Chiller LOAD) 6. (1) Decrease SPST, 5A contact (Chiller UNLOAD) 7. (1) Pump On SPST, 5A contact 8. (1) Bypassed SPST, 5A contact (When Optimizer is bypassed) 9. (1) Chiller FAIL SPST, 5A contact (only Chiller 0) 10. (2) +24vdc internal power supply terminals for use in powering the 4-20 mA loops All relay contacts may be set via jumper selection as Normally Open (Dir) or Normally Closed (Rev). Following are wiring pictorials of the two types of boards found in a typical 3-chiller centrifugal system.

7

Appendix A



MILLENNIUM SERIES CHILLER OPTIMIZER FX-681A POWER SUPPLY BOARD PICTORIAL AND SUGGESTED WIRING

A Master Control Unit (MCU) has one Power Supply Board and up to three Chiller Control Boards (CCUs). A slave unit has one Power Supply and one CCU. Below is a pictorial of an MCU Power Supply which powers and receives signals from all system analog transmitters and remote BAS digital inputs.

WHITE FROM FRONT PANEL SWITCH BLACK 110/220 VAC POWER IN OUTPUT 24VDCL1 L2 +

CHWRT RTD SENSORRED FX-5300A RED TEMP. XMITTER WHITE

OSAT RTD SENSORYELLOW WHITE

CHWST RTD SENSORRED FX-5300A RED TEMP. XMITTER WHITE

FUSE, 1A

POWER TO CPU BOARD

TB1

TB7

FX-5300A TEMP. XMITTER

-

PLACE TWO JUMPERS FOR 110VAC ONE JUMPER (AS SHOWN) FOR 220VAC

BLACK%RH CHWST OSAT CHWRT - + mA In1

ANALOG I/O

MODEM POWER

TB2

2

shld shld

ORANGE

FX-681A Power Supply Board

5

- + mA In

JP1

- + mA In

4

3

TB3

6

shldREMOTE CONTROL CONTACTS POWERED BY THE INTERNAL 24VDC SUPPLY

DIGITAL INPUTS

+ - - + 24vdc 24vdc

11 10 9

- + mA In

8

7

BYPASS CONN.

REM START LOAD SHED

110220J8

TB4

16 15 14 13

DIGITAL OUTPUTS BANK 2

- + 24vdc

RS-485 LOCAL BUS

TB5

+ 24vdc

DITAL OUTPUTS BANK 1

J5

TB6

TB8

GND

J4

A

B

CHILLER 3

CHILLER 2

CHILLER 1

RS-485 TO EXTERNAL SLAVES

J2

POWER TO CCU BOARDS

KWH In

18 17

- + 24vdc

Appendix A

LED5

LED4

LED3

110

12

ADD'L COOLING

REMOTE BYPASS

ORANGE

8

ORANGE

BLACK

BLACK

J7 LED1 LED2

J6



MILLENNIUM SERIES CHILLER OPTIMIZER FX-684 CHILLER INTERFACE BOARD PICTORIAL AND SUGGESTED WIRINGONLY ONE R6 RESISTOR INSIDE EACH MCU. REMOVE OTHERSPOWER EXPANSION CONNECTOR

FX-684 REV. C --- CCU BOARD2498R22 R21 R20 R3

POWER FROM FX-681

+5V GND +24V GND

+5V GND +24V GND

PL1

R19 DIG -I/0TP

R23

JP1

D7

JP2

D8

JP3

D9

D10

JP6 Q4 RC4 RL5 R17

D13

JP7 Q6 R18

D15

499TB7

17

DIRECT

R24 RL1 D3

RL2

D4

RL3

D5

RL4

D6

D12

RL6

D14

QUENCHARC 5

QUENCHARC 3

QUENCHARC 4

QUENCHARC 6

QUENCHARC 1

QUENCHARC 2

+ KW -

RELAY 4

RELAY 2

RELAY 5

RELAY 6

RELAY 1

RELAY 3

-

+24V+

20

4-20 mA

19

+

//SHIELD

6 1

JP5

R16

R12 R13

1

2

3

4

5

6

7

8

9

10R15

OK1 R7

INTLK

INCR

DECRCLOSE VANES

PUMPCHW PUMP ON

-RTL+

TB6

TB3

TB4

TB5

11

D11

BYPASS

12

TB8

13

//

FAIL

21

TYPICAL WIRING OF KWTRANSMITTER (2-WIRE TYPE)

START/STOP

OPEN VANES (PWM)

INPUT READY-TO-LOAD (24VDC/110VAC)

CAUTION: JUMPER MUST BE REMOVED FOR 110VAC RTL SIGNAL!

INSERT JUMPER AND ADJUST POT FOR BYPASS mA LEVEL

OUTPUT DRY CONTACTS

Notes: 1. Relays 1, 2 & 4 have their NC side of the contact brought out to their respective terminals. The circuit is thus closed when power is removed (connectors J1 and/or J2 unplugged). REVERSE selection is normally used for these relays. 2. Rev. B has a 4-20 mA repeater built-in when R6 resistor is in place. When R6 is removed, it becomes a 1-5v to 4-20 mA converter. R6 is on pin jacks so it can be removed without desoldering. 3. Rev. B accepts only analog CT Load signals. The CT Load signal typically comes from the 2wire KW Transmitter and wired as shown below. Externally powered KW signals use + and input terminals (21 & 22).

Appendix A

OUTPUT DRY CONTACTS

22

14

-

RC1

RC2

RC3

RC5

RC6

TB2

R8

18

+

R9

R10

R11

-mA OUT+

Q1

Q2

Q3

Q7 Q5

C4 +

9

ANALOG OUTPUT

REVERSE

U1

R14

1 C1

C3

J2 JP4

J1

R5 C2 +

R6 R6

R4

R2

R1

Q8

Installation InstructionsCONTROLLER POWER


AC power and ground to Chiller Optimizer should be supplied from a circuit separate from the chiller, pumps, or other heavy electrical equipment. The use of a clean dedicated power circuit with a separate ground wire is required. CONTROLLER POWER, 110/220 VAC LINE VOLTAG Connect 110/220 VAC + 10%, 50/60 Hz. line power to terminals labeled H & N (for 110 VAC) or L1 & L2 (for 220 VAC). If desired, a relay may be installed in the line supply leg to Chiller Optimizer to start or stop system operation. The relay may be controlled by timers, load controllers, central computer systems, or safety shut-off devices CONTROLLER CHASSIS GROUND Connect a separate dedicated ground wire from solid earth ground to terminal GND. Terminal GND goes directly to chassis ground through the EMI filter. A high quality ground connection to this terminal is required. Do not depend on conduit for grounding.

TEMPERATURE SENSORS The three temperature sensors provided with the Chiller Optimizer unit are identical in operation. They are all Platinum Resistance Temperature Detectors (RTDs) with 100.0 Ohm base resistance. The only difference is that the water sensors are stick-on type to be installed directly on the chilled water pipes and the air sensor is a probe type mounted in the end fitting of a j-box with its 4-20 mA transmitter inside. Although the transmitters (OCi-5300RTD) are pre-calibrated and marked with the temperature range, finer tuning may be done in the software. TEMPERATURE SENSOR INSTALLATION The effectiveness of the Chiller Optimizer in maintaining user comfort AND saving energy depends on correct temperature sensor location. A temperature sensor on the return water line is required, as this is the control point. A second sensor typically monitors the outside air temperature and a third one the supply or chiller leaving water temperature. SENSOR MOUNTING & WIRING Mounting and wiring instructions for various sensor locations are given below. Each temperature sensor is furnished with a 4-20 mA transmitter. The transmitter is used to amplify the low level signal of the sensor and send a higher level signal to the optimizer without being affected by the wire length. A two-conductor shielded, twisted cable is recommended but the use of two-conductor solid 18-gauge thermostat wire is permitted. If the sensor wiring is run outside the building, it should be placed under eaves or in well shaded areas. Conduit is not required for sensor wiring, but it is recommended.

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Appendix A

Installation Instructions Energy Optimization Chiller Optimizer Installation Instructions Energy Optimization Chiller Optimizer

Typical Temperature Sensor InstallationPlace sensor with adhesive side to the pipe (remove backing)

CHWRWh Red Red

Blk + Or'g - 4-20 mA 32-77

5300RTD

Air Sensor

Conduit Blk + Or'g 4-20 mA 32-122

Typical installation of the Outside Air Sensor. Recommended location: Under the eve of the northern or southern exposure of the building.

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Appendix A



AIR TEMPERATURE SENSOR The use of an outside air temperature sensor is recommended but optional. If the sensor is not used, the Optimizer should be so programmed (see appropriate Data Entry) and the sensor need not be installed. The correct location of an outside air temperature sensor, if used, is very critical. It should be located in an area of stable air that truly reflects the typical outside ambient air temperature. The best location for the sensor is usually high in the center of a north-facing masonry wall. Mounting locations that would expose the sensor to abnormal heat loads must be avoided. Avoid the following locations: 1. in direct sunlight 2. in metal walls 3. close to power transformers, pumps, water pipes, or machinery 4. near cooling towers, intake or exhaust vents, or other draft-producing equipment 5. over parking areas 6. where there is a possibility that the sensor could be unduly affected by ice or snow accumulations. In addition, the sensor should be located high enough to preclude tampering. The air sensor furnished with the Optimizer is an RTD platinum probe mounted through a cordgrip fitting on one end of a j-box. The OCi-5300RTD 4-20 mA transmitter is mounted inside the j-box and factory prewired to the sensor. Two output wires (4-20 mA signal) must be connected by the installer and terminated at the Master Power Supply Board (FX-681). The use of 18-22 g. shielded wire is recommended. The shield is connected to the 24vdc terminal. WATER TEMPERATURE SENSOR Select a water sensor mounting location on a straight run of return water pipe that is heavily insulated on both sides of the proposed sensor location. On lead-lag installations, the return water sensor location must be common to all chillers. One of the two mounting options described below should be used to mount the return water temperature sensor. SENSOR SURFACE MOUNTED ON WATER PIPE -- Using emery or sandpaper, thoroughly clean an area about two inches square on the pipe. All rust and other particulate contaminants must be removed to provide a smooth contact area. Put a generous amount of heat conductive compound (Honeywell Tradeline brand, part number 107408) on the flat surface of the sensor and on the center of the contact area. Use high temperature cable ties to fasten the adhesive side of the sensor tightly to the pipe. Restore the insulation removed from around the pipe to mount the sensor. Proper insulation in this area is required for proper operation of the Optimizer. It has been shown that properly installed sensors will measure the chilled water temperature to within one degree or better. 12

Appendix A



SENSOR MOUNTED IN THERMOMETER WELL -- Prepare a thermometer well in the water pipe. Partially fill the well with heat conductive compound (Honeywell Tradeline brand, part number 107408). Press temperature sensor deep into well and into heat conductive compound. Cap thermometer well opening. Install the OCi-5300RTD transmitters within 5 feet of the sensors in any electrical j-box. The transmitters are only 2x0.75x0.5 and they have a double-stick tape at the bottom. Connect the three like colored wires from the sensor to the transmitter using small wire nuts. The black (+) and orange (-) wires are the 4-20 mA signal which connect to the MCU. STATUS SIGNAL INPUTS READY TO LOAD Each time a chiller is started, Chiller Optimizer must receive the "ready-to- load" or RTL signal from the chiller before the RTL timer times out. This indicates the chiller has started and made transition from its start to its run windings. The RTL timer, a 45 second fixed software timer, starts at time of chiller start. If RTL signal is present when the timer times out, the chiller is loaded to start-up capacity. If the RTL signal is received after the RTL times out, the chiller is loaded immediately. If the RTL is not received within a maximum of 10 minutes, the Optimizer fails the chiller and places it in bypass. A manual intervention is required to bring it back to optimizer control. The RTL signal from the chiller is typically 120 vac or 220 vac, the Optimtizer input is optically isolated. A jumper is used to reduce the current limiting resistor in series with the led of the opto-isolator if the RTL signal is 24 vac or dc. Follow the polarity if dc. The RTL signal is wired to the Chiller Control Unit (CCU) board for each chiller. CAUTION: The jumper must be removed if the RTL signal is 110/220 vac or the resistor and/or the opto-isolator will be damaged. KWH DEMAND INPUT This is another optically isolated pulse input located in the MCU Power Supply board. It is designed to accept pulses from a building KWH meter with a typical 1.0 KWH/pulse. This input is utilized in conjunction with Maximum Demand limits and automatic load shedding if so programmed. USER OPTION SIGNALS Chiller Optimizer has four pairs of terminals on the Master Power Supply board (FX681) that are used to receive dry contact or 24vdc signals activating program options. The program options are "remote start", "load shed", "additional cooling and remote bypass. Again, these are optically isolated inputs with current limiting resistors sized for 24vdc power. If dry contacts, the system 24vdc power may be used. Refer to field wiring for more details.

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Appendix A



Remote Start -- Any remote command from a switch or a building automation computer system may enable or disable the Chiller Optimizer if it is so programmed. (See RTS programming details) Load Shed/Lag Chiller Lockout A 24vdc signal provided to these terminals will cause the Chiller Optimizer to decrease lead and lag chiller capacity by 10% per minute until the signal is terminated or until the "minimum operation %" level is reached. Additional Cooling -- The "additional cooling," signal will cause Chiller Optimizer to lower its target temperature by 3. This change affects both the lead and lag chillers. A target temperature 3 lower than normal will be maintained until the additional cooling signal is terminated. The signal can be sent by a humidistat, a thermostat, or a manual switch. Remote Bypass The remote bypass input places all chillers in Optimizer Bypass mode. Note that if a chiller is configured for remote start from its individual control panel, placing it in optimizer bypass will enable its remote start.

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Appendix A

Operating Instructions

Energy Optimization

Chiller Optimizer

Appendix B Chiller Optimizer Operating Instructions TABLE OF CONTENTSPage I. GENERAL DESCRIPTION Page Soft Start ........................................................................................ 2 MCU Setup.. ........................................................ 12 Soft Variable LoadSetup ............................................................ 12 Basic ......................................................................... 2 Extended Setup...................................................... 13 Temperature Reset ........................................................................ 2 Ready-to-Start Options.......................................... 14 Lead/Lag Options................................................... 15 Low Load Shutdown ..................................................................... 2 Notes on Lead/Lag options............................. 15 KW Demand Setup................................................. 16 Air Temperature Lockout.............................................................. 2 Calibrate....................................................... 17 Lag Chiller Operation .................................................................... 3 CCU Setup.. .......................................... 18 Calibrate .......................................................... 18 Load Shedding............................................................................... 3 Configure. ............................................. 19 Additional Cooling Capacity......................................................... 4 C. Chiller Bypass Function. ..................... 20 Control Safeties ............................................................................. 4 Diagnostic Mode..................................................... 21 D. Digital I/O ......................................................... 21 Reciprocating Control................................................................... 4 Analog I/O ............................................................... 22 Basic SetupAnalog Output ........................................................ 23 by Operator............................................................... 4 Base Return Water Temperature...................................... 5 Base Outside Air Temperature ......................................... 5 Air/Water Reset Ratio ........................................................ 5 Scan Time.................................................................... 5 Time at Minimum Capacity ............................................... 5 Lead/Lag Options .............................................................. 5 Simplified Block Diagram ............................................................. 6 II. OPERATIONAL MODES FOR CHILLER OPTIMIZERS IIII II Operational Modes. 7 A. Display Function..7 MCU Data..8 ..88 CCU Data ..................................................................... 9 System Data.................................................................... 9 Archive View................................................................... 10 B. Data Entry Function........................................................... 11 Starting the Lead Chiller ................................................... 12 Entering Operational Data...12 2

Appendix B


Energy Optimization

Chiller Optimizer

I.

GENERAL DESCRIPTION

The Chiller Optimizer (CO) is a third generation control instrument continuously marketed by Energy Optimization since 1980. It is a selff-contained solid state dedicated microprocessor system, specifically designed to reduce the energy consumption of centrifugal, screw, reciprocating or absorption chiller systems. It is capable of operating a single chiller or multiple (up to eight) chillers in switchable lead-lag sequence. The CO may be used as a stand-alone control or it can be interfaced with timers, load controllers, or central computer systems through the remote contact points. The main features of the CO are: SOFT START The controller soft starts the chiller compressor(s) at the lowest practical capacity level. This "soft" start saves money in two ways: (1) it significantly reduces the electrical peak demand produced each time a compressor is started, overshooting the correct capacity level at start-up. Soft start does not impact supply and return inrush, which is frequently not charged, to the customer by the utility company. SOFT/VARIABLE LOAD After the soft start , the CO uses a variable soft load. This means that the chiller is gradually brought up to match the building load, faster during the warmer months and after shutdowns and slower during cooler months. This is accomplished by having a variable step size that automatically adjusts from 2% to 10% of FLA depending on the requirements of the system. TEMPERATURE RESET Most chillers produce a constant temperature chilled water supply temperature year-round. While a user may occasionally reset this temperature, it does require extra effort and is not generally done. The ELECTRA program monitors outside air temperature and chilled water return temperature, using these parameters to adjust chiller loading at optimum setting. Allowing an increase of 1F in chilled water temperature results in about a 1.5% to 2% savings in energy costs. During cooler weather, an increase of 6 degrees will result in a 9% to 12% cost savings. That's significant! And that's why the Chiller Optimizer II has been designed to continuously and precisely adjust the water temperature to match current conditions. LOW LOAD SHUT-DOWN SEQUENCE During periods when the demand for cooling is low, as at night, a chiller system will reduce its capacity to a point where its operation is very inefficient (from 3 or 4 times the power per ton in constant speed systems). Additionally, operation at

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Appendix B


Energy Optimization

Chiller Optimizer

low loads frequently causes higher motor winding and bearing temperatures, and possibly compressor surging.

I.

GENERAL DESCRIPTION, cont

To avoid this problem, when the chiller reaches its programmed minimum capacity level AND the chilled water temperature is below the target by more than the programmed offset, the CO controller initiates this sequence: The low load timer starts, allowing the chiller to operate at minimum for that time. If the time expires, and the water temperature is still below the target temperature, the chiller is shut down, and will remain off for at least as long as the "TIME @ MIN" setting. If the demand for cooling does return within the time period allowed, then the "TIME @ MIN" is reset, and the sequence is ready to start again if minimum load is perceived. If the chiller does get shut down, a subsequent increase in demand will re-start the chiller, it will soft-start and soft-load in the normal manner. The net result is that the CO low load cycle saves energy by operating the compressor at more favorable efficiency levels and by reducing unnecessary compressor cycling. AIR TEMPERATURE LOCKOUT The CO can be programmed to monitor outside air temperature and hold the chiller system off as long as the outside air temperature is colder than certain user programmable set points. LAG CHILLER OPERATION When a system has two chillers, a front panel switch sets the assignment of which is lead and which is lag. This switch is effective only when the program selection is "local". If it is desired to have a chiller running when the controller wants it off, press the Bypass button to "BYPASS" the particular chiller from th

optimizer manual

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