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Optimizer Manual

Optimizer Manual

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Chiller Optimizer

By

Energy Optimization
Instruction Manual

Controller Face

Energy Optimization

Chiller Optimizer

Table of Contents
Controller 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 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 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 1°F 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 Optimizerä 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, cont’d
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 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

thereby requiring increased loading on the chiller. they are loaded evenly. If they have different capacities. General Description. the controller shuts down the lag chiller and Increases the capacity of the lead chiller to replace the lag chiller capacity that was removed. When an additional cooling signal is received. The system water temperature will be returned to normal when the signal is terminated. 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. Some operations may require lag chiller lockout rather than load shedding. 4 Instruction Manual . the same terminals are used for either. cont’d When the lead chiller can once again satisfy cooling requirements and lag chiller operation is no longer efficient. critical temperature thermostats. RECIPROCATING CONTROL (SERIES R) Capacity controls of reciprocating compressors may be accomplished in several ways. or similar devices can be used to request the CO to increase cooling capacity. The CO will decrease chiller capacity by 10% per minute until the signal is terminated or until the "minimum operation %" level is reached. (The full load capacity of each chiller is entered in the CCU Configuration tables). they are loaded proportionally.Energy Optimization Chiller Optimizer I. The lag chiller shut down is initiated by the "LOW LOAD OFFCYCLE" sequence described above. If the chillers have approximately the same capacity. 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. This may be accomplished by holding the inlet valve open. the controller will lower the return water set point temperature by 3 °F.) ADDITIONAL COOLING CAPACITY Humidity monitors. but all involve some method of bypassing a stage. (It is not necessary to use either. the programmed entry in the MCU Setup determines which operation occurs at contact closure. Routine capacity adjustments resume when the load shed 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.

Note: In later model recip or screw chillers. There are certain parameters that the operator may enter without a passcode.Energy Optimization Chiller Optimizer I. The front control panel of the CO consists of a numeric touch pad with UP/DOWN buttons along with four special function buttons: Mode. A dual line backlighted LCD display is also featured. The CCU is setup to output these signals for capacity control. Explanation of these entries follows with a complete listing of all entries. 5 Instruction Manual . Display. interface cards to accept 4-20 mA or PWM remote signals are available. cont’d Any of these methods are initiated by relays in the controller. enter the Basic Set-up variables and (with a passcode) to enter the Extended Set-up. A selection is made with the UP/DOWN buttons. The Extended Set-up tables are usually accessed by a qualified technician when the system is first set up. The Mode button is used to START/STOP the lead chiller. General Description. 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. The Chiller Optimizerä offers up to 12 Solid State Relays (SSR’s) for unloader control. Enter & Bypass. These are called the Basic Set-up and are accessed by pressing the Mode button twice.

The operator choices are: BASE RETURN WATER TEMPERATURE The desirable return water temperature is set by this control. 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. Conversely. when air temperature goes down. the water temperature set-point is increased. B. this setting should be within a few degrees of the highest summer temperature. The Optimizer Bypass Function entered by pressing the Bypass button button . The Display Function entered by pressing the Display button. Pressing Mode once brings a prompt to “Press Enter to Start or Stop Chiller”. Return water settings usually range between 50°F to 60°F. return water base temperature is reduced by a preset ratio (see below). Pressing Enter shows the numeric value of the variable. A different variable may be selected with the UP/DOWN buttons. 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. When the outside air temperature exceeds the base. Operational Modes There are three basic operational modes of the Chiller Optimizer: A. The Data Entry Function entered by pressing the Mode button C. 6 Instruction Manual . This water temperature will be maintained only when the outside air temperature is equal to the base outside air temperature set point. For system diagnostic or service purposes. 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. Typical settings are from 90°F to 100°F.Energy Optimization Chiller Optimizer II.

0°F change in water temperature.Energy Optimization Chiller Optimizer II. cont’d There 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.0 degF.0 where a 10 degF change in outside air will change the water target temperature by 2. CAPACITY TIME This control prevents the chiller system from short-cycling during low demand conditions. It governs the rate at which chiller capacity changes are made when needed. SCAN TIME The Scan time is set to match the reaction time of the system. MIN. 8 to 12 minutes on large central plants.0. The chiller system will be held at the minimum load for this time. Operational Modes. If water temperature reset from outside air variations is not desired. LEAD/LAG OPTIONS There are five choices of lead/lag selections explained in detail in the Data Entry section 7 Instruction Manual . and return to the chiller. The adjustment rate setting is typically 4 to 6 minutes on average systems. the conservation ratio should be set to 0. A more aggressive setting will be 20. preventing it from cycling on and off. The time should be set to the number of minutes that it takes for water to leave the chiller. a 10° change in outside air temperature from the base will result in 1. be pumped through the building. For a ratio of 10.

Mode button ... Lights up when control is within 1 degF of target temperature Setting MF LED (amber) .......... enter Basic or Advanced Setup Bypass button ............... Loadshedding...Energy Optimization Chiller Optimizer The Chiller Optimizer Face Plate Chiller Optimizer 1 4 7 2 5 8 0 Enter Mode Display Bypassed 10 4 In 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....... When any one of chillers within the MCU is being bypassed 10.......... LCD Dual line......... 6.... Display button ................ 4.. the following special functions are included: 1.......... 3......Enter displayed parameter into memory 2... Outside Air Cutoff 7.. High Limit...... Used to abort entries in process and go to Display mode 9. Supply Temp.. Used to bypass optimizer control of chiller(s) In Control LED (green) .. has tactile numeric buttons for data entry and UP/DOWN buttons for navigating through different tables and variables. Lights up when a chiller is not tracking the target capacity Override LED (amber). Bypassed LED (red)....... 5......... Lights up when a chiller is called to run and it fails to do so 8... on a hinged swing-out plate inside the door of the Optimizer. Chiller MF LED (amber) ......... Enter button.... Lights up when normal set-point control is overridden Examples: Additional Cooling............. In addition.......... Used to start/stop chillers.. back lighted alphanumeric disply 8 Instruction Manual .............

Supply and Return.3 48. Mode: Display Function The keypad Display. °F 54.3 Home Display: The dual line LCD display is typically displaying the header water temperatures. The choices for display in either line may be scrolled by using the arrow UP/DOWN buttons while the display is blinking.3 Display shows a blinking “MCU Data:” message on top line with CHWST on the bottom line (previously selected). °F Press Display button: 48. the second line of the display will start blinking. Enter button selects the blinking variable and returns to a steady Display MCU Data: CHWS T. such as MCU Data:. If pressed again. the top line of the display will start blinking with a message reflecting the previous selection made for that line. 9 Instruction Manual . °F CHWS T. UP/DOWN and Enter buttons are used to display variables. Display When the button is momentarily depressed. settings and miscellaneous data values of the Chiller Optimizer CHWR T. The display. The blinking line will be selected if Enter is pressed. Other variables may be selected as explained below.Energy Optimization Chiller Optimizer III.

Chiller Control Unit Data Sys Data: --.Viewing Collected Archives 10 Instruction Manual . UP/DOWN and Enter buttons are used to display variables. settings and miscellaneous data values of the Chiller Optimizer Display CHWR T.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 --.Energy Optimization Chiller Optimizer III. Mode: Display Function The keypad Display. °F MCU Data: 54.System Data Arch View: --.Master Control Unit Data CCU Data: --.

CHWS T.Energy Optimization Chiller Optimizer III.0 Press an Arrow key and the display will sequence to “CHWS T. °F Value:” Chilled Water Header Supply Temperature.MCU Data The 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. Mode: Display Function . OAT. Target °F °F 64.3 48.0 Press an Arrow key and the display will sequence to “OSA T. °F °F 64. °F Value:” Chiller Return Water Temperature CHWR T. Enter Each time an arrow key or is pressed the MCU Data is displayed in the following sequence: CHWR T. CHWR T. °F °F 64. CHWR T.3 48.3 Press an Enter key and the display will sequence to “CHWRT. Press the Enter key when “MCU Data” is blinking to start the selection of variables to display from the MCU data :table.3 48. °F Value:” (Outside Air Temperature) CHWR T. °F °F 64.0 Press an Arrow key and the display will sequence to “Target °F Value:” (Target Temperature for Return Water) 11 Instruction Manual .3 64.

Value” (minimum capacity timer in seconds). Sys Cap % °F 64. system is not at Minimum Capacity.3 0 Press an Arrow key and the display will sequence to “Curr Cap Value” (The Current Capacity in tons being used) CHWR T. Mode: Display Function .3 0 Press an Arrow key and the display will sequence to “Scan Tmr. If not changing. Chg 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.Energy Optimization Chiller Optimizer III. Value” (Time remaining in the load update Scan Timer in Seconds) CHWR T.MCU Data.3 0 Press an Arrow key and the display will sequence to “MinCap Tmr. cont’d The 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. Chg Value” (The Present System %Target Capacity Change) CHWR T.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. Avail Cap °F 64. 64. Curr Cap °F 64. °F 64.7 Press an Arrow key and the display will sequence to “%Cap. Scan Tmr. 12 Instruction Manual . °F MinCap Tmr. °F %Cap.3 14. CHWR T.

mcu: °F 64.MCU Data. Refer to the CCU Table for individual chiller parameters and/or variables. CHWR T.3 0 Press an Arrow key and the display will sequence to “Lo Ld Tmr.Energy Optimization Chiller Optimizer III. cont’d The Master Control Unit (MCU) Display Table contains most variables associated with the system rather than individual chillers. If not changing. Value” (Chiller operating sequence currently being used) CHWR T. system is not in OFF state.3 123xxxxxx Press an Arrow key and the display will sequence to “Seq. 13 Instruction Manual .3 MCU Clear Press an Arrow key and the display will sequence to “mcu Override/Clear” status of Master Control Unit. °F 64. Value” (off state timer in seconds). Mode: Display Function . CHWR T. CHWR T. Lo Ld Tmr. mcu: °F IDLE 64.3 Press an Arrow key and the display will sequence to “mcu Value” (Active/Idle Status of Master Control Unit). Seq: °F 64.

The up or down arrows determine whether Chiller 2. °F Chiller 2 64.Energy Optimization Chiller Optimizer III.3 Press an Arrow key and the display will show “Chiller 2” . CHWR T. Enter CHWR T. °F Chiller 1 64. °F Chiller 3 64.CCU Data These are all the parameters and variables associated with each chiller in the system. or DOWN arrow to rotate to another chiller. CHWR T. “Chiller 3” etc. 3… is chosen (depending how many chillers are in the system). let’s say.3 Press Enter key and the display will show “Chiller 1” blinking in the display. at chiller 1. Press ENTER to select. Mode: Display Function . CHWR T. blinking in the display. the following information may be displayed by pressing the Enter key and arrow key 14 Instruction Manual .3 When the display is.3 Press Display and Arrow key until the display shows Chiller Control Unit “CCU Data:” blinking. °F CCU Data: 64.

CHWR T. ccu1: °F 64.3 0.CCU Data.0 Press Arrow key and the display will show the “CT1 Targ %” . seconds). CHWR T. °F Run Time1: 64. This is the signal from the chiller 1 KW transmitter. chiller 1 is not waiting for a Ready-to-Load signal.Energy Optimization Chiller Optimizer III. RTL1 Tmr.3 No Fault Press Arrow key and the display will show the Fail State of ccu1. CHWR T. CHWR T. °F CT1 Load % 64. Mode: Display Function .3 0. The CO is calling for this percent of total capacity from chiller 1. chiller 1 is shown as an example. Any one chiller may be selected. 15 Instruction Manual . °F CT1 Targ % 64. If not changing.3 CONTROL Press Arrow key and the display will show the control state of ccu1. °F 64. ACTIVE or IDLE.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.0 Press Arrow key and the display will show the “CT1 Load % (Percent FLA Reading for Chiller1). cont’d These are all the parameters and variables associated with each chiller in the system.3 0 Press Arrow key and the display will show the “RTL1 Tmr value “ (Ready-to-Load Timer for Chiller 1. CHWR T. ccu1: °F 64.

Arch. °F Sys Data: 64.3 68 Press Enter key and the display will show the “Arch. Arch. Enter CHWR T.3 10 Press the Arrow key and the display will show the “Reset:Cnt. Max: Value” (Maximum number of Archives the internal memory can hold before it starts overwriting) CHWR T. Cnt: Value” (Number of Archives Stored) 16 Instruction Manual .3 Press Display and Arrow key until the display shows “Sys Data:” blinking. Cnt: °F 64.3 18:33:34 Press Enter key and the display will show the “Time: Value” (Present clock time in military time). Mode: Display Function . CHWR T.Sys Data The keypad buttons are used to display the System data values of the Chiller Optimizer CHWR T. Reset Cnt. Max: °F 64.” (Total number of Archive Resets) CHWR T. Time: °F 64.Energy Optimization Chiller Optimizer IV. °F 64.3 1945 Press the Arrow key and the display will show the “Arch.

Date: °F 64. Value” (Scheduled KWH Demand for current period) CHWR T. S/N °F 64. KwH Tot: °F 64.3 1.Sys Data. Value” (Total KWH since last reset) CHWR T. Value” (Power Demand in KWH for current period) CHWR T. Tot. Value” (present date in real time) 17 Instruction Manual .Energy Optimization Chiller Optimizer III. Mode: Display Function . °F KwHr Dmd: 64.3 0 Press Enter key and the display will show the “KwHr. Rmp. °F KwHr Rmp: 64.50000. Value” (The Embedded Controller Serial Number) CHWR T.3 mm/dd/yyyy Press Enter key and the display will show the “Date. cont’d The keypad buttons are used to display the System data values of the Chiller Optimizer CHWR T.3 000 Press Enter key and the display will show the “KwHr.3 0 Press Enter key and the display will show the “KwHr. Value” The Software code version of the Optimizer) CHWR T.0000 Press Enter key and the display will show the “Ver. Dmd. Ver °F 64.3 001e36440000 Press Enter key and the display will show the “S/N.

They are typically collected by the PC Monitor program. ? arch # °F 64. °F Arch View: 64. Mode: Display Function . When an archive is selected the following may be displayed by using the arrow keys: CHWR T. They can also be viewed in this Display mode.Energy Optimization Chiller Optimizer III. Archives are collected and stored in non-volatile memory once every Demand Period. Archives are numbered from 0001 to 1950. 15:00 °F 64.Arch Data The keypad buttons are used to display the stored Archive data values of the Chiller Optimizer.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. ? arch # °F 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 Enter CHWR T..3 00001 Enter the number 1 for Archive number Enter CHWR T.3 MM/dd/YYYY Time and Date of the Archive is displayed 18 Instruction Manual . CHWR T.

19 Instruction Manual . Target: °F 64. CHWR T. Mode: Display Function . They can also be viewed in this Display mode.0 Press the Arrow key and The Outside Air Temperature at the time and date of the archive is displayed. SupW: °F 64. KWH1 °F 64. CHWR T.3 0 Press the Arrow key and Tonnage Load for all running chillers at the time and date of the archive is displayed. cont’d The keypad buttons are used to display the stored Archive data values of the Chiller Optimizer.0 Press the Arrow key and the header Supply Water Temperature at the time and date of the archive is displayed. CHWR T. Archives are collected and stored in non-volatile memory once every Demand Period.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. OutA: °F 64.3 00. Load % °F 64.0 Press the Arrow key and The Target Temperature for Return Water at the time and date of the archive is displayed. °F Load Tons: 64. They are typically collected by the PC Monitor program.Arch Data.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.Energy Optimization Chiller Optimizer III. CHWR T. CHWR T. CHWR T.3 00.3 00.

CHWR T. RetW: °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. Mode: Display Function .3 00234 Press the Arrow key and Total Kw-Hr in this demand period at the time and date of the archive is displayed. KwDmd: °F 64. They are typically collected by the PC Monitor program. Archives are collected and stored in non-volatile memory once every Demand Period.Arch Data.3 00. 20 Instruction Manual .0 Press the Arrow key and The Return Water Temperature at the time and date of the archive is displayed.Energy Optimization Chiller Optimizer III. cont’d The keypad buttons are used to display the stored Archive data values of the Chiller Optimizer. They can also be viewed in this Display mode. Kw_Hr: °F 64. CHWR T.0 Press the Arrow key and Maximum Demand for this Period at the time and date of the archive is displayed. MD: °F 64. CHWR T.3 00. CHWR T.

Mode: Start/Stop Chillers The keypad buttons are used to input the data values of the Chiller Optimizer Starting the Lead Chiller Mode Press Mode The Lead Chiller may be started Press ENTER to Start Chiller Note: To avoid starting chillers press either the MODE or DISPLAY buttons to exit start-up.Energy Optimization Chiller Optimizer IV. 21 Instruction Manual . Enter Press ENTER This Starts the Lead Chiller. Display returns Home.

Energy Optimization Chiller Optimizer IV. Mode: Start/Stop Chillers. Display returns to Home Display. cont’d The keypad buttons are used to input the data values of the Chiller Optimizer Stopping All Chillers Mode Press ENTER to Stop Chiller If chiller(s) are not running. Note: To avoid shutting down chillers press either the MODE or DISPLAY buttons. 22 Instruction Manual . the display will prompt “Press ENTER to Start Chiller”. Press ENTER Enter This STOPS all Chillers.

There is also a password protected Basic Setup with more detailed Lead/Lag configuration options and certain other detailed parameters. ? Base RetW °F 056. Press “Enter” again to input the value into the controller. Mode: Data Entry-Basic Setup The keypad buttons are used to input the data values of the Chiller Optimizer BASIC SETUP Basic Setup Press “MODE” twice. By pressing the “0” then “5” then “6” then “0” buttons the value of 056.0 By pressing the ENTER at any of the Basic Setup screens you will be taken directly to that parameter’s input screen. Base RetW °F 059. 23 Instruction Manual .0 °F. This allows you to alter the basic setup for “Base Water Temperature” and other settings from the Basic Menu.Energy Optimization Chiller Optimizer V. Example: Pressing ENTER on Base RetW. was stored and the display returns to Home. It is intended for operating people to change basic parameters.0 will be entered into the display. Mode must be pressed twice again to change another parameter in the Basic Setup. the Base Return Water Temp. The Arrow keys allow you to scroll up or down for other basic setup parameters. Now the Base RetW is 056. Mode Mode Basic Setup: Base RetW Note: This Basic Setup is entered without a passcode.0 Enter By pressing Enter.

Basic Setup: Scan Time This is how frequently the CO makes a chiller load capacity change (in seconds). Mode: Data Entry-Basic Setup. Basic Setup: outAir Cutoff Below this Outside Air Temp.0 degF change. A setting of 20 makes a 2. Press Arrow to select another variable..0 for every 10 degF change in OSAT. Basic Setup: Air/Water Ratio Mode Mode If the OSAT deviates from the Base above. chillers will not startup (once turned off). A ratio of 10 makes a change of 1.Energy Optimization Chiller Optimizer V. 24 Instruction Manual . a change is made to the Base RetW. cont’d The keypad buttons are used to input the data values of the Chiller Optimizer Basic Setup: Base RetW Pressing Mode twice again you re-enter the Basic Setup. 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.

2. but the start and stop times are set under passcode (in MCU “Ext’d Setup”).3. the Return Water Temp. but the start and stop times are set under passcode (in MCU “Ext’d Setup”).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. cont’d The keypad buttons are used to input the data values of the Chiller Optimizer 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.2.3. 25 Instruction Manual . The User Sequence is scheduled under passcode.1 or any random sequence as set in MCU “Ext’d Setup” Basic Setup: Setback1 Temp This changes a Setback1 Base Water Temp.0 degF. Chillers 1. Mode: Data Entry-Basic Setup.Energy Optimization Chiller Optimizer V. is exceeded. Basic Setup: Setback2 Temp This changes a Setback2 Base Water Temp. SP is reduced by 1. Basic Setup: Sup Lim High When this Supply Water Temp.

Mode: Data Entry-System Setup The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Instruction Manual . Entry to the Configuration Tables is gained by pressing “Mode” three times . Most or all these parameters will likely be entered at installation time. Enter Passcode 0000 Enter This 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.Energy Optimization Chiller Optimizer V. System Setup Mode Mode Mode After the four digit pass code is input (factory default is 0000) and the ENTER Button is pushed. the Optimizer is in the Setup Mode.

Energy Optimization Chiller Optimizer V. Mode: Data Entry-MCU 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 done at installation time. Master Control Unit (MCU) Setup Mode Select: MCU Setup Enter This is a subset list of inputs for MCU setup Basic Setup Ext’d 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. Enter button at any subset you will be taken to the input menu for 27 Instruction Manual . By pressing the ENTER that subset.

Enter time to start in military format. the Start and Stop times will be prompted. Mode: Data Entry-MCU Setup. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. It replaces the normal Base Return Water Temperature Set-point at specific times of day. this prompt appears. except for the following additional entries. 28 Instruction Manual . It replaces the normal Base Return Water Temperature Set-point at different times from Setback1. Start Hour 00 Start Minute 00 If a non-zero entry is made above. Most or all these parameters will likely be done at installation time. If not desired. Basic Setup This is the same as the Basic Setup discussed above (without passcode).Energy Optimization Chiller Optimizer V. a second Setback Base Water Temperature. If entry is non-zero. Basic Setup: Setback2 Temp This is Setback2. Stop Hour 00 Stopt Minute 00 Enter time to stop and go back to the normal Setpoint. enter 00. Basic Setup: Setback1 Temp This entry is a Setback1 Base Water Temperature.

cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. This is the number of chillers controlled by the MCU controller (a maximum of 3). ? No. It should be done first because it defines the number of chillers in the system and other key system parameters.0 This is the minimum water temperature offset before the lead chiller can start or stop. MCU Setup: Ext’d Setup Pressing. ? Min Cap Time (minutes) At this Minimum Capacity. a timer starts 0001 ? Min Capacity % 030. the Extended Setup is entered. Extended Setup This is the main System Configuration table.Energy Optimization Chiller Optimizer V. Enter. Mode: Data Entry-MCU Setup. 29 Instruction Manual . ? # Local CCUs 03 ? RetW Offset °F 000. Chillers 03 This is the total number of chillers controlled by the Chiller Optimizer control system. Up to (5) additional slave units may be connected externally. Most or all these parameters will likely be done at installation time.0 Percent minimum capacity when the “Minimum Capacity” Timer starts. The Extended set-up configures the entire chiller system.

Most or all these parameters will likely be done at installation time. ? Gain 1% 001. 0=no) 0 Is Load Shed or Lockout used? This is the external control contact terminal assignment. Choice between °F or °C is made with Arrow then Enter. ? Gain 3% 001. it will stay off for this no. ? Ld Shed Lockout (1=yes. ? Air Sensor (1=yes. ? Temp Units Deg. ? Min Off Time (minutes) 002 Minimum off cycle time in minutes. outside air reset is disabled. 30 Instruction Manual . Mode: Data Entry-MCU Setup.0 Gain control per degree for 2 °F or higher deviation. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. ? Gain 2% 001. When the lead chiller is turned off by the optimizer.0 Gain control for 0 – 1 °F deviation. F Specifies units for all temperature inputs and calculations.Energy Optimization Chiller Optimizer V. 0=no) 1 Is an Outside Temperature Sensor used? If No.0 Gain control for 1 -2 °F deviation. of minutes.

31 Instruction Manual . Ready-to-Start (RTS) Options Choice for Start-up Mode Start-up starts the Lead Chiller MCU Setup: RTS Options RTS (Ready-To-Start) option allows the selection of the System start-up mode. Mode: Data Entry-MCU Setup. further prompts apply.Refer to Appendix B for details. next day on optimizer control). ? RTS Options: M and V Chiller Optimizer runs under the Measurement and Verification(M and V) Mode (one day in Bypass. ? 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. Most or all these parameters will likely be done at installation time. If Enter.Energy Optimization Chiller Optimizer V. ? RTS Options: Timer Start-up is based on time/day of week. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly.

32 Instruction Manual .8) 0 Enter the order of the chillers to be started starting with the 1st chiller. Most or all these parameters will likely be done at installation time. Basic Setup: Ld/Lag Options When in Lead/Lag Options the User Sequence is selected. Lead/Lag Options This is the same as the Basic Setup discussed above (without passcode). except for the following additional entries. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. Ld/Lag Options User_Sequence Enter the order of the chillers to be started as demand for cooling increases.. here the arbitrary sequence of chillers may be programmed. Mode: Data Entry-MCU Setup.. ? 1 st chiller: (1.Energy Optimization Chiller Optimizer V. ? 2 nd chiller: (1.8) 0 Enter the 2nd chiller to be started…continuing to the last chiller. Press Enter.

Mode: Data Entry-MCU Setup. It is defined as KW demand or KVA demand. 1800 or 3600 seconds respectively) as defined by the contract with the local utility or energy provider. The KW-HR’s accumulated during this period determine the rate at which the user is using electricity.Energy Optimization Chiller Optimizer V. if exceeded during any one demand period during the month. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. 30 minutes or one hour (900. Most or all these parameters will likely be done at installation time. ? Kw_Hr / pulse 01. KW Demand Setup This subset of menus is used to setup the KW Demand. The contract with the utility calls for a maximum monthly KW demand which. or electrical sensing and interpretation electrical sensed inputs for the Chiller Optimizer. 33 Instruction Manual .00 This is the numerical value in KWH for each pulse of a utility’s pulsing demand meter. This period is typically either 15 minutes. ? 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. A separate KW-HR transducer is recommended producing one pulse per KW-HR and installed in the main feed line metered by the utility. may impose surcharges and/or increased cost per KW-HR in the final bill.

Mode: Data Entry-MCU Setup.0 ? Max Kw_Hr Dmd 001000 This is the contractual maximum demand as set by the utility.Energy Optimization Chiller Optimizer V. a ramp is internally generated from zero to some max. cont’d The System must be setup for the chiller plant in order for Chiller Optimizer to function properly. 0=no) This clears out the Archive memory. ? Clear Archives (1=yes. 34 Instruction Manual . ? Kw_Hr ramp offset 00000 In order to schedule the demand over the demand period. value. The ramp reaces this number in one demand period. Most or all these parameters will likely be done at installation time. An offset is set here instead of starting from 0. 0 ? Set KwHr Total 00000020 This is the starting number for the total building’s KWHr’s.

Mode: Data Entry-MCU Setup. cont’d Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly. Pressing the ENTER button at this screen takes you to the a/d converter calibration screen 35 Instruction Manual . MCU Calibrate: Calibration of Temperature Sensors Detailed 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. Most or all these parameters will likely be done at installation time. 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.Energy Optimization Chiller Optimizer V.

Chiller Control Unit (CCU) Setup Mode Select: CCU Setup Each Chiller Control Unit (CCU) is configured in this Setup Table. Once an Option is chosen. Enter Pressing ARROW buttons will scroll through the chillers by number. press the Enter button to chose that Option 36 Instruction Manual . 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. Most or all these parameters will likely be done at installation time. Mode: Data Entry-CCU Setup Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly.Energy Optimization Chiller Optimizer V. Once a chiller is selected press the ENTER Button.

Enter Deadband for CT Load in %. Mode: Data Entry-CCU Setup. The KW rating at 100% capacity. ? Min. Select with Arrow then Enter.0 Enter Start-up minimum Load in % FLA. Enter ? Capacity Tons 1000 Enter rated capacity in Tons. This applies only when Direct Vane control is used . 37 Instruction Manual . cont’d Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly.Energy Optimization Chiller Optimizer V.0 Adjust Type: Variable Max Kw: Set KWHR Total 00067039 Initialize the KWH counter for this chiller. Select the type of load/unload adjustment between fixed step or variable step. CCU Configure CCU Options: Configure After chiller is selected. Adj. Most or all these parameters will likely be done at installation time. ? Minimum % 030.0 Enter Minimum Capacity in % FLA. % 002.0 Enter Minimum Load/Unload Step in %. ? Startup % 030. 0500 ? CT Deadband % 001. the parameters corresponding to that chiller are stored.

This applies to chillers with remote reset interface cards.0 Enter Capacity in % at 4ma. Mode: Data Entry-CCU Setup. 38 Instruction Manual . Available Chiller Types ? Chiller Type: Centrifugal Centrifugal Reciprocating ? Chiller Type: Reciprocating MA Output PWM ? Chiller Type: mA Output % at 4mA 000. Enter Capacity in % at 20ma.Energy Optimization Chiller Optimizer V. cont’d Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly.0 ? Chiller Type: PWM These are York chillers with PWM remote reset. Most or all these parameters will likely be done at installation time. % at 20mA 100.

cont’d Each Chiller in the chiller plant must be setup in order for Chiller Optimizer to function properly.. CCU Calibrate This is a software calibration procedure of the KW transmitter of each chiller to read 0-100% Full Load KW. Mode: Data Entry-CCU Setup.Run the chiller at a known low %FLA. Most or all these parameters will likely be done at installation time. 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.0 . “CT Load %” implies the Current Transformer Load as %FLA. enter the % and press Enter.Energy Optimization Chiller Optimizer V.Run the chiller as close to full load as possible.. CCU Options: Calibrate Enter ? Apply ct Low % a/d = 652 000. 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. 39 Instruction Manual . ? Apply ct Hi % a/d = 2902 ..

Use keypad and press Enter Use keypad and press Enter Use keypad and press Enter Use keypad and press Enter 40 Instruction Manual . System Time & Date Setup Mode Select: Time/Date This is a passcode protected mode. Mode: Data Entry-Time/Date Setup Time and Date are critical system variables because all archives are collected and stored based on this clock. Enter The clock must be reset for daylight time and for leap years. Hours are set in military format.Energy Optimization Chiller Optimizer V. ? Enter Hour 13 ? Enter Minute 45 ? Enter Month 08 ? Enter Day 18 ? Enter Year 05 Use keypad and press Enter.

Enter Slave Address (1-7) 1 Use keypad and press Enter. Mode: Data Entry-Comm. 4 etc. Setup This is a passcode protected mode. CAUTION: If a slave is connected to the local bus it will be assigned this address!!! Enter My Comm. Serial Communication System Setup Mode Select: Comm. Addresses start from 0 (only the Master has 0 Address) and slaves start from 1. 2. Address (0-7) Use keypad to enter the address of the Master. Enter The Communication Addresses are assigned when there are slave units present. (non-zero). 3. there will be slave units when there are more than three chillers in the system. Press Enter. 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.Energy Optimization Chiller Optimizer V. Typically. 0 41 Instruction Manual .

Diagnostics Detailed 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 42 Instruction Manual .Energy Optimization Chiller Optimizer V. Mode: Data Entry-Diagnostic This is mainly a troubleshooting aid for the technicians.

Mode Select: Set Passcode The factory passcode is 0000. Enter new Passcode The passcode should be a four digit number and easy to remember. Here you can set your own passcode.Energy Optimization Chiller Optimizer 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. press the UP or DOWN button to continue selection. 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. If not. Level 2: Passcode for locking/unlocking the keypad. 43 Instruction Manual . Press Enter. Press Enter.

Note that the “Bypass” indication LED on the Chiller Optimizer is On. If the chiller was not running. Bypass Bypass Select: Chiller 1 Use the UP/DOWN buttons to browse through chillers in the system. 44 Instruction Manual . It is also used to return chiller to optimizer control.Energy Optimization Chiller Optimizer VI. Press ENTR to Clear Chiller This is the prompt if selected chiller is already Bypassed. When the ENTER button is pushed. if the chiller was already running (RTL input active). the selected chiller will be under the control of its local OEM control system. restore it to the control of the Chiller Optimizer. t Chiller Bypass Function This function places a chosen chiller under the control of chiller control panel.” If the chosen chiller was already bypassed. Enter Bypassing a chiller does not “turn the chiller off. Bypass This is a dedicated button to facilitate quick transfer of chillers from optimizer control to chiller and back. Press Enter to select. Enter Press ENTR to Bypass Chiller When Enter is pressed again. it will simply be included in the lead/lag sequence to be started when the cooling demand requires additional tonnage. by pressing the BYPASS button again. the Chiller Optimizer will take control of the loading and unloading of the selected chiller.

the installation instructions given in this manual are general in nature. ordinances. TURNING OFF MORE THAN ONE DISCONNECT MAY BE REQUIRED TO REMOVE ALL POWER. and WARNING VOLTAGES CAPABLE OF CAUSING SEVERE INJURY OR DEATH ARE PRESENT IN AIR CONDITIONING SYSTEMS. For these reasons. 45 Instruction Manual .Energy Optimization Chiller Optimizer CHILLER OPTIMIZER INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CAUTION!! The wiring and controls for air conditioning systems are varied and frequently reflect the personal preferences of the installing or service contractor. THE INSTALLER SHOULD INSURE THAT ELECTRICAL POWER CIRCUITS ARE TURNED OFF WHILE INSTALLING CHILLER OPTIMIZER . Wiring and installation must be done in accordance with all applicable codes. 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.

Installation Instructions

Energy Optimization Chiller Optimizer

Appendix A TABLE OF CONTENTS
Page 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

Installation Instructions

Energy Optimization Chiller Optimizer

CHILLER OPTIMIZER INSTALLATION OVERVIEW
THE 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 Cabinet
Modem Board Connectors: 6. Serial (TTL) from FX-680 8. Power (8-12vdc) from FX-681

6 +

FX-689 Modem Board

8

DUAL LINE LCD DISPLAY
FX-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 Modem
2

RS-485

7

3

Chiller 2

11

Computer (DB9)

1

6

7 4 5
12

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

Installation Instructions

Energy Optimization Chiller Optimizer

DIRECT VANE RELAY CONTROL
The 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 Instructions
CHILLER PREPARATION

Energy Optimization Chiller Optimizer

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

the control cards for the additional chillers will be mounted inside separate boxes and close to their respective chillers. Another conduit should be used for all remote command dry contracts or 24vdc powered signals. The selected location should be dry. 6 Appendix A . All field wiring terminals are plug-in type and do not require any special lugs or tools. moisture. and easily accessible. The Chiller Optimizer MS is suitable for both indoor and outdoor surface mounting although it is typically mounted in a chiller room. The installer may drill the conduit holes in any one of the four sides of the cabinet.L. Locations of extreme vibration. or heat must be avoided. 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).S. Refer to the external wiring schedule below for correct termination of the field wiring. such as on a wall or mounting board. All field wiring terminates on two boards mounted on the back plate inside the MCU. The cabinet is rated NEMA 4X however with its fiberglass. Insulated spade connectors (furnished) should be used for connecting power (110/220 VAC) to the EMI filter directly as marked. 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. If more than three chillers are to be optimized. Field wiring is simply terminated by stripping the end of the wire and inserting it into its assigned terminal. The bottom of the cabinet is the side of choice to prevent condensation from entering the cabinet. INCR/DECR and INTLK wires. 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. corrosion resistant outer shell and a clear acrylic front window. It is connected to the P. Select a suitable location.Installation Instructions Energy Optimization Chiller Optimizer CHILLER OPTIMIZER INSTALLATION DETAILS CONTROLLER MOUNTING A typical Chiller Optimizer Millennium Series will consist of only one cabinet with up to three centrifugal chiller control cards inside. lighted. approved 600 volt 18-gage or 16-gauge stranded wire. Wiring should be done with U./Interface Board from where it receives its power and interfaces to the microprocessor Mother Board. There are no holes pre-drilled in the cabinet. Mark and drill the pilot holes for mounting screws. The remote optimizers communicate with the master cabinet via an RS-485 Modbus communication link (two wires and a shield). All electrical connections to Chiller Optimizer must be from a single-phase electrical power supply with a good earth ground. A separate conduit should be used for AC power and Chiller RTL. The FX-684 is a termination board for a centrifugal chiller. (see Dimension Drawing for mounting dimensions).

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

Installation Instructions Energy Optimization Chiller Optimizer 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 (CCU’s).+ 24vdc 24vdc 11 10 9 . 1A POWER TO CPU BOARD TB1 TB7 FX-5300A TEMP.+ 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 ..+ mA In JP1 . XMITTER WHITE FUSE. A slave unit has one Power Supply and one CCU. XMITTER - PLACE TWO JUMPERS FOR 110VAC ONE JUMPER (AS SHOWN) FOR 220VAC BLACK %RH CHWST OSAT CHWRT .+ mA In 8 7 BYPASS CONN. WHITE FROM FRONT PANEL SWITCH BLACK 110/220 VAC POWER IN OUTPUT 24VDC L1 L2 + CHWRT RTD SENSOR RED FX-5300A RED TEMP. Below is a pictorial of an MCU Power Supply which powers and receives signals from all system analog transmitters and remote BAS digital inputs.+ 24vdc Appendix A LED5 LED4 LED3 110 12 ADD'L COOLING REMOTE BYPASS ORANGE 8 ORANGE BLACK BLACK J7 LED1 LED2 J6 .+ mA In 1 ANALOG I/O MODEM POWER TB2 2 shld shld ORANGE FX-681A Power Supply Board 5 . REM START LOAD SHED 110 220 J8 TB4 16 15 14 13 DIGITAL OUTPUTS BANK 2 . XMITTER WHITE OSAT RTD SENSOR YELLOW WHITE CHWST RTD SENSOR RED FX-5300A RED TEMP.+ mA In 4 3 TB3 6 shld REMOTE CONTROL CONTACTS POWERED BY THE INTERNAL 24VDC SUPPLY DIGITAL INPUTS + .

REMOVE OTHERS POWER EXPANSION CONNECTOR FX-684 REV. Relays 1. it becomes a 1-5v to 4-20 mA converter. Rev. Rev. B accepts only analog CT Load signals. When R6 is removed. C --. 2 & 4 have their NC side of the contact brought out to their respective terminals.CCU BOARD 249 8 R22 R21 R20 R3 POWER FROM FX-681 +5V GND +24V GND +5V GND +24V GND PL1 R19 DIG -I/0 TP R23 JP1 D7 JP2 D8 JP3 D9 D10 JP6 Q4 RC4 RL5 R17 D13 JP7 Q6 R18 D15 499 TB7 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 10 R15 OK1 R7 INTLK INCR DECR CLOSE VANES PUMP CHW 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. 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 . The circuit is thus closed when power is removed (connectors J1 and/or J2 unplugged).Installation Instructions Energy Optimization Chiller Optimizer MILLENNIUM SERIES CHILLER OPTIMIZER FX-684 CHILLER INTERFACE BOARD PICTORIAL AND SUGGESTED WIRING ONLY ONE R6 RESISTOR INSIDE EACH MCU. R6 is on pin jacks so it can be removed without desoldering. 3. REVERSE selection is normally used for these relays. B has a 4-20 mA repeater built-in when R6 resistor is in place. The CT Load signal typically comes from the 2wire KW Transmitter and wired as shown below. 2.

Do not depend on conduit for grounding. The use of a clean dedicated power circuit with a separate ground wire is required. 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. A high quality ground connection to this terminal is required. Although the transmitters (OCi-5300RTD) are pre-calibrated and marked with the temperature range. line power to terminals labeled H & N (for 110 VAC) or L1 & L2 (for 220 VAC). 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. 10 Appendix A . The relay may be controlled by timers. If desired.Installation Instructions CONTROLLER POWER Energy Optimization Chiller Optimizer AC power and ground to Chiller Optimizer should be supplied from a circuit separate from the chiller. They are all Platinum Resistance Temperature Detectors (RTD’s) with 100. or other heavy electrical equipment. A temperature sensor on the return water line is required. CONTROLLER POWER. pumps. finer tuning may be done in the software. TEMPERATURE SENSORS The three temperature sensors provided with the Chiller Optimizer unit are identical in operation. central computer systems. 50/60 Hz. as this is the control point. but it is recommended. SENSOR MOUNTING & WIRING Mounting and wiring instructions for various sensor locations are given below. 110/220 VAC LINE VOLTAG Connect 110/220 VAC + 10%. Each temperature sensor is furnished with a 4-20 mA transmitter.0 Ohm base resistance. twisted cable is recommended but the use of two-conductor solid 18-gauge thermostat wire is permitted. load controllers. it should be placed under eaves or in well shaded areas. TEMPERATURE SENSOR INSTALLATION The effectiveness of the Chiller Optimizer in maintaining user comfort AND saving energy depends on correct temperature sensor location. If the sensor wiring is run outside the building. 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 two-conductor shielded. Conduit is not required for sensor wiring. A second sensor typically monitors the outside air temperature and a third one the supply or chiller leaving water temperature. a relay may be installed in the line supply leg to Chiller Optimizer to start or stop system operation.

Installation Instructions Energy Optimization Chiller Optimizer Installation Instructions Energy Optimization Chiller Optimizer Typical Temperature Sensor Installation Place sensor with adhesive side to the pipe (remove backing) CHWR Wh Red Red Blk + Or'g . 11 Appendix A . Recommended location: Under the eve of the northern or southern exposure of the building.4-20 mA 32-77 5300RTD Air Sensor Conduit Blk + Or'g 4-20 mA 32-122 Typical installation of the Outside Air Sensor.

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

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

The "additional cooling. 14 Appendix A . The signal can be sent by a humidistat. a thermostat. A target temperature 3° lower than normal will be maintained until the additional cooling signal is terminated.Installation Instructions Energy Optimization Chiller Optimizer Remote Start -. (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." signal will cause Chiller Optimizer to lower its target temperature by 3°. Additional Cooling -. This change affects both the lead and lag chillers. 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. Remote Bypass – The “remote bypass” input places all chillers in Optimizer Bypass mode. or a manual switch.Any remote command from a switch or a building automation computer system may enable or disable the Chiller Optimizer if it is so programmed.

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

This means that the chiller is gradually brought up to match the building load. GENERAL DESCRIPTION The Chiller Optimizer (CO) is a third generation control instrument continuously marketed by Energy Optimization since 1980. The main features of the CO are: SOFT START The controller soft starts the chiller compressor(s) at the lowest practical capacity level. faster during the warmer months and after shutdowns and slower during cooler months. Soft start does not impact supply and return inrush. reciprocating or absorption chiller systems. 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. using these parameters to adjust chiller loading at optimum setting. the CO uses a variable soft load. as at night. 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.5% to 2% savings in energy costs. overshooting the correct capacity level at start-up. load controllers. The CO may be used as a stand-alone control or it can be interfaced with timers. to the customer by the utility company. It is a selff-contained solid state dedicated microprocessor system. which is frequently not charged. Additionally. LOW LOAD SHUT-DOWN SEQUENCE During periods when the demand for cooling is low. screw. During cooler weather. TEMPERATURE RESET Most chillers produce a constant temperature chilled water supply temperature year-round. specifically designed to reduce the energy consumption of centrifugal.Operating Instructions Energy Optimization Chiller Optimizer I. This "soft" start saves money in two ways: (1) it significantly reduces the electrical peak demand produced each time a compressor is started. it does require extra effort and is not generally done. The ELECTRA program monitors outside air temperature and chilled water return temperature. SOFT/VARIABLE LOAD After the soft start . While a user may occasionally reset this temperature. an increase of 6 degrees will result in a 9% to 12% cost savings. It is capable of operating a single chiller or multiple (up to eight) chillers in switchable lead-lag sequence. operation at 3 Appendix B . Allowing an increase of 1°F in chilled water temperature results in about a 1. 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). or central computer systems through the remote contact points.

This switch is effective only when the program selection is "local". press the Bypass button to "BYPASS" the particular chiller from the optimizer. (The full load capacity of each chiller is entered in the CCU Configuration tables). they are loaded proportionally. when the chiller reaches its programmed minimum capacity level AND the chilled water temperature is below the target by more than the programmed offset. and possibly compressor surging. If they have different capacities. and the sequence is ready to start again if minimum load is perceived. If the chillers have approximately the same capacity. 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. a subsequent increase in demand will re-start the chiller. The lag chiller shut down is initiated by the "LOW LOAD OFF-CYCLE" sequence described above. the controller shuts down the lag chiller and increases the capacity of the lead chiller to replace the lag chiller capacity that was removed. and will remain off for at least as long as the "TIME @ MIN" setting. the CO regulates the capacities of both chillers. 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. and the water temperature is still below the target temperature. then the "TIME @ MIN" is reset. they are loaded evenly. When the lead chiller can once again satisfy cooling requirements and lag chiller operation is no longer efficient. the CO controller initiates this sequence: The low load timer starts. If the chiller does get shut down. allowing the chiller to operate at minimum for that time. LAG CHILLER OPERATION When a system has two 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. con’t To avoid this problem. If it is desired to have a chiller running when the controller wants it off. 4 Appendix B . If the demand for cooling does return within the time period allowed. GENERAL DESCRIPTION. between 75% and 100% capacity. The CO controller starts the lag chiller(s) when the lead chiller reaches a user programmed threshold set point. a front panel switch sets the assignment of which is lead and which is lag. If the time expires. I. to satisfy cooling requirements. The lag chiller is soft started. the chiller is shut down.Operating Instructions Energy Optimization Chiller Optimizer low loads frequently causes higher motor winding and bearing temperatures. The chiller may then be controlled from the chiller control panel. when the RTL signal is received.

Some operations may require lag chiller lockout rather than load shedding. 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.) 5 Appendix B .Operating Instructions Energy Optimization Chiller Optimizer I. the programmed entry in the MCU Setup determines which operation occurs at contact closure. GENERAL DESCRIPTION. the same terminals are used for either. (It is not necessary to use either. con’t 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.

Enter & Bypass. enter the Basic Set-up variables and (with a passcode) to enter the Extended Set-up. This may be accomplished by holding the inlet valve open. There are certain parameters that the operator may enter without a passcode. A dual line backlighted LCD display is also featured. thereby requiring increased loading on the chiller. The Chiller Optimizer offers up to 12 Solid State Relays (SSR’s) for unloader control. 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. GENERAL DESCRIPTION.9 1 4 7 2 5 8 0 Enter 3 6 9 In Control Setting MF Override Chiller MF Mode Display Bypassed Bypass Appendix B . The system water temperature will be returned to normal when the signal is terminated. 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. A selection is made with the UP/DOWN buttons. The Mode button is used to START/STOP the lead chiller. °F CT Load. the controller will lower the return water set point temperature by 3 °F. critical temperature thermostats. The Extended Set-up tables are usually accessed by a qualified technician when the system is first set up. These are called the Basic Set-up and are accessed by pressing the Mode button twice. Explanation of these entries follows while complete listing of all entries is found in the Data Entry section. con’t ADDITIONAL COOLING CAPACITY Humidity monitors. but all involve some method of bypassing a stage.Operating Instructions Energy Optimization Chiller Optimizer I. 6 CHWR T.8 69. BASIC SET-UP BY OPERATOR The front control panel of the CO consists of a numeric touch pad with UP/DOWN buttons along with four special function buttons: Mode. RECIPROCATING CONTROL Capacity controls of reciprocating compressors may be accomplished in several ways. When an additional cooling signal is received. CONTROL SAFETIES The CO will allow the control panel of the chiller to protect the system if any of the safeties are violated. Any of these methods are initiated by relays in the controller. Display. % 56. or similar devices can be used to request the CO to increase cooling capacity.

In general. air temperature:water temperature. A digit on the thumbwheel is a 100:1 ratio. this setting should be within a few degrees of the highest summer temperature. 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. The adjustment rate setting is typically 4 to 6 minutes on average systems. Return water settings usually range between 54°F to 60°F. Typical settings are from 90°F to 100°F. If air temperature water temperature reset is not desired. A different variable may be selected with the UP/DOWN buttons. 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. The coldest water temperature will be provided when the actual outside temperature exceeds this point. It governs the rate at which chiller capacity changes are made when needed. At this setting the CO will operate as a precision controller to maintain the water temperature at the base set point. a 10 digits change on the thumbwheel results in 1. For system diagnostic or service purposes. The time should be set to the number of minutes that it takes for water to leave the chiller.Operating Instructions Energy Optimization Chiller Optimizer I. GENERAL DESCRIPTION. 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. CAPACITY TIME This control prevents the chiller system from short-cycling during low demand conditions. con’t Pressing Mode once brings a prompt to “Press Enter to Start or Stop Chiller”. then the conservation ratio should be set to 00. be pumped through the building.0°F change in water temperature for every 10° change in outside air temperature from the base. BASE OUTSIDE AIR TEMPERATURE This is the set point at which maximum cooling is needed. 7 Appendix B . This water temperature will be maintained only when the outside air temperature exceeds the base outside air temperature set point. The operator choices are: BASE RETURN WATER TEMPERATURE The absolute minimum allowable return water temperature is set by this control. preventing it from cycling on and off. SCAN TIME The Scan time is set to match the reaction time of the system. The chiller system will be held at the minimum load for this time. that is. Pressing Enter shows the numeric value of the variable. and return to the chiller. MIN. 8 to 12 minutes on large central plants.

Operating Instructions LEAD/LAG OPTIONS Energy Optimization Chiller Optimizer There are five choices of lead/lag selections explained in detail in the Data Entry section 8 Appendix B .

Maximum Demand software in conjunction with the KWH Transducer.Operating Instructions Energy Optimization Chiller Optimizer Chiller Optimizer Simplified Block Diagram Notes: 1. 9 Appendix B . call for Load Shedding. call for additional cooling. Energy Management or Building Automation Systems may interface with the Optimizer to Start/Stop the chillers. 2. call for Locking Out lag chillers or Bypass Optimizer. 15-minute data is stored for retrieval via modem. may be used for auto load shedding when building total demand is likely to be exceeded. 3.

the top line of the display will start blinking with a message reflecting the previous selection made for that line. The different display groups are summarized below with more detailed explanation following: Display MCU Data: Enter CCU Data: Enter Sys Data: Arch View: Enter Time. DISPLAY FUNCTION When the Display button is momentarily depressed. . MinCap Tmr. Date Kw-Hr: KwDmd: MD: RetW: SupW: OutA: Target: Load %: Load Tons: KWH1 KWH2 * KWH8 Chiller 1 Chiller 2 Chiller 3 Enter for 3 chillers CT1 Load % CT1 Targ % RTL1Tmr. The Enter button selects the blinking variable and returns to a steady display. CT1 Tmr.Operating Instructions Energy Optimization Chiller Optimizer II. Run Time1 KWH1 ccu1: ccu1: CHWR T. The Display Function entered by pressing the Display button. OPERATIONAL MODES FOR CHILLER OPTIMIZERS There are three basic operational modes of the Millennium Series optimizers: A. The choices for display in either line may be scrolled by using the arrow UP/DOWN buttons while the display is blinking. °F (or °C) OSA T. The blinking line will be selected if Enter is pressed. Seq. Cap % Scan Tmr. Cnt: Arch. Low Ld Tmr. such as MCU Data:. Max: Reset Cnt: 10 Appendix B . the second line of the display will start blinking. °F (or °C) CHWS T. The Optimizer Bypass Function entered by pressing the button Bypass button A. B. If pressed again. The Data Entry Function entered by pressing the Mode C. Chg Avail Cap Curr Cap Sys.: mcu: mcu: ? arch # 0001 0002 0003 * * Time: Date: KWH Tot: KwHr Dmd: KwHr Rmp Ver S/N Arch. °F (or °C) Target °F (or °C) %Cap.

0(30. DISPLAY FUNCTION. °F (or °C) OSA T. con’t 1.0(8.: mcu: Typical Reading 59.0% 160 640 80% 360 300 150 123XXXXX IDLE Load Shed Remote Override Status of Master Control Unit mcu: 11 Appendix B . MinCap Tmr.0(15.3) 47. Chg Avail Cap Curr Cap Sys. .5(15. Cap % Scan Tmr.0) -6. °F (or °C) CHWS T.5) 59.3) 87. °F (or °C) Target °F (or °C) %Cap. Low Ld Tmr. Seq.0 MCU Data: Variable Description Return Water Temperature Leaving Water Temperature Outside Air Temperature Return Water Target Temperature Percent Target Capacity Change Capacity in Tons available in system System Capacity in Tons being used System Capacity in Percent being used Load Update (Scan) Timer in seconds Minimum Capacity Timer in seconds Off State Timer in seconds Chiller Operating Sequence Active/Idle Status of Master Control Unit Mnemonic CHWR T.Operating Instructions Energy Optimization Chiller Optimizer A.

0 CCU Data: When CCU Data is selected. con’t Appendix B Total No. seconds Timer for Current Load Signal for Chiller 1. DISPLAY FUNCTION. of Archive Resets 12 . con’t Arch. con’t 2. Run Time0 Total KWH ccu1: ccu1: Typical Reading 79. 1. The display choices for each chiller selected are as follows: Variable Description Percent FLA Reading for Chiller 1 Percent FLA Target for Chiller 1 Ready-to-Load Timer for Chiller 1. The Down arrow may be used to select chiller 0. 2 etc.1239 004742610000 DISPLAY FUNCTION. Max: Reset Cnt: A. month/day/year Total KWH since last reset Power Demand in KWH for current period Scheduled KWH Demand for current period Software Code Version of Optimizer Embedded Serial Number of Optimizer No.10903.0 65 8 250:48 5890 IDLE No Fault 3. Cnt: Arch. of Archives Mnemonic Time: Date: KWH Tot: KwHr Dmd: KwHr Rmp Ver S/N 968 2047 62 Typical Reading 15:47:29 10/01/01 123456 365 390 1. seconds Total Run Time for Chiller 1 in hours and minutes Total KWHrs used by Chiller 1 (since last reset) Active/Idle Operating Status of Chiller 1 Fail Status of Chiller 1 Mnemonic CT1Load % CT1 Targ % RTL1Tmr. of Archives Stored Maximum No. military time Present Clock Date.0 SYS Data: Variable Description Present Clock Time.5 81. another blinking display appears requesting the specific Chiller Control Unit to be chosen. DISPLAY FUNCTION.Operating Instructions Energy Optimization Chiller Optimizer A. CT1 Tmr.

A prompt will appear “?arch # 0000” which requires a valid archive no.0 OutA: 88. does not exist. to be entered from the keypad. a fault message “**Out of Range**” will appear on the display.3 753 13 Appendix B .4 75.Operating Instructions Energy Optimization Chiller Optimizer 4.0 Arch View: This function allows the viewing of a particular archive stored in memory.6 Target: Load %: Load Tons: KWH1 7890 KWH2 3450 KWH3 1230 KWH4 KWH5 KWH6 KWH7 KWH8 450 0 0 0 0 58. 10/02/01 RetW: 58.9 SupW: 48. Archive List: Variable Description Time and Date of the Archive Total Kw-Hr since last reset Total Kw-Hr in this demand period Maximum Demand Entry for this period Return Water Temperature Leaving Water Temperature Outside Air Temperature The Target Temperature for Return Water The Percent Load on all chillers (% of total capacity) The Tonnage Load on all chillers running KW-Hr reading for Chiller 1 KW-Hr reading for Chiller 2 KW-Hr reading for Chiller 3 KW-Hr reading for Chiller 4 KW-Hr reading for Chiller 5 KW-Hr reading for Chiller 6 KW-Hr reading for Chiller 7 KW-Hr reading for Chiller 8 Kw-Hr: KwDmd: MD: 1000 25985 756 Mnemonic Typical Reading 16:15. If such an archive no. The table below lists all possible variables as recorded at the end of the archive (demand) period.

DATA ENTRY FUNCTION The different functions of the Mode button are summarized below with more detailed explanation following: It is used to: a. Units Gain 1 % Gain 2 % Gain 3 % Air Sensor (Y/N) Ld Shed/Lockout Local/Rem Timer Local_Addr Least_Hours Tons_Lo_Hi Tons_Hi_Lo User Seq.Operating Instructions Energy Optimization Chiller Optimizer B. Enter the Operating Variables without a passcode. Capacity% Min. Chillers # Local CCU’s Lag Startup% Min. Start the Lead Chiller and Stop all chillers when pressed once (confirmed by “Enter”) b. Time Min. % ?CT Deadband % ?Chiller Type ?Adjust Type ?Max KW ?Set KWH Return Water (low & hi) Supply Water (low & hi) Outside Air (low & hi) ?Dmd Period ?Kw_Hr/pulse ?Kw_Hr Ramp Off ?Max Kw_Hr Dmd ?Auto Load Shed ?Clear Archive ?Set KWHR Total 14 Appendix B . Comm Setup Enter Chiller 2 Chiller 3 Apply ct low% Apply ct hi% Edit ct low Edit ct hi CCU Options: Calibrate Configure ?Capacity Tons ?Startup % ?Minimum % ?Min. when pressed twice c. Cap. Enter all variables including system parameters. Date Clear Archives Basic Setup Ext’d Setup RTS Options CCU Select Chiller 1 Ld/Lag Options Kw Dmd Calibrate No. Adj.8 My Address 0…7 Enter Enter Enter Enter Enter Time. Mode Start/Stop Chiller Basic Setup: Enter Enter Starts Lead Chiller or Stops all Chillers Base RetW Base Out Air Air/Water Ratio OutAir Cutoff Scan Time Ld/Lag Options Setback1 Setback2 Sup Lim High Dig In 00000000 Dig Out 000000 A/D XXXX Channel 0 Base RetW Base Out Air Air/Water Ratio Out Air Cutoff Scan Time Ld/Lag Options Setback1 Setback2 Sup Lim High Enter Passcode Enter 0000 Mode Select: Time/Date Diagnostic MCU Setup CCU Setup Slave Address 1…. Off Time Temp. when pressed three times with passcode.

If Enter is pressed. Base OutAir T.0 Outside Air Temperature Cutoff Load Adjustment Time OutAir Cutoff Scan Time 0-99°F 10-1200 sec 45. Operational data may be edited by pressing Mode twice and selecting the variable to edit. press Mode again to move to the next prompt. Other setup entries are made by pressing three times and entering a passcode. the message will be “Press ENTR to Stop Chiller”.1 Setback Water Temp. If not. Upper Limit Setback2 Temp Sup Lim High 40-70°F 40-70°F 15 50°F Appendix B . Local_Addr Enter or Skip (arrow down) Chiller with least run hours Least_Hours Enter or Skip (arrow down) Chiller with lowest ton rating Tons_Lo_Hi Enter or Skip (arrow down) Chiller with highest ton rating Tons_Hi_Lo Enter or Skip (arrow down) Arbitrary Sequence by local addr. cont’d The lead chiller is started by pressing the Mode key until the message “Press ENTR to Start Chiller” is read on the display. the optimizer will turn on the “Interlock” and “Pump” relays and wait for the “Ready-to-Load” signal to start loading the lead chiller in the sequence. ng the Lead Chiller Entering Operational Data Data is entered via the keypad on the front panel of the MCU or via a PC (through an RS-232 serial port) by running a proprietary loader program. Note: If the chiller(s) is running.2. These are entries made by a qualified technician. Variable Base Return Water Temperature Base Outside Air Temperature Air-to-Return Water Temp.0°F 90.0°F 360 Lead/Lag Chiller Selection Ld/Lag Options Enter or Skip (arrow down) Choices are: Comm Address No. This is assuming that the return water temperature is sufficiently above the target temperature (more than the Min. there is no demand for cooling and no chiller will be started. 1 Setback1 Temp 40-70°F Setback Water Temp. Water Temp. 2 Supply Temp.Operating Instructions Energy Optimization Chiller Optimizer B. Ratio Mnemonic Base RetW T. No passcode is required for entering the Basic Setup. DATA ENTRY FUNCTION. MCU (Master Control Unit) SETUP: BASIC SETUP Entered by pressing MODE twice (No passcode required) and selected with arrow UP or DOWN. If it is NOT desired to stop the chiller(s). Offset entered in the Ext’d Setup Table).0°F 15. Air/Water Ratio Entry Range 40-70°F 40-120°F 0-49 Typical 58. User_Sequence 3.

0% 10 Minimum Off Cycle Time. (*)The UP/DOWN buttons are used to scroll through the variables without changing the existing settings except when selecting temp. minutes Selection of Temperature Units(*) Control Gain for 0-1°F deviation Control Gain for 1-2°F deviation Control Gain for 2-3°F deviation Is Outside Air Temp.0 1 1=Lockout. Reset Used? Is Load Shed or Lockout Used? ? Min Off Time ? Temp. 16 Appendix B .0 001.Operating Instructions Energy Optimization Chiller Optimizer B. 0=Loadshed Note: The Remote Load Shed digital input has a dual function determined by the above entry. DATA ENTRY FUNCTION. cont’d MCU (Master Control Unit) SETUP: EXTENDED SETUP Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Number of Chillers in the System Number of Chillers controlled by MCU Minimum Water Temp. the digital input is used to force load shedding.0% 15. 0=no 25 °F 003. Units ? Gain 1 % ? Gain 2 % ? Gain 3 % ? Air Sensor ? Ld Shed/Lockout 0-500 °F. If 1 is entered. Chillers ? # Local CCU’s ? RetW Offset °F ? Lag Startup % Min Capacity % Min Cap Time Entry Range 1-8 1-3 0-20°F 75-100% 0-100% 0-500 Typical 2 2 2. Offset Percent Load for Lag Chiller Start Percent Minimum Capacity Time At Minimum Capacity. °C 1-10 1-10 1-10 1=yes. The arrow selects the units. units. minutes Mnemonic ? No.0 002. the Enter button must be used to continue.0°F 90. the same digital input forces a lockout of all lag chillers (only the lead chiller remains operational). When 0 is entered.

Arrow Down to go to Timer. When Timer is selected. units. DATA ENTRY FUNCTION.Operating Instructions Energy Optimization Chiller Optimizer B. the following prompts appear: ? RTS Timer: ? Start Hour ? Start Minute ? Stop Hour ? Stop Minute ? RTS Timer: ? HStart Hour ? HStart Minute ? HStop Hour ? HStop Minute ? RTS Timer: ? Sunday: Regular Start 00 00 00 00 Holiday Start 00 00 00 00 Holiday Mask (1=on. cont’d MCU (Master Control Unit) SETUP: READY-TO-START (RTS) Options Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Choice for Start-Up Mode Local Mnemonic ? RTS Options Entry Range Typical Local/Remote/Timer Press Enter to select Local. 0 1. 0=off) 0-23 Military Hour 0-60 0-23 0-60 0-23 Military Hour 0-60 0-23 0-60 1. 17 Appendix B . 0 1. The arrow selects the units and the Enter button must be used. 0=off) (1=on. 0 1. 0 1. 0=off) (1=on. Arrow Down to go to Remote. 0 (*)The UP/DOWN buttons are used to scroll through the variables without changing the existing setting except when selecting temp. 0=off) (1=on. 0=off) 1. 0 09 30 20 15 09 30 20 15 ? Monday: ? Tuesday: ? Wednesday: (1=on. 0=off) (1=on. 0 ? Thursday: ? Friday: ? Saturday: (1=on. 0=off) 1.

2.3..8) 0 0 0 0 0 0 0 1. say all 500 tons.8 1. assigning slightly different tonnage may be advisable if the tonnage sequencing is to be utilized..8) ? 4th chiller: (1. In the PC program..6. In the maximum of three local centrifugal chiller configuration system.6. the local addresses are defined by the three 10-conductor ribbon cable connectors in the FX-681 Power Supply Board.7.3. Arrow Down to go to the next choice.3. 4.8 1.7.3.3. 5. User_Sequence ? 1st chiller: (1..4.. Address 1 is the CCU connected to the cable nearest the screw terminals.8 1.4.3.8) ? 2nd chiller: (1. Tons High to Low.5.Operating Instructions Energy Optimization Chiller Optimizer B. DATA ENTRY FUNCTION. configuring machines at 499. the sequence will be ascending with the local chiller being the 1st and the slave chillers according to the Comm ID’s assigned to them. Using the configuration tonnage again.2. The configuration of each CCU includes its tonnage.. 2. every time it gets turned on.8) ? 7th chiller: (1. 3.6.2.6.3.5. which can be selected in sequencing chillers: 1.8) ? 5th chiller: (1.8 1.7. NOTE: If all machines are equal tonnage.8 1.4. cont’d MCU (Master Control Unit) SETUP: LEAD/LAG Options Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Choice for Chiller Sequence Mnemonic ? Ld/Lag Options Local_Addr Least_Hours Tons_Lo_Hi Tons_Hi_Lo User_Sequence Entry Range Press Enter to select User defined lead/lag sequence.4. Tons Low to High. It’s also used to report the total tonnage available or currently being used at any time and stored in the archives.2. a timer runs accumulating total hours and minutes for each chiller.2. For example.7.7.7. In a configuration where there is only one local chiller and the others are remote. This is an arbitrary sequence configured in the Extended Setup menu of the MCU but it is callable by the Basic Setup menu (no passcode).8 Notes on Lead/Lag Selection Choices There are five choices. Least Hours. 2 & 3 as assigned to these cables.8 1.7.4. The sequence will then be Chiller 1.5.5. User Sequence.4.6.6.6. 500 and 501 tons will not much affect any of the data but it will offer another sequence opportunity. the Basic Setup menu allows the full sequence configuration.5.8) ? 6th chiller: (1.4. This number is used for sequencing the machines from the lowest to the highest tonnage assigned to each machine.2..5. Local Address. As soon as a CCU is configured. machines are sequencing in the order of highest to the lowest tonnage.2. 18 Appendix B . The chiller with the least accumulated hours is the first to start followed by the next with the second least hours etc.8) ? 3rd chiller: (1.5.

if exceeded during any one demand period during the month. 19 Appendix B . A separate KW-HR transducer is recommended producing one pulse per KW-HR and installed in the main feed line metered by the utility. cont’d MCU (Master Control Unit) SETUP: KW DEMAND SETUP: Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Configuring the Demand period* Mnemonic Entry Range 1-3600 0-99. DATA ENTRY FUNCTION. 0=no 1=yes. may impose surcharges and/or increased cost per KW-HR in the final bill. The contract with the utility calls for a maximum monthly KW demand which. 0=no 0-99999999 (*) Demand Period is the time period the electric utility uses to define rate of energy use. This period is typically either 15 minutes.Operating Instructions Energy Optimization Chiller Optimizer B.99 ? Demand Period (seconds) ? Kw-Hr / pulse ? Kw-Hr Ramp Offset ? Max Kw-Hr Dmd ? Auto Load Shed ? Clear Archive ? Set KWHR Total 0-999999 0-999999 1=yes. 30 minutes or one hour (900. The KW-HR’s accumulated during this period determine the rate at which the user is using electricity. 1800 or 3600 seconds respectively) as defined by the contract with the local utility or energy provider. It is defined as KW demand or KVA demand.

cont’d MCU (Master Control Unit) SETUP: CALIBRATE Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN The software calibration routine is based on applying a live signal near the bottom part of the range and another near the top part of the range. 2. Outside Air Temp. a/d = XXXX 80.0 Use keypad to enter a hi Temp. XXXX=raw output counts of the A/D in the 0-4095 range Raw A/D value as read for the low calibration live point Raw A/D value as read for the high calibration live point 0-4095 0-4095 20 Appendix B . the may be edited if desired.0 Use keypad to enter a low Temp. Variable Mnemonic Entry Range ? MCU Calibrate: Software Calibration for the following input analog variables.Operating Instructions Energy Optimization Chiller Optimizer B. DATA ENTRY FUNCTION. Once the values are stored in non-volatile memory. The software reads the A/D values corresponding to these two points and draws a straight line between them. The actual numerical values used are not critical as long as they are known. Typical for all: ? Apply RetW low ? Apply RetW hi ? Edit RetW low ? Edit RetW hi a/d = XXXX 32. (optional) 3. Supply Water Temp. selected with arrow up/down: 1. Return Water Temp.

Operating Instructions Energy Optimization Chiller Optimizer B.0 Entry Range Use keypad to enter a low Temp. cont’d CCU (Chiller Control Unit) SETUP: CCU Select Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Select the Chiller Controller Mnemonic CCU Select: Entry Range 1.8 CCU (Chiller Control Unit) SETUP: CCU Options Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Variable Mnemonic Entry Range (select with arrow up/down) Calibrate Configure Select the Function CCU Options: CCU (Chiller Control Unit) SETUP: CALIBRATE Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN The only calibratable analog variable associated with each Chiller Control Unit is the Amps or KW drawn by the chiller. DATA ENTRY FUNCTION. XXXX=raw output counts of the A/D in the 0-4095 range for 4 mA = 650 0-4095 20 mA=3250 0-4095 21 Appendix B . . It is called the Current Transformer Load (CT Load) and it is expressed as Percent(%) Full Load Amps (or KW). a/d = XXXX 77.2 ….0 Use keypad to enter a hi Temp. Variable ? Apply RetW low ? Apply RetW hi ? Edit RetW low ? Edit RetW hi Mnemonic a/d = XXXX 32.

0 25.0 2. DATA ENTRY FUNCTION. % ? CT Deadband ? Chiller Type ? Adjust Type 0-9999 0-100. start up conditions etc. of compressor stages Minimum % = 0 Min.Operating Instructions Energy Optimization Chiller Optimizer B.0 Centrifugal Variable Enter the KW rating at 100% capacity Set starting KW-Hrs for the counter IMPORTANT NOTE: ? Max KW ? Set KWH 1000 0 When Chiller Type selection is a RECIPROCATING CHILLER.0 0-100. cont’d CCU (Chiller Control Unit) SETUP: CONFIGURE Entered by pressing MODE three times (with passcode) and selected with arrow UP or DOWN Each chiller controller must be configured to its chiller. Load/Unload Step in % Enter Deadband for CT Load in % Select (with Up/Dwn arrow) Chiller Type Select the type of load/unload adjust. Entry Enter Rated Capacity in Tons Enter Start-up Minimum Load in %FLA Enter Min. % = Same as Startup % Adjust Type = Fixed 22 Appendix B .0 Centrifugal Reciprocating Fixed Variable 0-9999 0-99999999 750 15. Capacity in %FLA Enter Min.0 0-100.0 0-100. Adj. ? Capacity Tons ? Startup % ? Minimum % ? Min. must be entered in this table.0 2. such as rated tonnage and KW capacity. Information specific to the chiller. Adj. the following settings are recommended: Startup % = 100 / no. Variable Mnemonic Entry Range Typ.

The following message will then appear: Press ENTR to Bypass Chiller When the Enter button is pressed again. the following message will appear on the display: Press ENTR to Clear Chiller Once the Enter button is pressed. Bypass button is used to bypass any one of the optimizers When the button is momentarily pressed.Operating Instructions Energy Optimization Chiller Optimizer C. CHILLER BYPASS FUNCTION The Chiller Optimizer running. If the optimizer was already bypassed and the desired task is to reactivate it. It simply allows the control panel of the chiller to load and unload the compressor. the optimizer will again take control of the loading/unloading of the chiller. the optimizer is bypassed but without shutting down the chiller or the pump. 23 Appendix B . the following message appears on the display: Bypass Select: Chiller 1 With the Up/Down buttons. select the optimizer of the chiller to be bypassed and press Enter.

the digital inputs shown will correspond to the following external digital input signals (from left to right): 1. RTL for chiller 2 5. The arrow keys are used until “diagnostic” comes up on the display. CAUTION: If the optimizer is already installed and connected to a chiller. In an MCU with three local CCU’s. KWH demand input pulse signal 3. RTL for chiller 1 If “1” is displayed instead of “0”. Digital I/O diagnostics b.Operating Instructions Energy Optimization Chiller Optimizer D. To enter the diagnostic mode. The top line shows all eight digital inputs to the optimizer. Remote Load-Shed (or Lag Lock-Out) 7. Additional Cooling 6. no. There are two parts to the diagnostic mode: a. Remote Bypass 4. 1 bit may be flickering because there is no signal to hold it in either “0” or “1” state. RTL for chiller 3 2. Analog I/O diagnostics Digital I/O Diagnostics The first display will be: Dig In 00000000 Dig Out 000000 This is the digital I/O test display. In such a case. Note: If a bit flickers between “0” and “1”. press the mode button three times and enter the passcode as prompted. Remote Start 8. DIAGNOSTICS MODE: The diagnostic routine is part of the embedded software of the optimizer designed to facilitate the input/output hardware testing of the optimizer before it is commissioned. it means that the corresponding input is active. as it would be if there are only two local chillers and no RTL for chiller 3. 24 Appendix B . make certain the chiller does not respond to the optimizer signals as the diagnostic routine will operate relays and or change the analog outputs. it is probably because that input is floating (not used). Press ENTER.

25 Appendix B . For example. Note: Two of the relays on the Chiller 2 and Chiller 3 CCU boards will not be activated because they are the 17th and 18th digital outputs which do not exist on the MCU board (there are only 16 digital outputs). To exit this part of the diagnostic routine. relays 1 and 2 (and lights “In Control” and “Setting MF”) will be activated.Operating Instructions Energy Optimization Chiller Optimizer D. if 3 is entered. the channel no. DIAGNOSTICS MODE: (con’t) Digital I/O Diagnostics. changes from 0 to 1 and the top line will display the “raw” A/D (Analog/Digital Converter) value for analog input 1. A/D XXXX Channel 0 If a “1” is entered on the keypad. enter “0” and press ENTER Analog I/O Diagnostics The next screen on the display will be the analog I/O test display. The following are the relays energized in the three-chiller system: 1 Interlock Chiller 1 (also “In Control” light) 2 Increase Chiller 1 (also “Setting MF” light) 4 Decrease Chiller 1 (also “Override” light) 8 Pump Chiller 1 (also “Chiller MF” light) 16 Fail Output (also “Bypassed” light) 32 Chiller 1 Bypassed 64 Interlock Chiller 2 128 Increase Chiller 2 256 Decrease Chiller 2 512 Pump Chiller 2 1024 Bypassed Chiller 2 2048 Interlock Chiller 3 4096 Increase Chiller 3 8192 Decrease Chiller 3 16384 Pump Chiller 3 32768 Bypassed Chiller 3 65535 Activates all digital outputs It may be noticed that the numbers entered are successive binary numbers. con’t T Any one of these relays may be energized when a number is entered on the keypad followed by ENTER. Any other numbers in between will activate a combination of relays (and lights).

one at a time. The calibration of the analog inputs may thus be checked. A 4-20 mA input is thus reflected as a proportional 4.20 mA output for diagnostic purposes. This will correspond to 655-3276 A/D counts. con’t Analog I/O Diagnostics. the voltage input range will be 2-10 vdc. 26 Appendix B .5 vdc.Operating Instructions Energy Optimization Chiller Optimizer DIAGNOSTICS MODE. corresponding to 0-12. When an input channel is entered above. 1 2 3 4 5 6 7 8 Analog Input CHWR Temperature OSA Temperature CT Load Chiller 1 CHWS Temperature CT Load Chiller 2 CT Load Chiller 3 Spare Analog Input NC Analog Output: There is only one 4-20 mA analog output from each CPU board. For a typical input of 4-20 mA and a dropping resistor of 500 ohms. The Diagnostic mode terminates after two minutes of inactivity. the raw A/D value is written to the analog output. The following channel numbers have been assigned: Channel No. con’t The A/D values cover a 12-bit range of 0-4095. as the corresponding channel numbers are entered. Enter a 0 on the keypad to exit or press “Display” at any time.

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