WMC Software Technical Manual 14B - T00

WMC Software Technical Manual
TM-14B
Group: Chiller
Part Number: none 00
Effective: Dec 2013
Supersedes: none
Magnitude™ Magnetic Bearing Centrifugal Chillers

Model WMC-B
Software: WMCU3UU14B_T00
HFC-134a
50/60 Hertz
Table of Contents
Page
Scope…………………………………………………………………………………………….2
Tools……………………………………………………………………………………………..2
Chiller vintage differences……………………………………………………………………...2
BMCC identification….……….………………………………………………………………..3
Definitions……………………………………………………………………………………….4
Start-up of WMC Compressors………………………………………………………………..7
Special Functions……………..…………………………………………………………….….10
Commissioning screens………..……………………………………………………………….12
Tuning the Compressor Start (Set Comp Sps)……………………………………………….16
Advanced Sps (advanced tuning parameters available)……………….…………………....18
Tower Control………………………….………………………………………………………27
Job specific setpoint recommendations………………………………………………………32
Alarm Handling/Processing………………………………………………………………......33
Troubleshooting….……………………………………………………………………………37
Refrigerant charge…………………………………………………………………………….40
OITS recommendations……………………………………………………………………….41
Scope: This document specifically applies to WMC-B vintage chillers fitted with compressors that are using
CC firmware v3.0.0 BMCC modules and 14B chiller software.
Tools:
•Software specific mask set (included with release of software)
•Software change of operation (included with release of software)
•Compressor monitor tool (latest version, download from www.turbocor.com, no password required). SMT
v3.0.8.23 or later is the only version(s) that will be compatible with the new v3.0.0 BMCC’s. There are three
levels of passwords. Basic=40200, Tech=54037, OEM=62876. All Daikin access should be performed by using
the Tech=54037 password. All normal operations can be performed with Tech access. The OEM level password
will allow access to points that if modified could result in unreliable operation. Note: The compressor
commissioning process has been greatly reduced. The only critical point that is to be set manually is the slave
address of comp 2(not applicable for single compressor chillers). To change the slave address of the BMCC,
simply open the “BMCC System Configuration” tab and change the address. The change will be accepted and
not interrupt the live pc/compressor connection.
Chiller vintage differences:

• A vintage: This vintage uses (3) pco2 controllers (dip switches for address selection). It is possible to convert
an A vintage chiller to a B vintage chiller if needed. Contact the tech response center for detailed conversion
instructions. This manual does not address A vintage software versions.
• B vintage: This vintage uses a single pco3 controller (no dip switches, the address is selected by setpoint at
power-up). The slave address setting is critical for B vintage chillers. Since both compressors communicate with
a single pco3 controller, the slave address setting within the compressor is used to keep them separate. The B
vintage unit (chiller) controller was upgraded to a faster controller (pco3) with two serial communication ports.
The original port that served the BAS interface continues to support that function (serial card), while the new
port is dedicated to communications with both compressors (field card). This requires the #2 compressor to have
its ModBus ID set to two (2) before the chiller can be operated.
2
BMCC identification:
All BMCC modules have a compressor part number listed on the sticker. This part number typically is used as a
verification to make sure the BMCC is compatible with the compressor that it was being applied to. BMCC’s that
ship on new compressors will have matching compressor part numbers. The new RF(refurbished) v3.0.0
BMCC’s also have a compressor part number listed which will not match the compressor part number on the
compressor data plate. Since these new BMCC’s are not amp range limited (G4, G6, G8….) and are able to cover
a wide range of amperages which are set by the chiller controller, they no longer will need to match the
compressor part number. What is important is the G designation, which means it is for 460v (F=575). The new
BMCC part number will simply be ~TT400-G-1-XXXXX.
The original MN’s were categorized by amp ranges.

G4, G6, G8……G8 shown below.
Original v1197
TT400 BMCC
New v300 TT400

BMCC
New bmcc’s will be more “universal” in that one module can cover a wide range of amperage for a given
compressor model. The Microtech controller writes the appropriate amperage to be used by the compressor.
The tech will set the compressor amperage by the value found on the chiller data plate. Notice only a G
identifier on the new module, which indicates the unit voltage.
3
All BMCC’s have
a unique SN
which is located
on the left side of
the module. A
“RF” preceding
the SN indicates
that the module
was factory
refurbished.
BMCC recommendations: When installing a new BMCC, always use the sync feature which syncs the BMCC
time date stamp to your computer. Having the time and date match between the compressor fault log and the
chiller trend data is of great value. These v3.0.0 and later BMCC modules will maintain a more accurate
time/date.
Definitions:
Demand: 0 to 1000 Signal sent from the compressor controller to the compressor indicating where the
compressor needs to be with capacity; increasing, stable or decreasing capacity.
IGV Capacity Control: The mode of operation after the Start Speed is obtained prior to the IGV reaching the
110% open position. This capacity control mode allows partial Demand control, and is significant because it
allows the compressor to reduce capacity before the IGV has been fully opened. A reduction in capacity is
achieved by holding the IGV position while the speed is reduced, to add capacity the speed is held and the IGV
position is advanced. This control mode is active until the compressor is able to work the IGVs fully open to
110%.
Demand Control: Once the compressor achieves the 110% IGV position, full Demand Control is in effect.
FROO (Front Radial Orbit Offset): This value is displayed as FROD (Front Radial Orbit Displacement) in
the v3.0.8.23 or later monitor tool. An elevated FROO value results in altered compressor activity. This value can
be viewed by use of the 3G monitor tool. Orbit 1 alarm will trigger the IGV to close. Orbit 2 will result in a speed
increase (which in some instances could lead to alarms). These alarm points are configurable, and in the past we
have increased the two orbit limit setpoints within some compressors which lead to the compressor not taking
any orbit limit action. The Microtech now writes to these two alarm limits. The default values for FROO limits
are 200 and 300 respectively. With the default settings being the higher of the two sets that we have previously
applied, all compressors should be covered even if previous adjustments had been made. No field applied orbit
adjustments should be necessary.
FROO in action: Once the vanes reach 110%, the compressor unloads for just a few seconds to gauge the
FROO or test the surge. When it sees surge and loads back up on speed, it is at this point that the compressor
is controller fully by the Microtech, even if the compressor moves back into vane control. The compressor
uses FROO to know when the compressor is at max unloading. This could also explain why one compressor
on the stack seems more capable of unloading further than the other.
Compressor speed/FROO interaction: When unloading (actual power > requested power), the actual
speed will follow the calculated surge speed until in part vane condition, then actual speed is allowed to go
below surge speed, provided the orbit limits are not encountered.
4
When loading (actual power < requested power), the compressor will wait for the IGV to open to 110%
before increasing speed even when actual speed < surge speed, unless orbit limit 2 is encountered.
Min and Max Speeds: The (respective) Surge and Choke speeds, determined by the DTC compressor
software, are based on suction and discharge pressures.
Dynamic SD: SD can be considered the “check valve surge line”. When set properly it guarantees that the
compressor is able to maintain the min flow required to overcome the check valve spring force. This function
uses an equation to continuously adjust the SD (spare capacity shutdown) setpoint. The equation returns an
approximated minimum capacity value for the operating conditions. As the chiller unloads below the target
temperature (target -1degree), the compressor selected for Next-Off will shutdown if its capacity falls below the
total spare capacity of all the compressors connected to the system. The active SD (Dynamic Shut Down) value
in Advance setpoint #5c will be determined based on the maximum lift the chiller at an unloaded state. This
value must be high enough to avoid surge at the minimum load condition, yet drop a compressor when best suited
to allow one compressor to carry the load, generally 30 to 45 percent of compressor RLA. The Dynamic SD
function will adjust to seasonal changes in tower operation. For this software to be fully responsive and effective
the chiller should have: control of the tower water; and the compressor must have BMCC module version 3.0.0 or
greater. The SD is now also in effect for single compressor operation. It is desirable to maximize the unloading of
both compressors which prevents short cycling. When only one compressor is running, the Microtech will force
the single compressor to ride the SD curve no matter if the building is unloading. The Microtech will calculate
and set the appropriate SD values for both conditions (two compressors transitioning to one and one compressor
transitioning to off) based on saturated evaporator pressure.
If two compressors are running, the one compressor that hits the SD first will be selected as the “next off”
compressor. With one compressor running, the Microtech will force the single compressor to ride the SD curve
no matter if the building is unloading.
HATS Mode: High Ambient Tandem Start (HATS) mode attempts to operate both compressors as one. This
logic has been introduced to assist with the lag compressor starts in high lift conditions where condenser relief is
not likely. It may also be used with chillers starting with known high loads, to reduce the load time to full
capacity. This function can be called on an, as needed basis. However, to be successful, it must be engaged before
the lift pressure ratio becomes too high.
Lenient Flow logic: This option affords the chiller the maximum tolerance to intermittent water flow loss
detection, and reduces nuisance chiller trips. Momentary loss of flow detection can be a result of valve changes
in the primary loop, as when staging another chiller, or sudden changes in water temperature around the flow
sensor. Variable speed pumps operating at minimum flow rates can exacerbate these flow issues.
Enabled, this logic detects a loss of flow signal (>5 Sec) in either the condenser or evaporator and sets an
internal logic flag. Chiller operation is allowed to continue as long as the vessel pressures and surge detection
remain valid.
Alarms with lenient sensing “ON”: If condenser flow is lost and the pressure rises to within 5psi of the
condenser pressure trip point the chiller will shut down on condenser flow loss alarm. If evaporator flow is
lost and the evap pressure drops to the EP-Unload set point the chiller will shut down on evaporator flow loss
alarm. If evap or cond flow signal is lost and the surge logic is tripped, the chiller will shut down and
generate a flow loss alarm for whichever flow was missing. The default setting for Lenient Flow logic in the
WMC code is “On”. Turning it off converts the flow loss alarms, to timer based. Evap flow loss is
adjustable from 12 down to 3s (default 12s), and the condenser flow loss is adjustable from 20 to 3s (default
20s). Flow loss alarms will be auto reset by the controller.
5
Part Load Balance Valves: Factory applied TT400 and TT500 compressor chillers are standard with this
valve as of ~Sep 2012. PLBV or simply LBV have been added to select field chillers that exhibit problems with
starting compressors with high lift conditions. These valves open before compressor start, to allow gas flow
through the compressor, which stabilizes the impeller as it ramps up in speed. The PLBV’s enable a staging event
that does not result in a small loss of ELWT in the staging process. The lead compressors PLBV will open 100%
and close when this compressor’s vanes reach 110% (open). The lag compressors PLBV will open to 100% as the
compressors starts and then closes when the pressure ratio of this compressor reaches that of the lead.
Rapid Re-Start Function (Option $$): This option is designed to be a purchasable upgrade. The Rapid
Restart setting is defaulted to “off” and should remain in this position until the customer decides to enable. This
logic has been introduced to reduce the time the chiller needs to recover from a power loss event. The chiller’s
run status is continuously stored in battery backed RAM. When power is returned to the compressors it checks
the status of this function, and if enabled it then checks if the chiller was running when power was lost. If so, it
clears timers, enables the pumps, and clears power loss alarms. Evaporator water flow must be detected before
the compressor is allowed to start; the re-circulation timer will be cleared. As the compressors start in quick
session the maximum pull down rate is relaxed to promote a fast return to set point. The function ends when the
ELWT has dropped below the Stage-Delta temperature, or a compressor shuts down (for any reason).
If other alarms are pending (such as a bearing fault) the Rapid Restart function will be canceled.
.
Scenario 1(both compressors running): Upon power up after a power loss that is short in duration (compressors
IO board led remain illuminated), both compressors will initiate a start sequence.
Scenario 2(one compressor running): Upon power up after a power loss that is short in duration (compressors IO
board led remain illuminated), one compressor will initiate a start sequence; the second compressor will start
soon after if needed.
Scenario 3(both compressors running): Upon power up after a power loss that is longer in duration (compressor
IO boards led de-energizes), one compressor will initiate a start sequence; the second compressor will start soon
after if needed.
Scenario 4(one compressors running): Upon power up after a power loss that is longer in duration (compressor
IO boards led de-energizes), one compressor will initiate a start sequence; the second compressor will start soon
after if needed.
Alarms will be generated on the OITS for each compressor; “Low Line Volts” and “Compressor Fault”. A red
light will be illuminated on the pco3 controller. The alarms will remain to alert building personnel that this event
occurred, however the compressors will start.
With this feature enabled, the chiller should be able to start in ~43 seconds. This is only possible if the power
returned in <25 seconds (before the compressor powers down completely). The chiller will start before the OITS
fully boots. The compressor IGV’s will move toward the start position when power is reapplied, however if load
is found, the IGV’s will stop this routine and load as needed.
These scenarios are true for “generator mode” alarms. Others alarms/inhibits could affect the restart ability.
During rapid restore:

-if plbv is set to yes then the exv will hold at 0 then release to program solution after the compressor(s) starts
-if plbv is set to no then the exv will hold at 0 then release to fully open for 45 seconds
6
Start-up of WMC Compressors:
The following sequence is intended to describe the order of events to start, run, and shutdown a WMC chiller.
Chiller Start-up Considerations:
Evaluate the total load profile which may be presented to the chiller. This evaluation will be necessary to make
judgments on some of the following setpoints. Of particular interest will be the minimum and maximum load
presented to the chiller, rate of load change, minimum necessary lift, tower control and setpoint.
The SD (Shut Down) value in Advance setpoint #4 will be determined based on the maximum lift the chiller will
see at an unloaded state. The dynamic SD settings are now auto configured based on the compressor
commissioning entries. If these values are changed manually, they must be set high enough to avoid surge at the
minimum load condition, yet drop a compressor when best suited to allow one compressor to carry the load. The
Dynamic SD function will adjust to seasonal changes in tower operation.
For this software to be fully responsive and effective the chiller should have control of the tower water.
New Feature-IGV will move to the start position at power up. Previous versions of software moved to the start
position only when compressor is starting. The IGV start vane position is12% for the lead and 40% for the lag.
The vane position of each compressor will be at these start positions (other than at calibration) when the
compressor is not running. This new feature was implemented to reduce start times and support inverted start
logic.
Determining “Next On” status

All the compressor controllers connected on a pLAN network will pole the status of each other to determine which
compressor will start first. The polling process looks at the enable switches, timed inhibits, number of starts, run hours,
sequence and mode configuration parameters, and more to determine the status of each compressor controller. Polling for
“Next On” status, takes about 1 minute. The Right Arrow key on the controller is illuminated to indicate the Next-On
status. If illuminated on the Unit controller then that chiller will be the next to start a compressor.
Once the lead compressor has been selected, its LBV will open fully, and hold this position through compressor start,
until the IGV is fully open, there after it will close.
Calibrate Expansion Valve
After Next-On status has been determined the Expansion Valve for that chiller will drive full close to reset its
step counter to zero. Default position at start is closed. Note: The default exv position “closed” release point at
start can be adjusted by use of Debug screen (12)-release at lift ratio 1.2(can be raised to a max of 1.5), if a low
pressure ratio/low lift start condition is present. After the valve is released based on the lift ratio setting Debug
screen (12); it will then open to a near full open position, if the actual leaving water temp is above the setpoint
by a value greater than the drop out. This is due to the logic anticipating a large amount of load based on the
delta T. The exact position will be determined by conditions on the chiller.
Evaporator Pump Start
The unit controller for the chiller with the ‘Next On’ compressor will start the evaporator pump and wait the
Evaporator Re-circulation timer (default ½ min) to determine if there is load. This is determined if the leaving
evaporator water is above the ‘LWT Setpoint’ plus ‘Startup Delta T’; otherwise it is in the state of ‘Awaiting
Load’. Evap flow is required for compressor start.
Interlock On
Once a load has been found, the compressor with Next-On will see its interlock switch closure and start a ten
(10) second timer. The compressor is expecting ModBus confirmation of the hardware closure before
proceeding with the start sequence.
7
Condenser Pump Start
After Interlock is confirmed, it starts the Condenser Pump and checks for condenser flow before starting the
compressor. If the default Lenient Flow option remains enabled, proof of condenser flow is not required for
compressor start.
Compressor Start
Starting the compressor is accomplished by writing a demand to the compressor (the interface interlock must be
closed). The Microtech looks at water temps to determine start speed. Microtech performs a prediction of where
the pressure range will be and bases its demand or start speed on the estimation. This speed range is adjustable
(basically commanding the compressor to start at min speed or maximum speed). The Demand low limit is set
somewhere between 300 (30%) and 700 (70%) depending on ELWT (based on Max Str LWT setpoint). This
allows the normal capacity control logic (described later) to run and manage the Demand setting for the present
conditions (i.e. setting the Demand higher), but blocks the Demand setting from falling below 45% until the
ELWT is within 1.5F of the target. Compressor Start Speed (adjustable Set Comp SP 8) is set to 15% (15%
higher than the compressors min speed for the lead comp and 3% higher for the lag) or 11,000rpms whichever is
greater. The IGV should be at the start position (12% for lead and 40% lag) as it would have moved to this
position at power-up. As the compressor loads up it will hold (stop loading) if it runs into a limit (Amps, Evap
Press, or LWT Slope limits).
During the initial start phase, once the motor current has exceeded ten (10) amps (the check valve is assumed
open) the Compressor Start Speed is set to the Minimum Speed. This is done to force the compressor into the
“IGV Capacity Control Phase”, during each start. Although somewhat unnoticeable, as the compressor makes it
to IGV 110 at the end of transition, the speed will dip just a bit. The compressor is finding the actual surge line. A
setpoint (SET COMP SPs (7)) has been added that controls the vanes start position; its default setting is (12% for
lead and 40% lag) which will allow the compressors to load up faster. During operation the vanes are controlled
by logic internal to the Turbocor compressor and are only active after the compressor has obtained minimum
speed at the existing lift conditions.
Compressor Running at Full Load

The compressor that is running will signal all other compressors when it is at full load and needs additional
capacity to achieve target ELWT. Full Load status is determined when any one of the following tests is true:
1. Percent RLA exceeds 100% or the Active-Amp-Limit from an external source.
2. Evap Saturation pressure drops below the Evap Inhibit Loading pressure set point.
3. The compressor is running with IGV fully open (110%), and Actual compressor RPM exceeds 96% of
Max RPM limit from compressor, and both have been true for 20 seconds. This third test is the one that
normally triggers the full load flag.
Lag Compressor Staging Up
If the lag compressor of a dual compressor chiller has the ‘Next On’ status, and all of the following
requirements are satisfied, the compressor will begin the start routine:
Full Load indication from the lead compressor.
Stage Up Delta Temperature – Evap LWT is above minimum staging setpoint, default is 10 F.
Pull Down Rate – ELWT slope is less than minimum rate, default is 0.1F.
The lag compressor will start with a demand setting as described in Compressor Start above. The lag
compressor start will be delayed until the LBV has opened to approximately 40%. This insures that the LBV
will be open enough to stabilize the impeller during the compressor start and ramp to speed. As soon as the lift
ratio of both compressors match, the lag compressors LBV will begin to drive closed.
At lead start PLBV opens to 100%, closes when vanes are 110%open. The lag compressor’s PLBV will open to
100% at start and will close when the pressure ratio of the lag matches the pressure ratio of the lead.
8
Condenser Relief (three control options) (PR less than 1.8 the lead will unload, PR greater than 2.2 the lead
will unload, PR’s between >1.8 and < 2.2 the lead will hold)
High Lift: If the Lift Ratio of the Lead compressor is above 2.2LR (selectable), the Lead compressor will
attempt to unload to minimum speed, and hold this condition for the Unload Time Period (Set Comp SPs (6)).
This state will force the chiller to sacrifice ELWT in an effort to generate some condenser relief. If the Unload
timer expires and the lift is still above the selected value the Lag compressor will attempt to start. Success
depends of the compressor model, the actual Lift ratio value, and if a PLBV kit is installed. Success cannot be
guaranteed in all conditions.
Adequate Lift: In the event the lift ratio on the chiller falls below the selected value (AdvSet #12) the
demand feedback value from the lead compressor will be locked in as the requested demand to prevent farther
reduction in capacity, and loss of ELWT. The unload timer will be aborted, and the lag compressor will be
cleared to start.
Low Lift: If the Lift Ratio is below the Low Lift Stage value 1.8LR (selectable) found in ADV SET #15,
alternate control logic is engaged. This logic will hold the Lead compressor at its present demand setting, until
the Lag compressor has started. Then it will unload the Lead compressor to the Low Lift IGV setting in the
AS#15 mask, and hold this demand until the Lag compressor has opened its IGV fully. This ensures maximum
capacity from both compressors can be available in the shortest amount of time, by encouraging the lag
compressor to open its vanes sooner. This provides the most lift possible for the lag compressor. This is due to
the dynamic conditions created when the second compressor starts. The pressure ratio will change when the lag
starts, and having the lead in a more unloaded state helps to make sure the two compressors are very close in
rpm. The two compressors will load balance faster.
Lag Start Expansion Valve Control
Since newer software default settings are for current production chillers (chillers with PLBV’s); the EXV at
lag start will switch from pressure control to programmed solution control which will result in a smoother lag
start sequence. The valve would be in programmed solution control if the lwt was under the drop out setting. For
chillers that do not have a PLBV, it may be desirable to reduce the lift during the lag start as much as possible.
This can be accomplished by changing the “Auto Control” to “Position” within Advanced set 16. When
“Position” is selected, a valve position can be selected. The valve will hold at this selected position during lag
start. The hold position duration is adjustable within Advanced set 16. By flooding the evaporator during this
time the lift is reduced, resulting in a slight increase in ELWT. As soon as the Lag Compressor starts the
Expansion Valve returns to normal control logic and the efficiency is restored. If the chiller is fitted with PLBV’s
exv adjustment during stage up is not necessary.
Managing the load- Capacity Control Algorithm
The chiller controller bases its demand signal to each compressor based on ELWT error and amp balance data.
A setpoint (SET COMP SPs (7)) has been added that controls the vanes start position; its default setting is
(12% for lead and 40% lag) which allows the compressors to load up faster. During operation the vanes are
controlled by logic internal to the Turbocor compressor and are only active after the compressor has obtained
minimum speed at the existing lift conditions. The Turbocor compressors are controlled through a ModBus
communication link that writes a demand signal in terms of tenths of a percent or simply 0-1000. Each
compressor controller looks at the difference between the evaporator leaving water temperature and the target
setpoint to determine the error value. This error signal is combined with amp balance data from other
compressors and is referred to as the Capacity Adjust Factor (CAF). This factor is then added to the “actual”
demand returned from the Turbocor compressor, and then it’s written to the compressor as the “desired”
demand.
Staging Off:
The orderly shutdown of compressors on a network of two or more compressors is accomplished by polling the
compressors in a way similar to the Next-On process (described above). This “Next-Off” process is governed
by the Staging Mode that has been selected, (normally this is based on run hours). A description of Staging
Modes is covered in the IOM manual and will not be covered in this document. Once the Next-Off
9
determination has been made, then the compressor selected to be next off, will monitor the combined spare
capacity of the other compressors. The SD Value (Shut Down value, Adv Set #4, Capacity) is a part of the
spare capacity calculation. When the combined spare capacity exceeds the next-off compressor capacity, and
the chiller is below the target temperature, by a selected amount (see Adv Set Mask #13), then that compressor
will shutdown, and the running compressor(s) will be allowed to ramp up and cover the capacity lost by the
compressor that staged off. If there are more than two compressors running then the process described above is
repeated until only one compressor remains running. As the heat load continues to drop off then this
compressor will shut off at the ‘Shutdown Delta T’ below ‘LWT Setpoint. Note that the running single
compressor on the chiller will unload down to the active SD point and not below. At no time will a running
compressor be allowed to unload to the point that it can‘t provide enough discharge gas to maintain the check
valve in a continuously open condition.
In the event that chillers of different capacities are linked (by pLAN), then a means was needed to determine
the absolute spare capacity of all the compressors in order to properly manage the stage down process. This is
accomplished with the ‘Nominal Capacity’ setpoint. The Nominal Capacity setpoint found under SET COMP
SPs (5) is actually a ratio-metric value of the capacity of each compressor. This value is most easily described
in terms of Tons, but an actual Tons calculation is not preformed within the control logic. This setpoint should
only be adjusted when mismatched compressors or chillers are networked together. For chillers with matched
compressors this setpoint may remain at the default of 100 Tons or Percent setting, even if this is not the actual
capacity of the compressors. Altering it to the actual Tons on a network of matched compressors will have no
effect on the staging (on/off) functions.
After Shutdown:
The Expansion Valve will close after the last compressor on the chiller has shutdown. When the evaporator and
condenser water temps have equalized the valve will reopen 30% to drain the refrigerant back into the
condenser. The condenser pump will turn off after 30 seconds. At compressor shutdown, the IGV’s move from
120% down to close (the motor is drive from a starting point that is 20% higher than the vanes are really
capable of moving). Once the vanes move to zero, the Microtech moves the vanes to their start position (12%
for lead and 40% lag) which readies the compressor for a future start command. The Evap pump will remain
running if the chiller remains enabled and no other chillers are networked together. If chillers are networked
together and enabled the chiller with the last running compressor, or the chiller with the first compressor to
start will maintain its evap pump in a running state.
Special Functions:
Rapid Restart:
Note: This is a prototype optional feature which will be sold as an option in the future. This special control
function attempts to quickly re-start the chiller following a power lost while running. This function is disabled
by default setting. When enabled, and the chiller is running, a power lost will set control flags that jump start
the compressors when power has returned. During this quick start event the Evap Recirculation, Stop to Start,
and Start to Start timers are skipped. Less than two minutes after power has returned, the chiller will restart, and
load quickly until the setpoint has recovered. Then normal operation resumes.
Note during the restart process the Operator Interface Touch Screen (OITS) may be slower to reboot than the
chiller controls. OITS operation is not required by the chiller controller, to start and run the chiller. Therefore it
is not uncommon for the OITS to record that the chiller was running as its first trend data recorded after the
power interruption.
This new feature will remember the operational state of the chiller at the moment power is lost. If the chiller
was running, the chiller controls will enable the pumps as soon as the controllers are booted-up and running
chiller code. The chiller will start after they have finished their power-up reset routines. Both PLBV will be
pre-opened for compressor start. However both PLBV will not close at the same time (this is normal).
10
This feature is defaulted to “OFF”. If it is desirable for the chiller to start in a reduced amount of time following
a re-application of power, then enabling (“ON”) this Rapid Restart (Adv set 11) function is desirable.
Restart times with Rapid Restart “off” = 180-240 seconds
Restart times with Rapid Restart “on” = 40-120 seconds
EEV Start Configuration:( Defaults to close on start)
WMC-10N code and later will default to an EEV closed start position. After the lead compressor starts the
valve will be held closed until either the Lift pressure ratio exceeds the setting 1.20(adjustable) or the suction
pressure falls to within 1.5psi of the Evap Pressure Inhibit setpoint.
Once the EEV leaves this pressure control function, it is locked out of returning to it until the chiller cycles off.
HATS Mode: This function runs both compressors as one, in an effort to avoid high lift Lag compressor start
issues.
Enabling the function
This function is enabled by going to the Unit controller Adv Set #2 mask, and changing the “Tandem Starts”
setting from “OFF" to "Chillr". It is then engaged by applying a 24 volt control signal to Unit controller digital
input #12.
Notes: 1.) The HATS function is not supported with Efficiency staging mode selected.
2.) If multiple chillers are connected via “pLAN” and Tandem Starts "System” is selected, all
compressors on all the linked chillers will start in rapid sequence.
Details of the function
Once the function is engaged, all compressors (that are available to run), will start in rapid sequence and
balance the load between them. As the load falls off (or by fault detection), and one compressor shuts down, it
is locked off until both compressors on the chiller are off. If the load increases while running on one
compressor and a restart is desired, the HATS switch can be toggled opened for a minimum of 5 seconds to
reset the lock-out protection. Care should be used to insure lift pressure ratio is below a reliable start level
before releasing the lag compressor for restart. If the shutdown was from a fault condition, all alarms must be
cleared before a restart can be attempted.
Management of the HATS Switch

It is intended that an intelligent system such as a Building Automation System (BAS) be used to manage the
HATS mode function. The BAS system should monitor ambient and forecasted weather conditions, and perhaps
manage the tower control to achieve reliable chiller plant operations.
EEV operation at an inverted start scenario:
Inverted water temperature start logic has changed. The new changes involve the exv and the IGV of the lead
compressor. Inverted start logic begins when the condenser entering is two degrees less than the evap entering.
Remember that the exv would have been open since the ecwt was less than 3 degrees above the eewt. If the
chiller is required to start in this condition, the exv will fully open until the inverted condition is not active
(CEWT is less than 2°F below the EEWT). Liquid refrigerant from the condenser will move toward the evap
when the compressor starts. The lead compressor’s vanes will move to 10% open. The compressor starting with
vanes slightly open helps to build a differential at the compressor which encourages liquid refrigerant from the
condenser to move through the compressor for cooling. This reduces the chances of increased compressor
temperature at a challenging inverted start condition. The compressor operation should move the chiller from this
inverted state and when this occurs the exv will close as needed and the lead compressor IGV’s will open. During
an inverted start, the low evap pressure alarm is ignored for 1 minute (after the low evap hold and unload are
triggered). If a low pressure condition exists after a minute then the alarm is generated.
Note: If no plbv is selected the exv will move to 100% open when the lag starts and hold for 45sec(adjustable)
after the check valve opens. The PLBV will remain closed during an inverted start.
11
Inverted starts:
Inverted start overrides -Enable EXV pressure control.
Inhibit Evap Low P Stop alarm, and PLBV opening for start.
Enable EXV pressure control until LiftP >30psi.
Inhibit Cond Pump and Bypass Valve until LiftP >30psi.
BAS Alarm Dwell

This feature to the BAS Alarm logic that will allow the chiller time to auto-clear an alarm before updating the
(BAS) alarm bit registers. The time is selectable, and the default period is 5 minutes. A typical compressor
alarm requires approximately 3 minutes to clear. If the alarm has not cleared after the selected time period the
alarm registers are updated and the alarm data is made available to the BAS.
If the BAS Dwell Time is set to zero (0) minutes then this feature is cancelled and alarms are presented as they
occur (without delay).
The following alarms are made available without delay. System Lock-out; Evap Water Freeze, Cond Water
Freeze, Gnd-Fault, and Chk-Valve.
If the BAS writes a Clear-Alarm command, the Alarm registers will update continuously for the next 30
seconds. This allows the BAS to confirm chiller alarm status. Note: The hard alarm contacts are separate from
the delay and will close anytime the controller is in alarm.
Commissioning screens:
This new screen set is accessed by having the tech level password active and choosing the commission set
within the main ALARM/VIEW/SET/COMMISSION screen. The chiller/compressor specific settings entered in
the first commissioning screen automatically configure the factory recommended setpoints for this chiller. This
main commissioning screen asks three questions; what is the compressor model; is the chiller fitted with a part
load balancing valve; and what is the compressor RLA? Screens 2-10 allow further adjustment if needed. In
addition to these screens, settings can also be modified in the normal screen sets. The information entered into the
commissioning screens flows down to the familiar locations within the compressor, unit, and advanced screens.
Its important to understand that setpoints only flow out of the commissioning screens. If a change is made on
another screen set, the change will be accepted; however it will not be shown on the commissioning screens. This
could be useful to know if settings had been changed by others since the chiller had been commissioned.
These important commissioning settings have to be “sent” from the commissioning screens. Notice that a CFG=0
status populates if changes have been made (and also an *), but not sent that information. It is only after the
CFG=0 has been changed to CFG=1that the changes are “sent”. Commissioning screen(1) and (10) are the only
screens that have CFG status. Screen 10 also has “jump” feature which moves the screen into the advanced
setting screen set.
The settings that are made within the lower level screens will be accepted; however they will not be transferred to
the commissioning screens. This feature could be used to to see if settings had been changed from they had been
left the last time the chiller was attended by authorized technicians.
New Feature- The software now has a setpoint for the harmonic filter output which is located in Commission (9).
The point in which the substitute output closes is adjustable based on compressor amperage.
12
Commissioning the Chiller Controls
A new feature has been added that facilitates configuration of the chiller controls for the WMC chiller model to
which it is being applied. This reduces the work load and time needed by the commissioning technician.
Commissioning mask #1 as described below makes twenty-five (31) setpoint adjustments and two (2)
calibrations based on just three parameters (Load Balance Valves, Name Plate Amps, and Compressor Model).
The set points are:
Minimum Motor current to determine if compressor is running – C-Str =10A (Set Comp (1))
Anticipated Target ( slope gain value) – PdG=1.0 (Adv Set (6))
Start Speed Ramp Rate used until check valve is open – Ramp=1(Adv Set (10))
Amp Alert NP-Amps x 1.05 (sent to compressor)
Amp Alarm (shutdown) NP-Amps x 1.10 (sent to compressor)
SD points “A”, “B”,”C”, and “D” to match compressor model. Dual Compressors running (Adv Set (5))
SD points “As”, “Bs”,”Cs”, and “Ds” to match compressor model. Single Compressor running (Adv Set (5))
SD points “Ks”, “Ls”,”Es”, and “Ms” to compensate the SD points for non ARI conditions (Adv Set (5))
Part Vane speed offset proportionally applied – VCmp=xxxx (RPM) (Adv Set (10))
Slip Speed Offset added during start – Slip=xxx0 (RPM) (Adv Set (10))
Advance IGV for Start – Adv-IGVxx% (Adv Set (10))
Unload for staging, Speed offset above minimum speed – High Lift Spd=xx0RPM (Adv Set (15))
Lift Ratio gain used for starting (without Load Bal Valves) – Gx=1.xx (Adv Set (6))
Unload for staging if Lift Ratio is greater than (>) – Stg/Unl Lift > x.x (Adv Set (12))
Expansion Valve Gain – Gain xx and Auxiliary Mode Gain – Md xx (Set Unit Sps (15))
Expansion Valve Offset – Offset xxxx and Auxiliary Mode Offset – Md xxxx (Set Unit Sps (15))
Expansion Valve pressure control drop-out below ELWT setting – Prs Ctrl DOut xx.x oF (Set Unit Sps (15
Choke Offset used to assist lead compressor with cool condenser operation – Choke-Ofs=(0).x (Adv Set
(15))
Expansion Valve Staging configuration and setting controlled by LBV selection (Adv Set (16))
Expansion Valve pressure control management (Adv Set (16))
Calibration of check Valve failure alarm pressure offsets for compressors #1 and #2 (Adv Set (6b))
Commissioning Mask (1 – 10)
Commission(1) Config Commission Mask #1 Quick (single page) Configuration

PLB Valve Staging Part Load Balance Valve : Off, Staging, Stg&Unl
Chlr NPlate RLA070 Compressor Run Load Amps as stated on Chiller Nameplate
C-Type TT400 CFG 0
Compressor Model; TT300, 350, 400, 500
CFG Set to 1; preloads 22 setup registers based on this Mask.
“CFG” appears only when an initial setting has changed.
13
Commission Mask #2 EXV
Commission(2) EXV
Expansion Valve Gain (while in Automatic control)
EXV Gain=078 Md078
Offset=0700 Md0700 Expansion Valve Offset
Prs Ctrl DOut10.0oF Pressure Control Drop Out
* Md – Mode switch active valve setting (example: valve setting for
heat mode).
EXV operation at lead start: Exv will move to a position based on many factors at start. The exv will be in pressure
control anytime the lwt is above the “drop out” setpoint. The transition to programmed solution takes place when
the lwt drops below the DO setpoint.
EXV operation a lag start: Exv will change from pressure control to programmed solution ~30-45 (adjustable Adv
Set (16)) seconds before lag compressor starts. This enables a smother exv operation at lag start. Pressure control
exv is more aggressive/responsive and you could see movement (peaks and valleys). Programmed solution exv
control is more stable during this unsteady lag start period.
The gain and slope values are set appropriately following the application of the commissioning screens. The TT400
and TT300 compressor chillers use a single head expansion valve. The TT500 compressor chillers use a dual head
expansion valve. Typically with the TT500 compressor chillers the gain could be lowered to ~65-58 which will
reduce the amount of refrigerant feeding the evap. The gain portion of the exv equation can be used to manipulate
the refrigerant levels in the vessels. The gain should be adjusted at or close to full load conditions. The offset is
used to trim refrigerant levels when the chiller is in an unloaded condition. EEXV general setup instructions can be
found in SB 10-0652-B.
Commission Mask #3 EXV

Commission(3) EXV EXV Configuration for Chiller Start
Configure Start
Default position is Closed to facilitate compressor cooling.
w/ Valve Closed
Release @ LR> 1.20 The valve is released for automated control after the
selected Lift Pressure Ratio has been exceeded.
Commission Mask #4 Mode

Commission(4) Mode
Pwr Loss Restart Off Pwr Loss Restart; Off, On
DCBus 1>000V 2>000V Low Ambient Tandem Start (continuous loading delay)
LATS 150s HATS Off High Ambient Tandem Start (operates both compressors as 1)
Commission(5) Start Commission Mask #5 Start

Str-Rdy + NxtOn 0 Chiller Ready (0) / Ready and Next to Start (1)
IGV Lead Str 012% Lead compressor IGV start position
IGV Lag Str 040% Lag compressor IGV start position
14
Commission(6) Start Commission Mask #6 Start
Lead Str Spd 015% Lead compressor Start Speed
Lag Str Spd 003% Lag compressor Start Speed
Stage w/Lift Ratio Staging logic based on Lift Ratio or Pressure
Start speed %, is the % above the min speed. The lead compressor will use an estimated speed range based on
chiller conditions plus 15%. The lag compressor will use the min speed of the lead compressor plus 3%.
Commission(7) Stage Commission Mask #7 Stage

Unl Target 2.2 LR When staging unload lead to Target setting
Stg EXV Auto Control Set EXV to; Auto Control, or Fixed position
Hold Duration 045s
Staging logic based on Lift Ratio or Pressure Select EEV staging mode:
Auto Control or Hold @ 50%. The selected mode is held during lag start
for the duration of the Unload timer. A detailed description can be found
on page 24.
Commission(8)WtrFlow Commission Mask #8 Water Flow

Lenient Sensing On On – Allows timers to be extended while operating within safe limits.
Evap Trip 12s Off – Trip timers are limited below Evap 12s and Cond 20s.
Cond Trip 20s Reference pages 22 and 5 for more information on lenient flow.
Commission(9) Power Commission Mask #9 Power

Harmonic Fltr Off Harmonic Filter – Off or Config*
Engages > 06 RLA% Engages output when RLA% is exceeded.
Outputs on R13 & R15 *if “Config” is selected it will pre-set the Substitute Relays.
Harmonic filters must be enabled/disabled by the chiller. The chiller should be configured to enable the filter
only when the chiller is running.
Commission Mask #10 Load
Commission(10) Load
New Values Entered * Message appears if changes in Mask 2-9 have been made.
Clears when CFG is set to load selections.
Mask 2 – 9 CFG 0*
Loads all setting in from Mask #2 - #9
Jump to Adv SPs 0
If set to 1 the Mask will jump to Adv Set series of mask to continue
customizing set points.
15
Tuning the Compressor Start:
After testing this code with the following DTC compressor models it has been determined that some models
require specific settings to achieve the maximum performance (both starting and running); TT300 (MS-2), TT400
(MS-2), and TT500 (MS-2).
Note: the underlined values are set points that can be adjusted, but they do not appear as underlined on the
control.
SET COMP1 SPs (4) Compressor Setpoint Mask #4Unload Offset (Lead) Above Surge
(Min) RPM during high lift stage
UL Surg Ofs=990 RPM
Lead Staging-Unload Offset Above Surge (Min) RPM
Name Plate RLA 070
Amps Cal=100> 056A Run Load Amps as stated on Compressor Nameplate
Amp Reading Calibration.
Only visible when Tech Password is active. Corrects what is displayed on the OITS and reported to the BAS.
Name Plate RLA: Run Load Amps as stated on Compressor Nameplate. This setting is very critical. The new
v3.0.0 BMCC’s will be default for the lowest possible amperage(~40 amps) and will remain there until the
Microtech writes this critical setpoint based on this setting. The Microtech adds the extra 5% that was previously
field added within the commissioning screens on older software platforms to compensate for the compressor
unloading when 95% of FLA was reached.
Amp Reading Calibration. Only visible when Tech Password is active. This adjustment can be used alter the Amp
and %RLA values reported to OITS and to the BAS. Each compressor has a separate cal setting. Caution=The
measurements are not instrument grade and may not track proportionally as conditions change. They cannot be
expected to match the accuracy of an instrument grade power meter. Note also that the calibrated values are not
recognized by the DTC compressor, and therefore high current alarms limits are not affected by these settings.
Additional amperage information:

FLA =compressor full load amperage, RLA=chiller rated load amperage per compressor, LRA=maximum
amperage the compressor is allowed to see (trip point). When the RLA is entered into the Microtech, the
Microtech will define the proper limits in the BMCC. Example: The new TT400 G BMCC’s version 3.0.0 are
adjustable to between 40-150 FLA, but you may have a chiller that is rated for 100 RLA. The Microtech sets
the alarm limit at 105 and the trip limit at 110; while the Microtech will modulate demand so the compressor
does not exceed the 100 RLA limit. The tech setpoint is based on the chiller nameplate.
Line reactors are chosen based on rated amperage when the chiller is built. Increasing the amperage (RLA)
past nameplate could push the actual amperage past the rated limit for chiller’s internal components and/or
amperage limits for the electrical components in the building.
SET COMP1 SPs (5) Compressor Setpoint Mask #5

Initial demand sent to lead compressor in high lift stage mode. Sets the
Lead Staging =030% maximum demand for the lead compressor while starting the lag. It
Nom Capacity=0100T functions as a forced unload command to provide condenser relief.
HG-Bypass=20% RLA Tons(Quasi) of the compressor, (Multi-chiller SP only)
Refer to the Compressor start paragraph-page 7. Hot Gas Bypass
Threshold (RLA%) | HG Control Logic (OFF, Water, or RLA)
Hot gas not normally used on WMC chillers.
16
IntrLokTmr=010sec Time allowed between switch and Modbus feedback (comm. link).
UnloadTimer=120sec Time the Lead is allowed to unload before Lag start.
Max Str LWT=10.0oF The Unload Timer controls the length of time the Lead compressor
unloads before the Lag starts. While the lead compressor is unloading to
stage-up the lag compressor, if the lift pressure drops below the Staging
Unload Lift setting in Adv Set #11 the lead compressor will hold at that lift (not unload farther), and the Unload
Timer will be cleared to allow the lag compressor to start. Extending the unload timer will increase the opportunity
for additional condenser relief. This could sacrifice LWT control.
Max Str LWT=LWT error below which Start demand is reduced from 70%
• * If ELWT is > 10 degrees F above the Target ELWT (44.0F) then the minimum starting demand will be
limited to 70%.
• * If ELWT is < 10 degrees F above the Target ELWT (44.0F) then the minimum starting demand will be
proportionally limited to between 30 - 70%.
• If ELWT is = 1 degrees F above the Target ELWT (44.0F) then the minimum starting demand will be
limited to 30%.

Vane Control Inlet Guide Vanes start position
Lead Start = 012% Lead Comp IGV start position
Lag Start = 040% Lag Comp IGV start position.
Sets the corresponding IGV start position for each compressor. The IGV will pre-open to this position as soon as
power is applied to the compressor and communication with the Microtech is established. Having the vanes pre-
opened to this position before the compressor starts results in a faster start sequence with the goal being to achieve
full demand control of the compressor.

Start Speed %Speed refers to the range between Min and Max RPMs
Lead Str Spd = 015% Lead Comp Start Speed (% based on present conditions)
Lag Str Spd = 003% Lag Comp Start Speed (% based on present conditions)
Sets the corresponding Start Speed for each compressor. The IGV will
not continue to move fully open unless the start speed is maintained. Basically this demand is requested to the
compressor with the ultimate goal of reaching the compressors “start speed”. Remember that once the start speed in
reached, then the Microtech has more precise control of the compressor. Refer to page 4(definitions for IGV and
Demand capacity control).
Caution – setting the Lag Str Spd too high may result in an over-amp alarm, or the compressor/s may overshoot the
target and trip off on the Stop-Delta-T setting.

ELWT OffSet= 0.0°F ELWT OffSet= -1 to +1°F offset range
Orbit Limit = C Orbit Limit = A=Low adjustment(default in the compressor),B=
Medium adjustment, C= High adjustment(default in 14B). Refer to the
FROO section on page 4 for a detailed explanation.
17
Additional Setpoints in Advanced Settings:
Access to the Adv Set series of mask (below) is unlocked by first entering the Technician level password. Then
press the Left and Down arrow keys together in unison. The first line of the display should display "Unit Switches
Tc##". Now press the Right arrow key.
Adv Set#1 General Advanced Setpoint Mask #1 General
Lag Start Cntrl=Spd Lag comp start based on Speed or Lift Ratio of the Lead
Aux Suct-Tmp Sel OFF Auxiliary Suction Temp Sensor selected On/OFF. The sensor is
connected to the Spare Temp input of the DTC I/O Module. This is
LATS=150s HATS=OFF
optional and field installed. Standard 10K chiller sensor.
Low Ambient Tandem Start (LATS) –Max Time Lead is allowed
to load before forcing Lag to Start. Forces lag start during a cold condenser pull down (without full load of the
lead). If the lead compressor has been continuously asked to load-up and the EWLT has remained above the Stage-
up delta-T for the duration of this timer, then the Lag compressor is cleared to start. This should help add heat to
the condenser to generate more lift and compressor capacity.
High Ambient Tandem Start (HATS) – Forces both compressors to run as one to avoid High lift Lag starts,( Enables
with ID12).
Advanced Setpoint Mask #2 - General

Adv Set#2 General
Alrm 5S A-Bal Unit Only Adjust the A-Bal setting.
Amp Surc CT Alarm clearing pulse (S) | Amp Balance Unit/Sys
Refrig Type = R134a Amp Source CT
Refrigerant used.
Only Refrigerant Type R134A is supported by DTC
A-Bal=Unit will attempt to balance the amperages of all running compressors on a single chiller. A–Bal=System
will attempt to balance compressor amperages from all running compressor on Plan.
Advanced Setpoint Mask #3 – Ext Fault (optional input)

Adv Set#3 Ext Fault State of input digital ID13 (not a setting)
Ext Fault ID13 = 0 Fault Logic 0= fault if voltage applied to input.
Ext Fault Logic = 0 Fault Logic 1= fault if NO voltage applied to input.
Rapid Stop Logic =0 Inverts the Logic of DI-8 (Rapid Stop Switch).
18
Adv Set#4 SD-Cap2 -* Adv Sp Mask #4 ShutDown Capacity (sel Comp #)
CompN0089 Dyn-SD 47 The “2” after Cap can be toggled to select other Comp.
cMAX=0100 %RLA= 089 The “N” when visible indicates Comp is Next one OFF.
Spare=0011 sSys=0011 Comp 0089 – shows Comp’ capacity.
SD(Sp)=20 (a fixed setpoint) is displayed when En on the next mask is
OFF, otherwise Dynamic Setting is active. This is obsolete.
cMAX - tallies total Capacity of all running Compressors
%RLA – shows %RLA of the selected compressor
Spare – Spare (unused) capacity of the compressor
sSys – Total spare capacity of all other compressors connected to this chiller
Note – Total System Spare Capacity (sSYS) exceeds CompN value of the Next-Off compressor, and the ELWT is
below target the compressor will shutdown.
-* The Asterisk shown in that position indicates the #2 compressor’ capacity is below the spare capacity of the
system of chillers. If the Dash switches to an Asterisk in that position it indicates #1 comp capacity is below the
spare capacity of the system of chillers.
Dynamic SD function
Factory recommended SD settings are automatically loaded based on commissioning settings. If the SD curve
should need to be field modified, the following information should be used. As a general rule, if check valve
chatter is heard when both compressors are unloaded below setpoint, then increasing the “A” or “B” value would
change the point at which the next off compressor would shut down. The “A & B” values should be increased by
units of 1000 individually, until desired shut down is achieved. Alternately, lowering the “A” value will allow
further unloading (this may be desirable for chillers maintaining a higher LWT). Be aware that the recommended
settings have been accurately mapped and that the SD equation uses a quadratic equation with many variables
(including lift/volts/amps/sat evap). With this known, a slight change in one of the variables (utility fluctuation,
faulty sensor) could result in a different shut down point. Note: It is not recommended to use negative values.
The SD was designed by using the current style single flapper check valve (RitePro). If this software was used on
an older chiller that was fitted with an “other” style check valve the SD points may need to be modified. The
older style valves (poppit and butterfly) imposed more of a pressure drop and the SD values A-B would be
increased individually until the desired unloaded point is reached. Remember that increasing the A or B values
will raise the SD value and the compressor will not unload as far. This higher loaded shut down point will
prevent check valve chatter at low loads. Alternately, decreasing the A-B values will allow the compressors to
unload further. Care must be taken when adjusting these values that the ability to keep the check valve open is
not lost. A-B only moves the curve up and down to obtain desired results; C and D would change the entire
curve.
This function uses an equation to continuously adjust the SD (spare capacity shutdown) setpoint. The equation
returns an approximated minimum capacity value for the operating conditions. As the chiller unloads below the
target temperature the compressor selected for Next-Off will shutdown if its capacity falls below the total spare
capacity of all the compressors connected to the system. With a standalone dual compressor WMC chiller, the
remaining compressor will ride the SD point.
19
Adv Sp Mask #5 Dynamic SD Configuration
Adv Set#5 Dual DSD DSD- Adv set5 is the normal coefficient screen used for dual
Np=160A 11100 compressor operation. These values are adjustable, however the
A=+0000 B=2000 C=250 factory recommended values will populate based on commissioning
entries. The SD displayed is 3 digits now. The additional digit is to the
D=5 460V Lp068 SD=470
right of decimal point that is not displayed, so 470 would be 47.0.
Np – NamePlate Amps entered from Set Comp (4) mask
A,B,C,D – Four variables (A,B,C,D) are selected based on compressor
model, voltage and chiller service.
460V – Line voltage reported by Compressor.
Lp068 – Lift pressure (psi) derived by the Unit controller.
SD – Result of SD equation, accounting for Lift, Volts and compressor
model (TT300, 400, or 500). No offset applied.
Bit Flags - defined:
1____ = ELWT is below target.
_1___ = Next-Off Comp#1
__1__ = Next-Off Comp#2
___1_ = Comp#1 capacity exceeds systems spare capacity
____1 = Comp#2 capacity exceeds systems spare capacity
Dynamic SD settings: One group for dual and another for single compressor operations
TT300 TT300 TT350 TT350 TT400 TT400 TT500 TT500
Dual Single Dual Single Dual Single Dual Single
A 0 0 0 0 0 0 0 0
B 0 0 2000 1800 2500 2000 6000 5500
C 360 355 500 500 175 175 575 575
D 1 1 1 1 5 5 6 6
Evaporator Saturated Temperature Offset for Non ARI conditions.

TT300 TT350 TT400 TT500
K 1822 -9105 -8427 -16967
L 1228 3226 3035 7726
E -485 2115 2026 3913
M -28 -75 -70 -179
Note additional Mask to the right of the one above are used to configure single compressor and non-ARI
conditions. These settings are preloaded by compressor selection during the commissioning process. Contact
the factory for directions to these masks, if you need to make further adjustments.
20
Advanced Setpoint Mask #5a – Single Dyn
AS#5a Single Cmp-DSD Scroll to the right to access screen 5a. This is the additional screen
NP=070A 10000 which displays single compressor SD coefficients. These are
A=+0000 B=2000 C=250 configured with factory recommended values based on commissioning
D=5 460V Lp068 SD=47 setpoints. Lp=lift pressure, SD=% RLA with no offset applied
Advanced Setpoint Mask #5b – Non ARI Delta

AS#5b DSD ESatT Ofs
Scroll to the right again to access screen 5b. This screen displays the
K= 000000 L= 00000 non AHRI SD coefficients. New logic is based on saturated evap and
E= 00000 M= 00000 lift. 4 additional coefficients are displayed on this screen. These
EST21 Lp535 OFS-001 coefficients are auto configured based on commissioning settings. Do
not adjust these points. EST= evaporator saturated in °F, Lp=lift
pressure, OFS-SD offset applied due to non ARI conditions (moves
the SD curve if needed).
Advanced Setpoint Mask #5c – Non ARI SD F

AS#5c Unload Limit % Scroll tot the right again to access screen 5c. This screen should be
C1 ST38 L552 RLA0000 used for SD/unloading t-shooting. This screen will display sat evap
C2 ST38 L552 RLA0000 temperature, lift pressure, and RLA for each compressor.
D047 S047 -001 UL46.9 D047=Dual compressor shutdown point (% rla where one of the two
running compressor will not unload below)
S047=Single compressor shutdown point (% rla where the single
compressor will not unload below). -001 is the offset applied to the actual UL(unload point)
The compressor will ride this SD curve until the conditions changes and more loading is needed or the
lwt+shutdown delta is reached. The offset is the calculated amperage adjustment converted to %rla adjustment.
UL= the shutdown point with the offset applied or the new calculated SD.
Troubleshooting tips=It is possible to make changes to the curve for testing purposes just to see what the result
would be. This can be accomplished by making changes to the mode that is not in use. For instance, if the chiller
was in operation with one compressor running, you could make changes to the dual compressor
coefficients(AS%5) and then see what affect it would have by referencing (AS5c). If the values are reduced too
low, check valve activity may occur. The compressors audible pitch will change just before this point occurs
(especially at higher lifts). It would then be desirable to increase A-B coefficients to a higher value. If the 3G
monitor tool is used, the control status will display “min capacity” when further unloading is not achievable. If
changes from default are made, it is recommended that the dual amperage be ~ 2% higher than the single.
If saturated evaporator temperatures are similar for each compressor but the lift is different, you should verify
the suction and discharge sensors accuracy. Unloading curve calculation will use the higher of the two lifts, so
sensor accuracy is important.
Advanced Setpoint Mask #6

Adv Set#6 Lift Ratio Cond Press (derived from tmp) | Gx=1.XX (Max 2.0)
CondPD=095.3 Gx=1.00 (use 1.15 for Milestone1 Compressors only)
Amb=14.7psi PdG=1.0 Ambient Pressure | Predicted Target gain * (Max 5.0)
Suct P=035.4 LR=1.2
Suction Pressure | Lift Ratio (measured)
Gx applies to Milestone 1 compressors only.
PdG is the gain factor multiplied by the ELWT-slope and added to the target temperature to allow a soft
approach to the target Evap Leaving Water Temperature.
21
Compressor TT300 TT350 TT400 TT500
Gx (.00-.20) 00 00 00 00
PgD (0.5-5.0) 1.0 1.0 1.0 1.0
CE (.0-.4max) 0 0 0 0
VE (.0-.5) 0 0 0 0
Advanced Setpoint Mask #6a Check Valve Alarm & Cal
6a Chk-Val Alr Cal 0 Cal 1 = Calibrates pressure offsets for this alarm only (set when stable).
CV-LR Trip=107 /100 See 6Cmask for offset values.
20 LR C1 = 204 /100 Flooded Comp alarm trip lift ration 107 /100 (1.07 LR)
19 LR C2 = 198 /100 20 = LR derived from Cond water temperature & C1 Evap Press..
LR C1 = Lift ratio as measured by DTC compressor..
19 = LR derived from Cond water temperature & C2 Evap Press..
LR C2 = Lift ratio as measured by DTC compressor..
The trip point no longer needs to be changed. The software separates the sensor offsets used for the alarm
from the actual sensor feedback used by the chiller controls & OITS. The Cal =0 point can be used to manually
calibrate the sensors for this alarm. Change the 0 to a 1 to manually calibrate.
Advanced Setpoint Mask #6b Flooded Alert enable

6b Flooded Alert= On Flooded comp alarm On /Off
Cal Press Offset-> Calibrate Pressure sensor offsets next mask to right (6c)
Suction SH=03.0 oF Suction SH trip point 03.0 (alarm trips below setting).
Discharge SH=08.0 oF
Discharge SH trip point 08.0 (alarm trips below setting).
6b allows the tech to disable the flooded compressor alert or also to adjust the flooded compressor alert trigger
points
Advanced Setpoint Mask #6c Flooded Alert Cal
6c Flooded Alert Cal Discharge SH trip point = 8.0 oF (from 6b mask)
Discharge SH=08.0oF C1 -3.0 Condenser pressure offset (applied to alarm logic only)
1 Ofs-3.0psi 12.0 oF 12.0 oF C1 Discharge superheat with offset applied
2 Ofs-3.0psi 11.4 oF C2 -3.0 Condenser pressure offset (applied to alarm logic only)
11.4 oF C2 Discharge superheat with offset applied
The calibration for the suction/discharge pressure transducer input (as it applies only to the failed check valve
alarm) is now auto calibrating. The calibration occurs when you execute the CFG=0 or 1 command on the
commissioning page. The calibration is performed only if the compressors are off and the exv is closed (no inverted
condition active). The calibration is not transparent to the user.
6c does allow the tech to enter manual sensor offsets for this alarm logic. These offsets would be adjusted when the
compressor is not running. You would use the offsets until the lift ratio's shown on screen 6a were a 100/100 or a
value of 1 for each compressor. Verify this is true in software.
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Adv Sp Mask #7 Lift Ratio in Vane Effect
Adv Set#7 LR-Assist Percent Inlet Guide Vanes are open (0-110%)
VE-Ofs=0.0 IGV=110%
VE - Offset proportionally applied to LR as IGV drops between 110
Choke-Ofs=.3 TR=250% and 95% (full offset < 95%).
Lift Ratio +Ofs =1.3 Used with Milestone 1 compressors to increase speed while in vane
effect to avoid stalling the compressor.
Choke-Ofs = Fractional PR offset value tapered from 1.2 to 1.9, with a full offset applied at 1.2 and below. This
setpoint can be used to achieve a slightly higher speed at compressor start. Care must be taken not to set this value
too high. Choke offset can help to get out of a low pressure ratio condition (tower control, and exv could also be
used). This small ratio offset applied to the compressor when in low lift. This adds .3 or 3 tenths to the compressors
perceived PR from 1.2 to 1.5 actual PR . Once the actual PR reaches 1.5, the offset tappers to 0 by the time the pr
reaches 1.9. The Microtech can only write in tenths, so it’s a large step. There is a condition where a .4 could throw
the compressor out of its desired speed range. .3 is the recommended max setting.
TR= Tower Reset percentage.
Lift Ratio (LR) with Offsets added (sent to compressor).
Adv Sp Mask #8 Lenient (water flow) Sensing

Adv Set#8 Flow Alarm On – Enables Lenient Flow Sensing feature
Time allowed (Lenient Sen OFF) before alarm. (3-12 sec)
Lenient Sensing On
Evap Trip 12 Sec Time allowed (Lenient Sen OFF) before alarm. (3-20 sec)
Cond Trip 20 Sec Lenient sensing is defaulted to on, which will enable the function.
With this default value, the chiller can start without condenser flow and
run without evap and condenser flow. The chiller will not start without evaporator flow. With lenient sensing
on, the timers are not in effect.
Adv Sp Mask #9 Condenser Pump Staging option Alternate

Adv Set#9 CW Pumps Condenser Pump strategy - used to stage pumps in lieu of VFD control.
CW Pump Modes of Operation
Stage Mode = OFF OFF - Pumps operate as before.
Lift-T - Primary Pump runs until Lift Temperature is reached and
then secondary (lag) pump is started. A setpoint will become visible if
this mode is selected.
#-Comps - Primary Pump runs until a number of compressors are running, and then secondary (lag) pump is
started. A setpoint will become visible if this mode is selected.
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Adv Sp Mask #10 BMCC Configuration (TT400)
Adv Set#10 BMCC Cnfg
BMCC - software version, Ramp - VFD rate of change.
BMCC=0.0.0000Ramp=01 C-Str – Check Valve is considered open > Amp setpoint.
C-Str=10A VCmp=1100 VCmp – RPM added to Comp min speed when in IGV control (applied
Adv-IGV15% Slip=1600 inversely proportional between 0 -105% IGV). Used to stabilize RLA
while in vane effect.
Adv-IGV – percent of IGV start position allowed before rotor levitation and rotation. Basically this would
equate to 15% or our 12% open start position. Proves that the vanes are being asked to open.
Slip – RPM added to Start-Speed during start.
Use the setting in the table below that match the compressor model on your chiller.
Compressor TT300 TT400 TT500

Ramp* (do not deviate) 1 1 1
C-Str* (10 – 50A) 10 10 10
VCmp ( Max 4000 RPM) 1463 1100 846
Adv-IGV* (< 25%) 15 15 15
Slip* (10-3000 rpm) 2000 1600 1200
If set too high it can result in High current trip, or ELWT overshoot and compressor shutdown.
If LBV’s are installed Slip and VCmp RPMs may be reduced, from stated values.
Adv Sp Mask #11 BMCC Configuration (continued)

Adv Set#11 Unit Cnfg Rapid restart- Restores Chiller to same condition before
Rapid Re-Start OFF power loss.
IGV Control Rate IGV rate of change while chiller is not on ELWT target.
Trg: Off=21 /On=21 IGV rate of change while chiller is on ELWT target.
Caution! – Do not change either IGV Rate. Must use 21 to match
starting IGV Rate (of lag comp).
Adv Sp Mask #12 BMCC Configuration (continued)

Adv Set#12 BMCC Cnfg Control Loop Speed – has been converted to follow the dynamic load
Dyn 00 Cntrl-Spd 03% (00) on the evap. Once on condition (ELWT) a value of 1 is written to
Stg/Unl Lift >2.2LR the compressor to obtain stable target temperature. No user adjustment
Unload Margin = 60% is allowed.
Stg/Unl_Lift - if the Lift Ratio parameter is above the value selected,
the Stage-Up Unload function is enabled. If enabled the Lag will delay its start until the Lift pressure drops
below setting, or until the Stage-up unload timer expires.
Unload Margin - Sets the minimum Demand (based on the highest Demand from either compressor) that the
compressor can unload. This prevents the low KW compressor from stalling completely in a chiller unloading
situation. Also prevents a case where a slightly more capable compressor could unload too far below a less
capable compressor.
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Adv Set#13 Stage Cfg
Lead Unl Cycles = 03 Adv Sp Mask #13 Staging configuration
2>1 StgDn Err -1.0oF Maximum number of Unload Cycles before Lead aborts “stage-up-
Start Rdy + Next = 0 unload” and returns to normal chiller control.
Used as a fail-safe (loaded) setting.
Temperature below target and on SD when a transition can occur from 2 to 1 compressors running. This can be
adjusted if needed to alter the amount of time both compressors are running together(ridding the SD curve) before
one is cycled off.
The Start Rdy + Next setting is used to configure the logic presented on the "Ready Start" signal that can be
selected on either of the Substitute Relay outputs available in Adv-Set Mask #20.
By setting this value to one (1) the Next-On flag is included in the chiller ready-to-start signal. With this
configuration the "Ready Start" will be true “1” when this chiller will be the NEXT chiller to start.
If this setting is a zero (0), then the "Ready Start" signal implies the chiller is able to start. Or stated another way,
all alarms and timers are cleared. It does not imply that the chiller is enabled to start.
Adv Sp Mask#14 Hot Gas Relief (optional)

Adv Set#14 HG Relief
HG Ramp > 25% 1.5Min Sets Ramp time from 100% to 25% (1.5 minutes)
Close HG Valve @ 25% Sets, point on ramp (duration) of the HG cycle.
HG = Off 075%
If a proportional valve is fitted to the chiller, the valve will fully open as the lag compressor starts and then begin
to ramp closed at an exponential rate over time. Both valve types (solenoid and proportional) will close as the
ramp drops below the “Close HG Valve @ 25%” set point. This setpoint is found on the third line of the Adv Set#8
HG Relief mask of the compressor controller (controlling the valve).
Adv Sp Mask#15 Staging Unload Options

AS15 Stg Unl Options
Under High Lift conditions unload to Min Spd +RPM
High Lift Spd=990RPM
Low Lift Stg < 1.8 Under Low Lift conditions unload below Lift Ratio
Low Lift IGV= 108% Under Low Lift conditions unload lead to IGV percentage.
This encourages the Lag Comp to open vanes faster and exit IGV
capacity control mode. Once this occurs, the lag compressor is released to our demand and can load balance with
the lead.
25
Adv Sp Mask#16 Staging Unload Configurations
AS16 Stg Unl Config
Stg-On Lift Ratio Staging Logic Based on Lift Ratio or Lift Pressure (psi) Release of
Lead Comp based on Chk-Valve(pressure ratio of the lag should equal
Stg-EEV Auto Control
that of the lead when the check valve opens) or IGV-Open of the lag
EEV Duration 045s compressor.
Select EEV staging mode: Auto Control or Hold @ 50%.The selected mode is held during lag start for
the duration of the Unload timer. Auto Control will switch the exv from pressure control to programmed solution
(45seconds adjustable) before lag start. This ensures stable exv position. When “Hold” is selected, the 50%open
(adjustable) position will be held throughout the lag start.
If LBV’s are installed, tuning of this eev valve point will be unnecessary. If equipped with LB Valves the
Lead compressor will open its Load-Balance value when the lead is selected as Next-On. It will not close the
valve until the IGV is fully open
The Lag compressor will not open its Load-Balance Valve until just before compressor start. Actually the
compressor will delay its levitation until the valve is open 45%. The valve should be fully open before the check
valve has opened, and the Load-Balance valve should close within seconds of this event as the Lift Ratio
approaches that of the Lead.
Note - See Rapid Re-Start function for special Load Balance Valve op
Note - See Rapid Re-Start function for special Load Balance Valve op
Adv Sp Mask#17 Load Balance Valve

AS17 Load-Bal Valve
Config=Start Only LD-Bal mode ("Off","Start Only","Str & Unload",
"Manual","Start Only","STR & UNL")
Target 1=0000 2=0000
Valve 1=0000 2^1000 Target position = Manual Position or Commanded position.
Valve position = (^ indicates opening, & v is Closing)
Adv Sp Mask#18 Extended Unloading w/ LBV
AS18 Extended Unload Pos= Valves feedback position %; “L” = “LAG status”
On-set(SD+00) Full3% Dly= Dwell Time after comp start; Closed position %
Mode Enabled SD Ofs
D-SD A=+0000 B=+2000 Extended Unload with 1 compressor running.
On-set of LB valve opening Valve Fully open @ % >SD
Adv Sp Mask#19 Primary Loop Temps & Slopes

19Pri-Loop Ts & slps
EWTF30.0oF +30.0 oF/m Entering Chiller/s Primary Return Temp and Slope
LWT 44.2oF +02.0 oF/m
Leaving Chiller/s Primary Return Temp and Slope
Loc-LWT43.0oF P&SOFF
Local Chiller Leaving Evaporator Temp
Primary/Secondary Multi-Chiller Control Mode OFF or ON
Advanced Set point mask #19 is primarily intended for use with the Multi-Chiller Primary Loop Monitor function
incorporated into the this version of WMC chiller control logic. Call McQuay Service for details regarding this
function.
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Adv Sp Mask#20 Auxiliary Output Functions
20 Substitute output
Y6=U-RLA 8V=100% 0875 Selected analog function for Y6, with active readout.
R13=Ready Start 0 Selected digital function for R13, with active readout
R15=Chiller Runing 1
Selected digital function for R15, with active readout
R13 and R15 are isolated Form C Relays
Analog Out Selections for Y6
"Tower Bypass",
"Tower Fan VFD",
"Exp Valve",
"Tower Reset",
"U-RLA 8V=100%",
"Prop HG-Valve"
Functional Outputs Selections for R13 & R15
"Evap Wtr Pmp#1",
"Evap Wtr Pmp#2",
"Cond Wtr Pmp#1",
"Cond Wtr Pmp#2",
"Tower Fan #1",
"Tower Fan #2",
"Exp Valve Cal",
"Alarm(not SSR)",
"Harm Fltr C1",
"Harm Fltr C2",
"Chiller Runing",
"Relay Test Off",
"Relay Test On",
"HG-Bypass",
"System Lockout",
"Ready Start"
Tower Control: A variety of strategies are used for tower control. The chiller can control a tower bypass
valve, tower fan VFD and additional tower stages. The ideal tower control strategy would employ a bypass valve
and tower fan VFD control. Basically the bypass valve is used to warm up the water (needed to increase the
compressors pressure ratio which enables loading), and the tower is used to cool down the water. In some cases
the traditional tower bypass valve has been replaced by a choke or pinch valve which reduces the condenser
water flow rate (the recommended/most responsive control method would be “pressure” in this case, as ECWT
would not change quickly as flow was reduced) . An additional method to build heat in the condenser would be to
use the tower bypass valve signal to control the condenser pump vfd. Tower and valve control setup can be
challenging. Your jobsite will ultimately govern your settings, as each jobsite can have different pipe
sizes/lengths and tower configurations (number of fans, tower size, sump size, tower cleanliness).
It is very important to set the tower/valve settings appropriately, for instance if you have two stages of tower
fans selected but you only have one stage it can cause the first stage of tower fans to act/react as if there were two
stages. In this case you would see fan VFD signal activity as you move into and out of temp zones. Normally this
expected VFD activity would provide a cushion when fan stages were changing; however the VFD movement
would lead to unneeded temp swing if performed in vain.
27
New Features:
(New) Condenser Recirculation Timer must expire before the tower fan can start.
•Tower bypass valve is only active if chiller is starting or running. When the chiller is ‘off” the signal goes to
zero and the output is not energized.
•Tower Fan logic can be selected to use Entering Heat Recovery Temp (B9) as a remote tower sump sensor,
(however, the tower bypass valve logic is locked to the Entering Condenser Water Temp sensor).
•Tower Reset function that proportionally raises all tower fan and bypass valve set points up to a user selected
value as a means to satisfy the minimum lift ratio requirement of Danfoss Turbocor Compressor. This
feature is only affective if the chiller is allowed to control the cooling tower and tower bypass valve.
•For BAS controlled cooling towers an analog output has been added that represents the tower reset function
described above. This zero to ten volt signal provides a relative reset parameter that a BAS system can use to
offset its tower control points. As the signal increases from zero (no reset) to ten volts (maximum reset) it is
left to the commissioning personnel to determine the exact measure and units of reset to apply to their control
logic (hence the term relative). The degree of reset should be based on climate and tower size.
Tower Control Logic:

Improvements to the Tower Fan and Bypass Valve operation have been added. These control modifications
center around the adoption of two independent Bypass Valve and Tower Fan VFD control routines. The
Bypass Valve uses a step and wait algorithm, and the Tower Fan VFD uses a PID control loop. Tower control
is based on one of two user selected parameters: Condenser Entering Water Temp, or chiller Lift Pressure.
A Tower reset function has been added that works to elevate the condenser return water temperature in an
attempt to coax more capacity from the Danfoss Turbocor compressors when operating in low lift conditions.
The amount of reset is adjustable by the service technician (Set Tower Sps 5), and should be based on weather
conditions in your region.
Tower Fan VFD PID

The PID control used Proportional, Integral, and Derivative functions to control tower fan speed. The
Proportional term sets an output value based on the error between the target and the selected control parameter
(Lift or Temp).
The Integral term looks at the error (difference) from target over a time period. The longer it is off target plus
the size of the error combine to add a correction to the output. If it is off target by a small amount for a long
period a small correction is made. If it is off target by a large amount for the same period a larger correction is
made. The integral value is similar “wait” portion, or how fast to update.
The Derivative term looks at the feedback signal to determine if the system is responding. If it is, it looks for
how fast it is responding (slope) and applies this as a breaking action to the control signal. This prevents major
overshoots and oscillations in the system. Reduce this value to make smaller steps. Used to decrease or
increase the output signal as the actual return temp ascends or descends toward sp.
Bypass Valve Step and Wait

The bypass valve functions has some initial positions to start from that do not lend itself to PID control logic,
therefore a Step and Wait method of control has been used.
This method takes the error between the valve target and the selected control parameter (Lift or Temp) and
multiplies it by a Gain factor (default 20). The derivative (slope) is subtracted from the result and summed into
the control command signal at the step interval. Conditional overrides are added to effectively build the valve
control signal. Logic is applied to limit the valves control range and inverts the signal if a normally open valve
is installed.
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Controller Mask Navigation of Setpoints
Set Tower Sps mask #1 and #2 have not changed from previous versions, see IOM for operation.
SET TOWER SPs (1)

SET TOWER SPs (1)
Tower Control mode= None/Temp/Lift
Tower Control=None
Tower Stages=1 Tower Stages= 1-4
StageUP/DN=80/20 StageUP/DN=080/020? Used to help cushion or to create a buffer
(prevents cycling) between tower staging events. Example: If tower
stage 1 and 2 were set to 70 and 75 respectively, and a stage up of
80%, then the next stage would start at 74 degrees instead of waiting until 75°F.
SET TOWER SPs (2)

SET TOWER SPs (2)
Stage ON= settings used to define the stage up and stage down
Stage ON (Temp)°F temperatures. It is very important to set the tower/valve settings
#1 #2 #3 #4 appropriately, for instance if two stages of tower fans are selected and
the tower only has one stage it can cause the first stage of tower fans to
act/react as if there were two stages. In this case there would be fan
VFD signal activity as you move into and out of temp zones. Normally this expected VFD activity would provide a
cushion when fan stages were changing; however the vfd movement would lead to unneeded temp swing if
performed in vain.
Set Tower SPs (3) Fans

Fan VFD Minimum Speed percentage of Max speed
SET TOWER Sps(3)Fans
VFD Min Spd = 20.0% Staging Differential – difference between StgUp setting and StgDn
StageDiff = 10.0psi setting for same stage number.
Stg Up=02 Dn=05Min
Delay between the same direction staging events.
The min speed is used to set the min speed for the VFD. If set too low, vibration and noise will occur at the fan.
SET TOWER SPs (4)
SET TOWER SPs (4)
VALVE/VFD Control= Any one of the following modes can be selected.
ValveSP/VFDStage "Valve Setpoint","Valve Stage","VFD stage", “None” or
Valve Type=NC "ValveSP/VFDStage"
Valve Type can be Normally Open (NO) or Closed (NC). It is
imperative to know the normal/non powered position of the bypass valve.
29
SET TOWER SPs (5)
SET TOWER SPs (5)
Valve SP= 065F Bypass Valve Sp (Temp of Lift-psi).
Reset = 05.0F Maximum Tower Reset (Temp of Lift-psi). This reset is applied to both
Sensor = ECWT-B3 the tower sp and the valve sp and would be used in situations where the
compressors require a min pressure ratio to load. If tower reset is not
required, this value should be set to 0.
Select EHRT-B9 for a Remote Tower CEWT sensor.
ECWT-B3", normal sensor connection point; or "EHRT-B9 remote sensor connection point on the controller.
Remote sensor (10k sensor) lands on B9 at the controller. This remote sensor input could be quite useful in
situations where the tower water return temperature was fluctuating due to a large sump or distance to the tower.
The sensor could be placed in a position where it could measure the tower temperature more accurately. The use of
this remote sensor could help to stabilize the output signal fluctuation and entering condenser water.
Tower Reset Function:
This function attempts to elevate the condenser return water temperature to coax more capacity from the Danfoss
Turbocor compressors when operating in low lift conditions.
If the chiller is not controlling the tower, this tower reset analog out is always active. The servicing agent or
chiller plant operator must decide is how many degrees the 10V A04 signal will add to the tower control setpoint.
Note: The reset function will not engage until the compressor/s is at or above 95% of max to min speed for the
current conditions. If the compressors approach max amps or max condenser pressure, the reset function will be
limited or cancelled as needed. As the pressure lift ratio increases between 1.5 and 1.9 the reset function is
tapered off, (no tower reset above 1.9LR).
The WMC “B” vintage control platform (single pCO3 controller) has a 0-10V output on Analog out #4 to offset
the tower control setpoint on an external controller (BAS tower controller). At 0 volts the normal control temp is
followed, but if the chiller finds itself limited in capacity because of low condenser pressure (LR = Lift Ratio).
The Analog #4 output will begin to increment in value toward 10V. This signal is then used to offset the control
setpoint to a higher value. The concept is that this will increase the LR which will allow the compressors to load.
As the chiller pulls down the Evap Leaving Water temp setpoint the Analog #4 signal will ramp down to 0V. If
staging on another compressor is required then the A04 signal will quickly dump to zero voltages to help with
condenser relief to facilitate the lag start.
The servicing agent or chiller plant operator must decide is how many degrees the 10V A04 signal will add to the
tower control setpoint. This is not a precise function; the goal is to position the tower to allow the condenser
return water to warm up. It is not possible to know at what precise temperature the compressor needs to load for
any given conditions. As the compressor begins to load the heat in the condenser will increase and the
compressor will then load more, and more. There are no real settings to adjust in the chiller control code just the
size of the step to unload for staging.
The Capacity Adjust Factor (CAF see Managing the load - Capacity Control Algorithm above) is summed with
the percent speed to derive a correction factor that is summed with the other compressor (see the “S” value
below).
The “F” parameter is shown on the mask below. This value is also the Tower Reset Analog output (0-1000
equates to 0 to 10Volts).
The “R” value is the amount of reset (Set Tower Sp 5) applied to the internal tower control. It is in the terms
selected for tower control. The amount of reset should be based on weather conditions in your region.
30
The last line of the mask deals with limits to the reset function. RLA+ is the percentage over 100%. As this
value exceeds 100% the reset is proportionally reduced, limiting the reset.
CsP is a value scaled from 20 psi below the pressure alarm 0, to the alarm limit 200. As the pressure
approaches the limit and the value increases from 0 – 200 the reset value is proportionally reduced.
The “m” value is the combined limit for the tower reset.
Db Tower R06.0 F0600 Debug Tower Reset Function

CAF*+018 *+015 UT250 R04.3 – Reset Temperature or Lift-psi
Spd 088 086% S0602 F0812 – Reset signal sent to analog output Y4 (8.12V)
RLA+01 CsP+075 m1000 Outputs R & F (above) should track together.
Limiting Parameters
RLA compared to 100% - ie. +05 = 105%RLA (highest value from either compressor).
CSP Condenser Sat Press – i.e. 200 = High Cond Stop Alarm, 0 = 20 psi below alarm.
m1000 – is the combined Tower Reset Limiting variable.
UT250 – The UT setting is the only adjustment on this mask. It controls how quickly the Reset value can be
unloaded, by subtracting the number (250) of counts from F, as when staging up another compressor. This
setting is used to adjust the reduction of the tower reset. Increasing this UT value would drop the tower reset
faster.
SET TOWER SPs (6)
SET TOWER SPs (6) Bypass Valve Start Position.
ValveStartPosition The Valve will be set proportionally between Min and Max
Min=010% @ 060F temperatures or Lift-pressures.
Max=100% @ 090F
SET TOWER SPs (7)

SET TOWER SPs (7)
Bypass Valve Control Range. These settings correspond to the actual
Valve Control Range output signal. Example: Min=20% and Max=100%, the actual signal
Min=010% Max=100% strength from the controller would be 2vdc and 10vdc.
Tower Loop = 1.7min Tower Recirculation Timer (delays Tower Fan start from Condenser
flow switch).This feature will delay in making any tower output
decisions for this time period at start. This can be used to allow for warmer mechanical room water temps to mix
with colder tower piping and sump temps. Allowing the water to circulate before making an initial valve/vfd
decision can help to prevent output signal swings.
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SET TOWER (8) Bypass Valve Control
SET TOWER(8)ByP 063% ByP 063% - Indicates Present Valve position.
FB +036.0 Intg Derv FB = Valve Error | Trg = Valve Target Position
Trg+038.0 006s 001g Step and Wait Logic settings:
Gain20 Deadband01.0 Integral – Time of the integrating function
Derivative g – gain of the Slope used to retard correction.
Gain – Size of correction step.
Db – Dead band of the control range. Deadband= this is the area on either side of the sp where no output activity
would be seen.
The Gain factor in a Step & Wait routine is applied to the error from target. It does not use a control band in the
same way as the PID below. Gain=this helps to establish how big of a correction the integral will make.
EXAMPLE: If the gain is set to 99 and the integral is set to 6, every 6 seconds the signal would make a large move.
In other words, it’s updated every 6 seconds.
SET TOWER (9) PID for Tower Fan VFD

SET TOWER(9)VFD 089%
VFD 089% - Indicates Present Fan Speed.
FB +038.0 Intg Derv
FB = VFD Error | Trg = VFD Target Speed
Trg+038.0 600s 001s
K08.0 Db0.0 Tc0500ms PID settings:
Integral – Time of the integrating function
Derivative – Time of the derivative function
K – Control band of PID function.
Db – Dead band of the control range. Deadband= this is the area on either side of the sp where you would not see
any output activity.
Tc – PID output update rate, in terms of milliseconds. Time that the controller waits in between processes, default
to 500 miliseconds. Do to not adjust this controller timing. The control band “K”factor is applied above and
below the target set point. In the mask above the control band would be from 30.0 to 46.0. Units of measure
would be what was selected (Condenser return water Temperature or Lift Pressure).
Job specific setpoint recommendations:

Lag compressor start issues (front radial displacement faults):
Is the chiller fitted with PLBV’s? Are the valves opening as expected?
Is the lead compressors demand signal decreasing? If yes, is the lead compressor unloading to min rpm (+unload
surge offset)?
Is the expansion valve reacting per AdVanced set 16 setpoint (open/hold)?
What is the lift when the lag tries to start? It should match AdVanced set 12 (Stage unload lift).
Is the chiller seeing any decrease in lift from condenser relief and lead unloading?
Setpoints that could assist:
-Stg/Unl lift- (lift ratio or pressure) could be lowered if the lead compressor stops unloading to soon (Low lift Stg
should be set lower than Stg/Unl lift)
-Unload timer could be extended(Set Comp (8))
-Lead Unl Cycles could be extended(Adv Set (13))
Note: Use caution with these settings to avoid losing the building load during lag start.
32
Inverted starts or low lift starts:
The best recommendation is to not start these compressors inverted. If the condenser is at a lower temperature
than the evap, the compressor may not load as expected (due to compressor choke). The liquid refrigerant
available for motor cooling is not thermally encouraged to move toward the compressor. Alarms could result.
Items that could assist:

-LATs (timer could be decreased, refer to page 8)
-Tower/Bypass valve control by the chiller (the chiller would be closing the bypass valve)
Low mass flow causing check valve chatter (light load/vane effect):
• Remember that the SD function is dependent on several factors. Sensor accuracy is very important. If the
compressor unloads too far (lose of ability to keep the check valve open), the SD values A-B could be
increased.
•Evaluate the refrigerant charge page 38.
•Verify exv operation (test mode, or power cycle, white line movement in window).
•Increase vane compensation (last option, speed added to compressor while in vane effect) .
Check valve chatter could come from loading, low charge, faulty exv, and drastic changes in flow.
Variable flow has a big impact due to the evap saturation changes and the low side makes a huge impact on
pressure ratio. So as the evap sat changes, the PR changes, so do the compressor speed ranges. Focus may need to
shift toward the building to slow down the building valves.
Troubleshooting and alert/alarm identification:
WMC Alarm Processing in 14B Chiller Code:
Preface
Alarm processing in the WMC chiller code is quite complicated. It is felt that with a better understanding of the
alarm code technicians and BAS programmers would find it easier to troubleshoot and diagnose issues resulting
in chiller alarms.
It must be understood that all refrigerant suction and discharge pressures and temperatures are derived from the
pressure/temperature sensors on the Turbocor compressor. There are four areas in which alarms may be viewed,
the Operator Interface Touch Screen (OITS) alarm screen, the unit controller “Alarm” partition, the unit
controller mask and the compressor controller through the compressor software management tool (SMT). There
are a large number of faults and alarms generated within the compressor that are not indicated individually on the
OITS. A major portion of those internal compressor alarms can be viewed in the “View Compressor” mask sets, 9
through 11, on the unit controller. Although those alarms are only retained there until the conditions correct and
the controller resets them. Individual specific compressor alarms can be viewed with the SMT software.
This document describes the alarms and alarm handling logic used in the WMC Control with Milestone II
compressors and 10N code. It is limited to those alarms shown on the Operator Interface Touch Screen and those
generated within the Turbocor compressor. Not covered in this document is a second generation Building
Automation System (BAS) alarm and parameter schedule which was implemented in the fall of 2012. Those
parameters and alarms provide easier access to certain chiller parameters and increased diagnostics for alarms
within the BAS. With the exception of the dwell time for sending alarms to the BAS these additional specifics are
not covered in this document. Documentation specific to BAS interfaces should be referenced for additional
information for specific points, currently ED15100-2.
33
The “Starter Fault” alarm text was a predecessor in the first generation alarm schedule. This alarm, from a
WMC machine, indicates a general fault from the Danfoss Turbocor Compressor (DTC). It is active for any
bearing, motor, or compressor fault detected by the internal compressor logic. It has been replaced in the 2nd
generation alarm schedule and 10N code with the general “Compressor Fault” alarm. Some software versions
may indicate either alarm.
The “Starter Transition” alarm text is also a predecessor of the first generation alarm schedule. This WMC
alarm indicates a communication fault between the Danfoss Turbocor Compressor (DTC) and the chiller controls.
It has been replaced in the 2nd generation alarm schedule and 10N code with the “Compressor Comm Loss”
alarm. Some software versions may indicate either alarm.
Instantaneous Lockout Alarms
Certain critical alarms will result in the compressor and/or control instantly shutting down and locking off.
Danfoss Turbocor Compressor (DTC) identifies two alarms as Instantaneous Lockout Alarms; they are Discharge
Pressure and 3 Phase Over-Current. Once this type of alarm is triggered, it is flagged as a System Lockout alarm
in the compressor and a Compressor Fault in the controller and requires the power to the compressor to be cycled
off for approximately 30 seconds to clear the lockout status. A System or Compressor Lockout will be posted to
the OITS “Alarm” screen.
Note, either one of these alarms will result in three alarms, such as the 3 Phase Over-Current event will trigger
the following; Motor Current Overload, Compressor Fault, and a System Lockout.
Special Case – The Discharge Pressure alarm has two sources. One trigger is from a limit within the DTC
compressor and this is a Lockout alarm; 173psi limit / 180psi trip. The other alarm trigger source is the chiller
controller, and this adjustable alarm limit is below the limit stored in the compressor; SET ALARM LMTs,
HiCondPr 130 to 160psi. If this lower pressure limit is tripped the chiller controller will shutdown the
compressor that reports the alarm. The controller will attempt to clear this alarm and a strike will be recorded. If
three of these alarms (strikes) occur within a 50 minute time period from the first, the controller will lockout both
compressors, and therefore the chiller. The difference in this case from the Instantaneous Lockout Alarm, is that
this alarm can be cleared (after plant inspection) by direct operator intervention at the chiller control panel
without doing a compressor power cycle. This alarm cannot be cleared through a BAS interface.
Three Strike Alarms
The logic inside the Danfoss Turbocor Compressor (DTC) commonly known as “three strikes and you’re out”
locks out (off) the compressor for any combination of the following alarms occurring within a 30 minute period:
Inverter Temperature, SCR Temperature, Motor Current High, Inverter Error, Rotor Locked, and Motor Back
EMF. If the three strike combination is activated the System Lockout alarm will also be triggered, and a power
cycle is required to clear the Lockout alarm.
A secondary three strike alarm detection looks for any of the following; Discharge Temperature, Discharge
Pressure, Suction Pressure, Cavity Temperature, Pressure Ratio, Bearing Control, Sensor Fault, Motor Heat,
Super Heat, and any of the first group above. If any three alarms occur within a 50 minute period, the compressor
is inhibited from auto-clearing the last alarm for a period of 20 minutes. This logic was implemented to disrupt a
continuously reoccurring alarm condition.
Auto-Clear Alarms
The logic inside the chiller controller attempts to automatically clear all alarms, with the following exceptions;
System Lockout (Compressor Fault), Check Valve Failure, Ground Fault, Low DC Bus Voltage (Compressor
Fault -compressor not running), and the third strike on the (low limit) discharge pressure alarm (Condenser
Pressure High). See the complete OITS alarm table attached.
The Low DC Bus Voltage alarm generated while the compressor is not running is not cleared because it defeats
rapid restart of the compressor in a power loss or cycle. This alarm will be automatically cleared when the unit
controller writes a demand to the compressor. It may take up to10 minutes for this alarm to actually clear. A short
power cycle on a non-running compressor can generate this alarm. In a nuisance situation the alarm can be reset
by cycling the unit control switch inside the unit control box.
34
Manual Intervention Alarms
A Compressor Fault alarm may or may not require manual intervention to reset the alarm. If it is created by one
of the compressor system lockout alarms “System Lockout” it will require manual intervention, a 30 second or
more power cycle to the compressor exhibiting the alarm. Internal compressor alarms that create a System
Lockout are: Condenser Pressure High and High Motor Amps; and any of the Three Strike Alarms in 30 minutes.
The OITS panel will display a Compressor Fault. A review of the unit controller Alarm Active mask will list the
last 25 alarms with a date and time stamp. The unit controller mask “VIEW COMPRx (9 through 11)” screens on
the controller will designate the actual compressor alarm(s) generated prior to their being reset. These alarms are
only present for three minutes after posting provided the alarm condition is not active. A Condenser Pressure
High alarm created by the chiller, SET ALARM LMTs, HiCondPr=140psi, will attempt to auto clear for three
events in 50 minutes, see prior Special Case description. A High Motor Amps alarm will display as “Motor
Current Overload” on the OITS panel and will require a manual power reset of the compressor power.
A Check Valve Failure alarm will lockout the chiller and require a manual reset of the alarm at the unit controller
or OITS panel alarm button.
A Ground Fault alarm will require a manual reset of the trip switch on the ground fault relay and a reset of the
unit controller or OITS panel alarm button.
Alarm Dwell Time

The Alarm Dwell Time is the amount of time an auto-clearable alarm is held in the chiller controller buffer,
pending an auto-clear attempt, before forwarding the alarm to the BAS interface. If the alarm is cleared on the
chiller within the time period, the alarm is cancelled, and no alarm is transmitted to the BAS. If the alarm has not
cleared during the dwell period the alarm is then passed to the BAS interface. This dwell time is adjustable, 0 to
99 minutes, and can be set to zero; this will allow the controller to immediately pass all alarms to the BAS.
The following alarms are not held for the Dwell time but immediately passed to the BAS interface: Condenser
Freeze, Evaporator Freeze, Ground Fault, Check Valve Failure, and System Lockout.
Alarm Digital Relay Output, OITS Panel Alarm Button & PCO3 Red Left Arrow Button
Currently in this software version, 10N, the Digital Alarm Relay and OITS Panel Alarm Button are activated
independently. The OITS Alarm Button is activated on any alarm which is posted to the Operator Interface Touch
Screen (OITS) see ‘OITS Viewable Alarms WMC’ below. The Alarm Relay and PCO3 red left arrow button is
activated on any alarm registered in the PCO3 alarm buffers, see ‘PCO3 Viewable Alarms’ below. All OITS
alarms are posted to the OITS independent of the alarm dwell timer to insure the event is captured for tech
review, see ‘OITS Viewable Alarms WMC’ below. Note: The red button on the OITS panel is not resettable by
the PCO3, it must be reset manually. It remains active to alert an operator to a potential issue. But the alarms will
reset in the PCO3 and the chiller will restart and run unless the alarm is a lockout alarm.
BAS programmers need to be aware that a Digital Alarm Relay output does not necessarily mean a
compressor or chiller is inoperable. This output should be compared to the alarm reported to the BAS, if
any, and analyzed as to the severity of the event.
Rapid Restore (Power Failure Restart)

On a power failure, if both compressors are running at the time of the event, a Generator Mode alarm will be set
in the compressor. The unit controller will clear this alarm and attempt to restart both compressors. Any other
alarms generated at the time of power fail will be cleared automatically by the unit controller unless they resulted
in a System Lockout. The compressor should restart immediately, once it receives a demand to run.
On a power failure, if one compressor was not running at the time of the event, that compressor will most likely
experience a Low DC Bus fault. That alarm in the compressor will not immediately be reset by the unit
controller. The alarm should reset automatically when a demand is written by the unit controller to that
compressor but may take up to 10 minutes, as the compressor has to go through a complete IGV vane reset and
recalibration.
35
Disabled Low Evap Pressure Inhibit and Hold alarms during Rapid Restore (+10 sec). Control actions remain
active, just not alarmed. Prevents nuisance alarms that occur near the end of the Rapid Restore Function, hence 10
sec.
WMC Alarm Handling Summary (14B with v3.0.0 BMCC)
Instantaneous *Lockout Alarms:

Discharge pressure (compressor DTC set to 173#, Trip 180#) and 3 Phase Over current.
*Activation of these alarms will result in a compressor fault requiring a power cycle to clear.
3 Strikes and *Lockout Alarms:

30 Minute Period Alarms (**any combination within 30 min)
Inverter Temperature
SCR Temperature
Motor Current High
Inverter Error
Rotor Locked
Motor Back EMF
*Activation of these alarms will result in a compressor fault requiring a power cycle to clear.
**If these conditions are met then the alarm is passed to the BAS without a dwell time.
50 Minute Period Alarms (**any combination within 50 min)

Discharge Temperature
Discharge Pressure
Suction Pressure
Cavity Temperature
Pressure Ratio
Bearing Control
Sensor Fault
Motor Heat
Superheat
Condenser Pressure (while in lenient flow detection)
Surge(while in lenient flow detection)
Plus any of the previous 30 min group alarms above. **If these conditions are met then the alarm is
passed to the BAS without a dwell time. Three strikes on any combination of the above alarms will not clear the
last alarm for 20 mins, which will inhibit the compressor from restarting for 20 mins. There will not be any
indication that is transparent to the user that the compressor is not available to run.
The chiller control attempts to clear all alarms except:

System Lockout (DTC catch-all for Disch Pressure and 3 phase Lockout)
Check valve
Ground Fault
Low DC Bus Voltage
Third strike on Discharge Pressure (chiller control parameter)
Alarm Dwell Time:
36
Non-instantaneous lockout alarms are held in a buffer for the time period set by this control function. It is
adjustable from 0 to 99 minutes; a 0 setting effectively turns the function off. This timer delays the time in which
an alarm is generated then sent to the BAS. If the alarm resets prior to the timer expiring, the alarm is cleared and
not passed to the BAS. The following alarm are not held for the dwell time but are immediately passed the BAS:
Condenser Freeze, Evap Freeze, Ground Fault, Check Valve Failure, and System Lockout Alarm Relay.
The digital output alarm relay is activated on any alarm that is posted to the PCO3 alarm registers. All
alarms are posted to the alarm register regardless of the dwell timer. It’s important for the BAS programmer to
note this fact, as all alarm contact closures may not warrant a BAS shutdown of the unit.
Viewing Alarms:
1) OITS History (double tap) 8 most recent alarms. Tap the alarm for detailed unit data.
2) Unit Controller (HMI)-Alarm/Active, 25 most recent alarms with data and time.
3) Unit Controller (HMI)-View Compressor(n) #9 thru #11, alarm are held here until they are cleared.
4) Compressor SMT (HMI software)- Compressor fault logs, all logs indefinitely. Compressor fault
history.
Troubleshooting:
Heat Balance= troubleshooting tool used to check system thermodynamics/performance. Using the heat
balance tool can help to confirm suspicions of an underperforming system. This tool will not specifically point
out the culprit; however each component (Compressor/Evaporator/Condenser) can be verified individually for
sensor accuracy, vessel approach, pressure drops, etc... The chiller “heat” should be balanced, ie “heat in” should
equal “heat out” (no more than a 10% unbalance) which confirms that your data is good.
Building considerations:
Chiller load is delta T and GPM.
The load change on the chiller should not change more than a 10% per min.
10% per min is the maximum rate of change for flow. Example min flow=700gpm, max flow 1400 gpm. Max
flow change per min would be 70gpm’s.
Compressor Warning-Flooded Compressor (formerly Load Balance Valve alarm) This warning is generated
when a non-operating compressors SSH is < 3 (adjustable Adv set 6b) and DSH < 8(adjustable Adv set 6b) and
other compressor running, and this compressors has been shutdown for at least 3min. The intent of the warning is
to acknowledge a possible failed load balance valve. If the load balance valve fails in the open position, liquid
refrigerant from the bottom of the evap could fill the discharge volute and even fill/pass through the compressor
towards suction. If this occurred the compressor could have difficulty starting. If the load balance valves were
field installed, the likelihood of this occurring is less due to the location of the discharge relief into the evap. The
warning will be active in this version of software with or without load balance valves installed.
Since this warning in now based on the SSH and DSH, sensor accuracy is very important. If a sensor is
too far out of tolerance, the sensor should be replaced. Other items that have been seen to cause this
alarm are:
•A rapid change in EEWT. The pressure change could lead the temperature change and result in a SSH value that
in some cases result in alarm. A slow rate of change (temp and flow) is required.
•Leaking or open compressor cooling solenoids. A leaking cooling solenoid could allow liquid refrigerant from
the condenser to pass through the cool, inop compressor, and influence the suction temp sensor. Faulty
BMCC’s, serial drivers, and backplanes lead to open cooling solenoids when the compressor is off. Cooling
solenoids should not be energized when the compressor is off. If a leaking solenoid is suspected, use the
monitor tool to check the cooling solenoid status(should be off or zero when the compressor is off). A
sweating compressor and or “lo cool-hi-cool” leds on the backplane could identify this issue.
• Based on the exv settings: Refer to ‘Adv Sp Mask#16. Repeated-rapid starts could eventually drive the SSH
down in the evaporator (an increased refrigerant level). At each compressor start (stand alone or lag) the main
exv performs a certain routine. Based on this routine, repeated starts could affect the refrigerant level in the
37
evaporator. Reducing the stop-start timers is possible; however nuisance alarms may result, not to mention
increased wear on all components. 10N default exv settings should eliminate this risk.
Sweating compressor causes:

There could be situation where the cooling solenoid would be energized based on a “motor thermal
raw” value (only when the compressor is running). This value can be referenced on the main compressor
monitoring tab. The MTR value is basically the feedback from the embedded motor thermistors. If the value is
elevated, the motor cooling solenoid could be on full time to try to bring it down. Of course with the solenoid
open full time, this would increase the chance of developing a sweating compressor. The cavity temp when this
occurs would likely stay depressed at ~40 degrees.
Cooling solenoid operation:

TT300 and 400
Motor cooling solenoid on at ~111°F cavity temp and/or MTR value is >1290
Motor cooling solenoid off at ~108°F cavity temp and MTR value is <1190.
TT500
Motor cooling solenoid on at ~86°F cavity temp and/or MTR value is >1290.
Motor cooling solenoid off at ~82°F cavity temp and MTR value is <1190.
All Electronics cooling solenoid on at ~115°F, off at ~105°F measured at the igbt.
So, a poor motor thermistor connection at the backplane, or bad/open sensors could keep a motor cooling
solenoid open full time on a running compressor. It could be possible for refrigerant to pool in the motor end if
the compressor is not warm enough to boil the liquid. This could lead to skewed SSH readings at shutdown also.
Check Valve Failure alarm (OITS should display a Backspin Prevention” text) (chiller stop
alarm)- 1 compressor must be running to trigger this alarm. This alarm is generated when a failed (open) check
valve, increases the pressure ratio of the inop compressor. The normal pressure ratio of an inop compressor is
very close to 1.0, as the discharge pressure equalizes towards suction. When a check valve fails (open), the
potential exist for the discharge pressure that is generated from the running compressor, to create a backflow
though the inop compressor. When this occurs, the inop compressor’s shaft spins. The contact between the
spinning shaft and the touchdown bearings results in intense heat and could lead to compressor failure. In the
event of a failed check valve, the discharge pressure of the inop compressor will match the discharge pressure the
running compressor. It takes some time before the inop compressors shaft begins to spin. It is within this time
period, when the pressure ratio is not close to 1.0, that the alarm will be generated. This alarm will shut down the
chiller.
Pressure Ratio= Cond sat P+14.7

Evap sat P+14.7
Example (good CV): 40+14.7 54.7 = 1.00 PR

40+14.7 54.7
Example (open CV, bad): 74+14.7 88.7 = 1.15 PR
62+14.7 76.7
Example (good CV, discharge sensor off) 40+14.7 54.7 = 1.07PR
36+14.7 50.7
The alarm threshold is set to 1.07. This alarm point is not to be adjusted. If the alarm point is raised too
high, an actual failed check valve condition could exist and an alarm would not be generated! This is the
default pressure ratio that when met, will trigger the alarm. Again, sensor accuracy is critical. If a sensor is
identified to be out of an acceptable tolerance, replace the sensor. In the last example, the check valve is good,
however the discharge sensor is a bit high, this results in a PR that is at the alarm point. The discharge sensor will
be out of its ideal range when exposed to the lower suction pressure. This software version 10N separates the
38
sensor offsets for the chiller controls & OITS display from the ones used for this alarm logic. The calibrations for
the suction/discharge pressure transducer input, as it applies only to the failed check valve alarm, are now auto
calibrating. The calibration occurs when you execute the CFG=0 to a 1 command on the commissioning page.
The calibration is performed only if the compressors are off and the exv is closed (no inverted condition active).
The calibration process is not transparent to the user.
Note: The pressure ratios of the two compressors on a single stack will likely never match. Contributors to this
would be entering water end, vessel length, and sensor accuracy.
Motor cooling/High inverter temp (compressor stop): This alarm would be generated when the
compressor’s inverter temperature approaches the limit set within the BMCC. A corresponding alarm may not be
seen within the compressor alarm logs due to the preemptive action of the Microtech controller. The Microtech is
trying to avoid a compressor lockout fault. Inverted starts, low lifts, faulty cooling solenoids, faulty BMCC,
faulty serial driver module, and/or a lack of refrigerant could contribute.
Compressor capacity low:

IGV 110=90degrees, no pre-swirl. Leds for the IGV should be flickering if the backplane and serial driver and
IGV are healthy. If the lights are out or not flickering when the IGV should be moving, time to t-shoot. Verify
that the magnetic ball indicator is moving as expected.
IGV assemblies are model/software specific-do not attempt to replace unless the replacement parts are verified
by Daikin Applied Parts.
WMC IGV testing info:

If an IGV coil or IGV wiring shorts to ground, there could be damage upstream or downstream from this event.
Verify both stepper motor coils, and also check each to ground. The IGV cable should be removed from J21 on
the backplane and also at the IGV assembly connection and ohm’d from one end to the other to verify continuity.
All 4 LEDs on the backplane above J21 should blink when the valve is being asked to move and the motor and
wiring are healthy. If a IGV motor short did occur, the 6 associated J21 resistors should be verified. There are 4
resistors below and two resistors above the J21 connection. The top two resistors are ~30 ohms and the bottom
four are ~15 ohms. Remove the serial driver and also the IGV cable from J21 to get an accurate resistor
measurement.
J 21 IGV stepper 6 resistors that are involved

motor signal with the stepper motor. The
connector. D16 thru top two should measure ~30
D13 are LEDs that ohms and the bottom four
pulse when the vanes should measure ~15 ohms.
are being asked to You would be looking for an
move. open or short.
39
Here is an example of
damage that occurred to
the two lower J21
resistors when a stepper
motor wire shorted to
ground. The tech
reported that the valve
would not move and he
only did ever see three
of the 4 LEDs flash
when the motor was
being commanded to
move. Fix=Identify and
repair short, replace
backplane.
WMC refrigerant charge:

Bubbles in the liquid line indicate that the liquid seal is broken. Condenser subcooling is based on the chillers
selection. The chiller must be level. The warmer return water will always cause more refrigerant condensing
action on that end of the condenser. This action results is a disproportionate “rain” and liquid level on this end of
the vessel. The condenser design is such where half of the heavier saturated gas (mostly liquid) enters the
beginning of the subcooler section on each end of the vessel. This subcooled liquid, serpentines through baffles
(forced to spend more time in the warmest environment to ensure subcooled refrigerant is maintained) until it
exits either through the liquid line or the compressor motor cooling lines. If the condenser was low on refrigerant,
it is possible to break the liquid seal and pass gas (which moves faster than liquid) to the exv or motor cooling
lines.
Today, the refrigerant charge for WMC chillers is fixed and does not change based on site conditions (lwt) or tube
count. Daikin achieves Leed points for maintaining a ratio of 3.1lbs ref per ton, which means that some
refrigerant quantities will change in the future.
New vessel design will not include a sight glass. If all tubes are covered, this is when your best approach occurs.
When the wmc is running at full load, the refrigerant should be to the top of the evap tubes. Whatever is left is of
course in the condenser. As the building load decreases, the bubbling in the evap decreases and the exv must feed
more liquid into the evap. At min capacity; most of the charge is in the evap. What remains must provide
adequate motor cooling. The evaporator is the main driver for exv control.
7-8 degrees of subcooling at full load is the typical WMC value.
40
OITS:
14B software can be complemented by use of the latest OITS software v3.02.01(its use is highly recommended);
which can be found on the SalesPortal website(formerly McQuayBiz).
The new OITS software will display compressor demand, compressor feedback (from the compressor), and
compressor IGV position. New OITS software will have less status messages than previous version. The actual
messages should be more accurate for actual status. Since the same OITS software is used for all centrifugal
chillers, some previously displayed messages were not appropriate for the actual chiller/compressor status.
The demand signal is now visible in the trend data. It is common to see this signal swinging by a large value.
This action is normal, and is a product of the compressor responsiveness and lwt fluctuation. An inhibit
condition, such a high or low pressure would also result in a larger than normal demand signal change.
Compressor vane position display enable instructions:

1.Connect a usb keyboard
2.Depress Alt & F4 simultaneously (maybe twice)
3.A Windows home screen should appear
4.Double-click “My Computer”.
5.Open the C drive
6.Open the Plan folder
7.Open the OITS.ini file
To enable vane position on

the OITS, simply add the two
lines of text under
ExpValve=EXV. Enter these
two lines exactly as shown in
the photo. Note: extra spaces
and/or misspelled words will
lead to undesirable results.
Once complete, “red X” out off all screens. Expand the “start menu” (lower left on home screen), and launch the
TPRUN utility. The normal chiller screen should populate the screen. The software is defaulted for a 2
compressor WMC. If another chiller model is desired, simply open the OITS.ini file and change the Model=XXX
to the desired chiller type. Similarly, if a single compressor chiller is used, the “NumberCompressors=?” can be
modified also.
41

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WMC Software Technical Manual

Magnitude™ Magnetic Bearing Centrifugal Chillers

Chiller vintage differences:

The original MN’s were categorized by amp ranges.

New v300 TT400

During rapid restore:

Determining “Next On” status

Compressor Running at Full Load

Management of the HATS Switch

BAS Alarm Dwell

Commissioning Mask (1 – 10)

Commission(1) Config Commission Mask #1 Quick (single page) Configuration

Commission Mask #3 EXV

Commission Mask #4 Mode

Commission(5) Start Commission Mask #5 Start

Commission(7) Stage Commission Mask #7 Stage

Commission(8)WtrFlow Commission Mask #8 Water Flow

Commission(9) Power Commission Mask #9 Power

Additional amperage information:

SET COMP1 SPs (5) Compressor Setpoint Mask #5

SET COMP1 SPs (7) Compressor Setpoint Mask #7

SET COMP1 SPs (8) Compressor Setpoint Mask #8

SET COMP1 SPs (11) Compressor Setpoint Mask #11

Advanced Setpoint Mask #2 - General

Advanced Setpoint Mask #3 – Ext Fault (optional input)

Evaporator Saturated Temperature Offset for Non ARI conditions.

Advanced Setpoint Mask #5b – Non ARI Delta

Advanced Setpoint Mask #5c – Non ARI SD F

Advanced Setpoint Mask #6

Advanced Setpoint Mask #6b Flooded Alert enable

Adv Sp Mask #8 Lenient (water flow) Sensing

Adv Sp Mask #9 Condenser Pump Staging option Alternate

Compressor TT300 TT400 TT500

Adv Sp Mask #11 BMCC Configuration (continued)

Adv Sp Mask #12 BMCC Configuration (continued)

Adv Sp Mask#14 Hot Gas Relief (optional)

Adv Sp Mask#15 Staging Unload Options

Adv Sp Mask#17 Load Balance Valve

Adv Sp Mask#19 Primary Loop Temps & Slopes

Tower Control Logic:

Tower Fan VFD PID

Bypass Valve Step and Wait

SET TOWER SPs (1)

SET TOWER SPs (2)

Set Tower SPs (3) Fans

Tower Reset Function:

Db Tower R06.0 F0600 Debug Tower Reset Function

SET TOWER SPs (7)

SET TOWER (9) PID for Tower Fan VFD

Job specific setpoint recommendations:

Items that could assist:

Troubleshooting and alert/alarm identification:

WMC Alarm Processing in 14B Chiller Code:

Alarm Dwell Time

Rapid Restore (Power Failure Restart)

WMC Alarm Handling Summary (14B with v3.0.0 BMCC)

Instantaneous *Lockout Alarms:

3 Strikes and *Lockout Alarms:

50 Minute Period Alarms (**any combination within 50 min)

The chiller control attempts to clear all alarms except:

Alarm Dwell Time:

Sweating compressor causes:

Cooling solenoid operation: