McQuay MicroTech II Operation Manual
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McQuay MicroTech II Operation Manual

Chiller system manager (csm) hardwired chillers
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See also: Operation & Maintenance Manual , Installation and Maintenance Manual
   
MicroTech II
Chiller System Manager (CSM) Operation Manual
For
MicroTech II Chillers
Hardwired Chillers
Operation Manual
OM 780-2
Group: Controls
Part Number: OM 780-2
Date: November 2005
Supersedes: OM 780-1

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Summary of Contents for McQuay MicroTech II

  • Page 1 Operation Manual OM 780-2 Group: Controls Part Number: OM 780-2 Date: November 2005 Supersedes: OM 780-1     MicroTech II Chiller System Manager (CSM) Operation Manual MicroTech II Chillers Hardwired Chillers...

  • Page 2: Table Of Contents

    Table of Contents Figures ..............................4 Tables ..............................5 Limited Warranty...........................6 Notice ..............................6 Reference Documents ..........................7 Revision History ............................7 CSM Software ID ..........................7 Chiller Unit Controller Software Compatibility..................8 Introduction..........................9 Getting Started........................11 Connecting to the CSM........................11 PC Requirements ..........................11 Connecting Your PC to the CSM.....................11 Changing the CSM’s IP Address and Date/Time................13 Connecting to the CSM’s User Interface ..................16 Connecting to the CSM’s User Interface Remotely Using a Modem..........18...
  • Page 3 Loop Bypass Valve Control ......................80 Scheduling ............................80 Weekly Scheduling ..........................82 Holiday Scheduling..........................83 Special-Event Scheduling ........................84 Timed Override..........................85 External Time Clock ........................86 Modbus Scheduling..........................86 BACnet Scheduling..........................86 Optimal Start............................86 BAS Communication ...........................90 BACnet Settings..........................90 Modbus Settings..........................91 Alarm Notification ..........................91 Physical alarm outputs ........................92 E-mail alarm notifications........................93 BACnet alarm notifications......................95 Saving Your CSM Database Configuration ..................95...

  • Page 4: Figures

    Figure 7. User Admin Screen (Main > Configuration > BAS Config > USER ADMIN-button) ..20 Figure 8. Device Addressing (Main > Configuration > Device Addressing) ........22 Figure 9. Service Pin Location on the MicroTech II Chiller L Communication Module..24 ORKS Figure 10.

  • Page 5: Tables

    Figure 36. Configuration 7: Primary-Only System ................71 Figure 37. Example of Pump Sequence Order Table (Main > Configuration > Load Flow Control) .75 Figure 38. Menu of Schedules (Main > Configuration > Sched > Schedule Icon) ......82 Figure 39. Weekly Schedule (Main > Configuration > Sched > Schedule Icon > Weekly)....83 Figure 40.

  • Page 6: Limited Warranty

    Limited Warranty Consult your local McQuay Representative for warranty details. Refer to Form 933-430285Y. To find your local McQuay Representative, go to www.mcquay.com. Notice McQuay International reserves the right to change any information contained herein without prior notice. The user is responsible for determining whether this product is appropriate for his or her application.

  • Page 7: Reference Documents

    CSM Software ID MicroTech II CSM software is factory installed and tested in each panel prior to shipment. The software is identified by a program code (also referred to as the “Ident”), that is printed on a small label above the controller.

  • Page 8: Chiller Unit Controller Software Compatibility

    At the time of this writing, the program code for CSM Software is MTII-UC-x-CSM01.8-x. This CSM software is compatible with MicroTech II chillers unit controller software versions listed in Table 1 below: Table 1. Chiller Unit Controller Program Code Software Compatibility...

  • Page 9: Introduction

    For information on CSM components, field wiring options and requirements, network wiring, and service procedures, refer to IM 781, MicroTech II Chiller System Manager Installation Manual. For specific information about the MicroTech II chiller unit controllers, refer to the appropriate MicroTech II unit controller installation or operation manual (see the Reference Documents section of this document).
  • Page 10 Operating this equipment in a residential area is likely to cause interference which the user will be required to correct at his or her own expense. McQuay International disclaims any liability resulting from any interference or for the correction thereof.

  • Page 11: Getting Started

    The MicroTech II Chiller System Manager (CSM) is a self-contained device that is capable of monitoring and controlling up to six (or 12 if properly licensed) McQuay MicroTech II chillers via network communications. It can also monitor and control a variety of system equipment such as cooling tower fans, bypass valves, and cooling load pumps. All operator interactions with the CSM are achieved using the Internet Explorer browser on a PC connected to the CSM through an Ethernet Local Area Network (LAN), the Internet or a modem.
  • Page 12 Required Tools You need the following tools to configure the CSM for network operation: • PC with Ethernet card and TCP/IP protocol. • Internet Explorer browser. • Ethernet Cable. Either an Ethernet crossover cable for direct connection or a standard Ethernet cable for connecting through a hub.

  • Page 13: Changing The Csm's Ip Address And Date/Time

    Connection to the existing LAN provides multiple user access for the user’s PC and also allows user access through high speed Internet connections at remote locations. A document titled “Net Connect Guide” is available at www.mcquay.com to assist you in making remote connections to the CSM. Close interaction with your building’s IT department is required for successful operation, obtain IP addressing and firewall security support from your IT department.

  • Page 14: Figure 3. Enter Network Password

    Log on to the CSM with the default user name and password, as it appears on the packing list. Typical defaults are User Name = McQuay and Password = Password. Click OK. The Niagara Web Administration dialog box will appear.

  • Page 15: Figure 4. Niagara Web Administration

    Figure 4. Niagara Web Administration Set the CSM’s Date, Time and Time Zone. Assign the CSM a unique IP address and other network settings to be used for communications. Consult with local IT personnel to obtain an IP address and Subnet Mask for integration into the existing building network. Be sure to write the IP Address down in a safe place to remember the assigned address.

  • Page 16: Connecting To The Csm's User Interface

    Log on to the CSM with your user name and password, as it appears on the packing list. Typical defaults are User Name = McQuay and Password = Password. Click OK. The CSM’s User Interface Main Screen will appear. Page 16...

  • Page 17: Figure 5. Csm's User Interface Main Screen (Http://)

    Figure 5. CSM’s User Interface Main Screen (http://<IP Address>). The Main Screen of the CSM’s User Interface has three tabs to navigate to the different CSM web pages (called screens throughout the rest of this document). These screens are grouped in the three categories of Configuration, System Status, and View Alarms.

  • Page 18: Connecting To The Csm's User Interface Remotely Using A Modem

    Windows NT 4.0, Windows 2000 or Windows XP operation system. Additional information on setting up a dial-in host computer and modem is available in the “Net Connect Guide” available at www.mcquay.com Attach the dial-in host’s modem to an analog phone line Set the IP address of the dial-in host computer to the IP address listed as the value of the remoteAddr parameter in the CSM’s ras.properties file (default = 192.168.1.111).

  • Page 19: Figure 6. Example Of A Configuration Screen (Main > Configuration > System Control)

    Figure 6. Example of a Configuration screen (Main > Configuration > System Control). Notice that when you are viewing a Configuration screen, the white tabs across the top allow you to navigate to any of the other Configuration screens. Also, the blue bar just below the white tabs contain white-letter tabs, which allow you to navigate to any of the System Status screens.

  • Page 20: Password Protection

    The second type of variable setting on a configuration screen is the property input. Property inputs are displayed as white boxes (see the white box that reads 00:00:00 to the right of the Rapid Restart Time in Figure 6). Entering a new value for the variable in this white box changes the value on the screen only.

  • Page 21: User Account Categories

    Table 2. Default Passwords User Password Category Description Name McQuay Password System This allows full read/write capability plus full administration privileges needed to change Administrator passwords. BACnet BACnet BACnet Do not change this user account or a BACnet BAS will not be able to communicate with the CSM...

  • Page 22: Connecting Chillers And Remote I/O To The Csm

    Connecting Chillers and Remote I/O to the CSM This section explains the setup variables in the CSM that must be set to integrate the CSM and its associated chillers into a working network. It also explains the setup variables that are related to the CSM’s analog inputs and outputs. Once set in accordance with the job requirements and characteristics, most of these variables should never need to be changed.

  • Page 23: Commissioning A Chiller To A Csm Chiller Number

    The Hardware Selection needs to be set to the type of chiller you are connecting to. If you are connecting to a Hardwired Selection chiller, select Hardwired. If you are connecting to a MicroTech II chiller you have 2 options. If your chiller has a LONW ORKS Communication Modulewith chchla22 XIF file loaded, then select MicroTech II –...

  • Page 24: Commissioning A Remote I/O Module To A Csm Remote I/O Letter

    Figure 9. Service Pin Location on the MicroTech II Chiller L Communication Module ORKS Network Connector S ervice Pin S ervice LED Anomaly LED 8-Pin Connector 2.36 in De-commissioning a Chiller or Remote I/O Module from the CSM To remove a chiller from the CSM, replace the existing Neuron ID address numbers with zeros and press the SAVE CHANGES button on the Device Addressing screen.

  • Page 25: Setting Up The Csm's Chiller Data

    The Evaporator Flow Sensor variables tell the CSM if the chiller has an evaporator flow sensor. If Yes is selected, the evaporator Sensor flow rate will be displayed on the Misc page. This variable applies only to MicroTech II chillers. Default = No . Condenser Flow The Condenser Flow Sensor variables tell the CSM if the chiller has a condenser flow sensor.

  • Page 26: Communication Loss Control At The Chiller

    Sensor rate will be displayed on the Misc page. This variable applies only to MicroTech II chillers. Default = No . Communication Loss Control at the Chiller If the communication between the chiller and the CSM that is commanding the chiller is lost, the chiller’s L...

  • Page 27: Setting Up The Csm's I/O

    • Set the Comm Loss/Power Up State to Enable • Set the Comm Loss Cool Setpoint to 50. If the chiller’s L communication module does not receive an updated command on its Chiller Enable input within ORKS 250 seconds, it determines that it has lost communication with the CSM. The chiller’s L communication module ORKS will then enable the chiller (if it is not already enabled).
  • Page 28 Default = 0 Loop DP Sensor High Calibration Use this variable to enter the differential pressure when the transducer signal is one of the following: a) Pressure 20 mA for 4–20 mA transducers or b) 10 Vdc for 2–10 Vdc transducers. Range = 0 – 150 psi (0 – 1035 kPa).
  • Page 29 Remote D Analog Input #1 Type Remote D Analog Input #2 Type Remote D Analog Input #3 Type Remote D Analog Input #4 Type Remote E Analog Input #1 Type Remote E Analog Input #2 Type Remote E Analog Input #3 Type Remote E Analog Input #4 Type Remote F Analog Input #1 Type Remote F Analog Input #2 Type...

  • Page 30: Chiller Unit Controller Settings

    Some of the features that exist on the chiller unit controller for stand-alone operation must also be disabled so that they do not interfere with the CSM’s control features. For information on making changes to the MicroTech II chiller unit controllers, refer to the proper chiller Operation Manual (see the Reference Documents section of this document).

  • Page 31: Table 7. Chiller Unit Controller Setup Variables

    Table 7. Chiller Unit Controller Setup Variables Chiller Controller Variable Value Description Protocol The CSM communicates with MTII chillers through the chiller’s L ORKS communication module Source Network The chiller must allow the L network control ORKS Mode Cool (not Ice or Cool/Ice) The CSM does not support the Heat, Ice or Cool/Ice modes Start Delta 1°F (0.6°C)

  • Page 32: Configuring The Chiller System Manager

    Configuring the Chiller System Manager This section describes how the various CSM control processes can be configured to manage chiller system operation. Each sub-section describes one of the screens under the Configuration tab on the CSM’s user interface. The adjustable variables that affect these control processes are tabled near the beginning of each applicable sub-section.

  • Page 33: Rapid Restart

    Automatic To allow other methods to schedule the CSM, this variable must be commanded to Automatic. After the Automatic command is issued, this variable will read Occupied or Unoccupied @ various priority (see Scheduling on page 80 for each scheduling method’s priority). This means that the CSM’s occupancy is now determined according to its internal scheduling, timed override, external time clock, network scheduling, or optimal start features.

  • Page 34: Chiller Sequencing Control

    Chiller Sequencing Control As the cooling load varies, the CSM enables and disables chillers so that the current cooling capacity is matched to the current cooling load. This action is commonly called chiller sequencing. The two fundamental elements of any sequencing control strategy are the sequence order, the order in which chillers are enabled and disabled, and the sequencing logic, the rules by which chillers are enabled and disabled to match the cooling capacity to the load.
  • Page 35 does not allow it to operate unless at least one other chiller is off-line. Range = Normal, Standby. Default = Normal (for all chillers in all rows) Max Tower Stage This input is used to restrict cooling tower staging. The CSM restricts the tower staging to the Max Tower Stage value of the highest sequence running chiller.

  • Page 36: Sequencing Logic

    Designating a First-On Chiller When Using Automatic Sequencing You can designate one chiller that is always lead regardless of its run time. The first-on chiller is placed in Row 1 and assigned Sequence Number 1. All additional chillers can also be placed in Row 1 and all given Sequence Number 2. These additional chillers will be enabled based on lowest run time.
  • Page 37 Up Differential System Setpoint > Chiller Stage-Up Differential, the Next-ON chiller may be enabled. Range = 0 – 9.5°F (0 – 5.2°C). Default = +1.0°F (+0.5°C) Spare Capacity This input sets the spare capacity multiplier required for the CSM to stage-down, which is used to reduce short cycling. If the Factor Active Capacity for the Next-OFF chiller <...

  • Page 38: Figure 11. Typical Primary-Only System

    Figure 11. Typical Primary-Only System Cooling Loads Optional pressure-controlled loop bypass Differential pressure transducer Chilled water supply temperature Primary pump Chiller #1 % Load Chiller #2 % Load a0141 Standard sequencing logic uses each chiller’s load and the chilled water supply temperature to stage the chillers. The values of the sequencing variables discussed below can be viewed on the System Status screen.

  • Page 39: Figure 12. Typical Primary-Secondary System

    The purpose of primary-secondary (Decoupled) systems is to maintain relatively constant flow through the chillers while at the same time allowing variable flow to the cooling loads. Because the relationship between a building’s total cooling load and its required chilled water flow rate is seldom proportional, situations can occur in which partly loaded chillers cannot provide enough chilled water to the secondary loop.

  • Page 40: Special Sequencing Logic

    Condition 2 assures that the chillers that would still be on after a stage-down continue to meet the building’s flow requirement. As an example, consider a system in which Chiller #3 is the only chiller that is part of stage 2 and not part of stage 1.
  • Page 41 A chiller is unavailable when the CSM cannot influence its start/stop operation. This can occur for either of two reasons: All compressors (or circuits) on a chiller are unable to run. MicroTech II chiller compressor controllers send the CSM an indicator; AVAILABLE (1) if the CSM can influence it’s stop/start operation. The indicator is cleared (0) when the...

  • Page 42: Designating A Standby Chiller

    2 with all other chillers except one. The capacity of row 2 will need to be designated to be less than the capacity of row 1. Contact the McQuay Controls Support Group at 866-4MCQUAY(866-462-7829) for comprehensive setup assistance for determining the designated capacity of row 2.

  • Page 43: Figure 13. Chiller System With Evaporators Piped In The Series/Parallel Configuration

    Stage-up with Series-Piped Chillers Consider the chiller system in Figure 13. A typical sequence order would be to enable chiller 1, then 2, then 3, and finally 4. A problem would occur because chiller 4 would not be enabled by the CSM. Chiller 1 is enabled normally. Chiller 2 will be enabled when chiller 1 reaches full load.

  • Page 44: Stage-Up Inhibiting

    Stage-down with Series-Piped Chillers Series-pipe chiller pairs will be disabled together unless they are the last two chillers enabled. In the example shown in Table 11, when all four chillers are enabled, the Next OFF chiller will be chiller 4. When system conditions allow a stage- down to occur, both chiller 3 and 4 will be disabled at the same time.

  • Page 45: Load Limiting Control

    Network Method If a BACnet or Modbus BAS is connected to the CSM, the BAS can use a BAS Stage-Up Inhibit inputs to turn stage-up inhibiting on and off. Whenever stage-up inhibit is ON, stage-up inhibiting prevents additional chillers from becoming enabled.

  • Page 46: Figure 14. Screw Chiller Demand Limiting

    How Demand Limiting Works Demand limiting control requires a capacity limit value, which must come from an outside source. You can choose one of three possible sources with the Demand Limiting Type variable: • External (analog signal) • BACnet • Modbus After receiving the capacity limit from the selected source, the CSM generates the System Demand Limiting Load Limit (Load Limit screen).

  • Page 47: Load Balancing

    Figure 15. External Signal Demand Limiting Function 0–10 Vdc: 0–20 mA: External Signal Demand Limiting via Network Signal If the Demand Limiting Type variable is set to “BACnet” or “Modbus”, the CSM accepts a capacity limit value sent by a BAS.

  • Page 48: Soft Loading

    How Load Balancing Works The CSM continually reads the percent load (% RLA) from each chiller that is running. It then selects the lowest of these percent load values and adds the Load Balancing Capacity Difference Limit variable (default is 8%) to this minimum. The result is the Load Balancing Load Limit Group X (Load Limit screen).

  • Page 49: Chilled Water Temperature Control

    There are many other chiller controller variables that affect leaving evaporator water temperature and load recycle control; for example, Start-Delta and Max Pull Down rate. For more information, refer to the appropriate MicroTech II chiller unit controller operation manual (see Reference Documents on page 7).

  • Page 50: Temperature Control

    37.4°C). Default = 70.0°F (21.0°C) Constant Return This value sets the Constant Return setpoint used in controlling the System Setpoint if Reset Type = “Constant Return”. The Setpoint System Setpoint is modulated to maintain the Chilled Water Return Temperature at this setpoint. Range = 20.0 – 80.0°F (–6.7 – 26.6°C).

  • Page 51: Figure 17. Csm Leaving Evaporator Water Temperature Setpoint Flow Chart

    Figure 17. CSM Leaving Evaporator Water Temperature Setpoint Flow Chart a0145 OM 780-2 Page 51...

  • Page 52: Setpoint Reset

    System Setpoint The Chiller Setpoint is derived from the System Setpoint, which is the CSM’s chilled water supply setpoint for the system. You can set the System Setpoint manually using the Operator System Setpoint variable or let the CSM reset it automatically.

  • Page 53: Figure 19. Return Water Or Outdoor Air Reset (English)

    • Outdoor Air • External (analog signal) • Constant Return (PI control) When a reset strategy is active, it automatically changes the System Setpoint as required. Regardless of the reset method, the Minimum System Setpoint and the Maximum System Setpoint define the range of possible System Setpoint values. The current value of the System Setpoint is determined by the current value of the input variable (e.g.

  • Page 54: Figure 20. Return Water Or Outdoor Air Reset (Si)

    Figure 20. Return Water or Outdoor Air Reset (SI) Max System Spt= 12°C Min System Spt= 7°C Max Sys Spt At= 15°C Min Sys Spt At= 25°C Return Water or Outdoor Air Temperature (°C) a0149 For example, if the settings of the Figure 19 and Figure 20 are used, the following occurs when Outdoor Air reset is selected: Outdoor air temperature Corresponding System Setpoint...

  • Page 55: Figure 21. External Reset (English)

    Figure 21. External Reset (English) Max System Spt= 54°F Min System Spt= 44°F 0–10 Vdc: 0–20 mA: a0150 External Signal Figure 22. External Reset (SI) Max System Spt= 12°C Min System Spt= 7°C 0–10 Vdc: 0–20 mA: External Signal a0151 For example, if the settings of Figure 21 and Figure 22 are used, the following occurs when External reset is selected: External Analog Signal Corresponding System Setpoint...

  • Page 56: Cooling Tower Control

    The CSM automatically resets the System Setpoint. You can ignore the remaining reset variables. Note: To use the External reset method, an external analog signal (0–10 Vdc, or 0–20 mA) must be connected to UI-10 of the CSM’s onboard I/O panel, see the Field Wiring section of IM 781. Constant Return Chilled Water Temperature Control The constant return reset method uses a proportional-integral (PI) control loop to generate a System Setpoint that keeps the return chilled water temperature at the Constant Return Setpoint.
  • Page 57 Number of Tower This input sets the highest tower stage that the CSM will enable. It is typically set to the highest Stage # row with a Tower Stages Output set to On in the Tower Stage Table. Range = 1 to 12. Default = 6 Tower Stage The cooling tower will not be staged down until the Control Temperature is less that the current Stage Setpoint minus this Tower Differential...
  • Page 58 When to Use the CSM’s Cooling Tower Control MicroTech II water-cooled chiller unit controllers and the CSM both have cooling tower control capability. If the cooling tower system is piped so that it is common to all chillers, you should use the CSM for cooling tower control. This type of configuration is shown in Figure 23.

  • Page 59: Tower Staging Logic

    Figure 23. Typical Condenser Water Loop Optional cooling tower bypass Common entering condenser water temperature Common leaving condenser water temperature Leaving condenser water temperature Entering condenser water temperature Chiller #1 Condenser Chiller #2 Condenser a0159 Tower Staging Logic Cooling tower staging logic depends on whether or not there is a bypass valve in the system, and if there is, it further depends on how the valve is controlled.

  • Page 60: Figure 24. Tower Stage Table (Main>Configuration>Clg Tower Control>Tower Stage Table)

    When constant approach reset is used, the Control Temperature Source variable must be set to “Entering Cond Water” Note: An OAT sensor and Relative Humidity Sensor must be installed and not in an alarm condition. Tower Stage Table A tower stage is defined as a set of tower outputs. An output might be used to start a fan, set the speed of a two-speed fan or enable a VFD.
  • Page 61 Place all fans controlled by VFDs in Stage 1. This provides the highest efficiency by maximizing the tower heat exchange surface area used (reference ASHRAE Handbook - HVAC Applications). Place all fans not controlled by VFDs in the Tower Stage Table as desired. If multi-speed fans are used, best performance is typically achieved by staging all fans on at low speed first, then staging up to higher speeds.

  • Page 62: Figure 25. Tower Staging Only

    The stage-up timer has expired. (See “Interstage Timers” above.) The Control Temperature is greater than the Tower Stage x Setpoint, where x is the next higher tower stage (1 through 12). The current tower stage is less than the Max Tower Stage setting of the highest active sequence. Stage-Down Control: The CSM stages down when the Control Temperature is too low.

  • Page 63: Figure 26. Tower Staging With Low-Limit Controlled Bypass Valve

    Figure 26. Tower Staging With Low-Limit Controlled Bypass Valve 25.5 79.0 Legend 25.0 78.0 SptV Tower Valve Setpoint Tower Valve Deadband 24.5 77.0 Spt1 Tower Stage 1 Setpoint Tower Stage Differential 24.0 76.0 23.5 75.0 23.0 74.0 – Df – Df –...
  • Page 64 Examples of Applications Examples of the three tower staging control applications are shown in the three previous figures. All three applications have six stages, and all stage setpoints are the same. The tower-only application (Figure 25) is straightforward. The first four stages have successively higher setpoints, which effectively resets the Control Temperature as the load increases.

  • Page 65: Tower Bypass Valve Control

    • Tower Stage-Down Delay Time If you are using VFD controlled fans, set the following valve variables as required: • Tower VFD Control Flag • Tower VFD Deadband, Prop Band, Sample Time, Integral Time • Set the Tower VFD AO Zero variables on the I/O Config screen to match the VFD’s analog input. •...

  • Page 66: Figure 28. Initial Tower Bypass Valve Position (English)

    For example, if the settings of the figures are used, the following occurs: Outdoor air Temperature Initial Valve Position 55.0°F (12.5°C) 20% open to tower 75.0°F (22.5°C) 60% open to tower 90.0°F (30.0°C) 100% open to tower When at least one chiller enters the Running chiller state, the CSM begins modulating the bypass valve to maintain the Control Temperature, starting from the initial position.

  • Page 67: Chilled Water Flow Control

    • Tower Valve Propband • Tower Valve Sample Time • Tower Valve Integral Time • Minimum Tower Valve Start-Up Position • Maximum Tower Valve Start-Up Position • Minimum Tower Valve Start-Up Position At (OAT) • Maximum Tower Valve Start-Up Position At (OAT) Chilled Water Flow Control The CSM can maintain a constant differential pressure across the cooling loads by controlling a loop bypass valve, variable speed cooling load pump(s), or a set of constant speed cooling load pumps.
  • Page 68 Propband position or VFD speed. Range = 1 – 99 psi (6 – 683 kPa). Default = ±10 psi (±69 kPa) Loop Differential This value sets the “sampling period” used in the PID control function that modulates the loop differential pressure. In Pressure Sample general, increasing this value has a slowing effect and decreasing this value has a speeding effect on the control of the valve Time...

  • Page 69: Figure 30. Configuration 1: Constant-Speed Single Pump

    Sequencing Constant Flow Pumps (if Pump Control Option = Sequencing, the following inputs are valid) Name Description Number of Sequenced If the Pump Control Option = Sequencing, this input defines the highest stage that the CSM will stage-up to in its Pump Stages Pump Sequence Order table.

  • Page 70: Figure 31. Configuration 2: Constant-Speed Lead/Standby Pump Set

    Figure 31. Configuration 2: Constant-Speed Lead/Standby Pump Set Cooling Loads Optional pressure-controlled loop bypass Differential pressure transducer ChWR ChWS a0153 Figure 32. Configuration 3: Constant-Speed Sequenced Pumps Cooling Loads Differential pressure transducer Optional pressure-controlled loop bypass ChWR ChWS a0154 Figure 33. Configuration 4: Variable-Speed Single Pump Cooling Loads Differential pressure transducer Variable frequency drive...

  • Page 71: Figure 34. Configuration 5: Variable-Speed Lead/Standby Pump Set

    Figure 34. Configuration 5: Variable-Speed Lead/Standby Pump Set Cooling Loads Differential pressure transducer Variable frequency drive ChWR a0156 ChWS Figure 35. Configuration 6: Multiple Variable-Speed Pumps Cooling Loads Differential pressure transducer Variable frequency drive ChWR ChWS Figure 36. Configuration 7: Primary-Only System Cooling Loads Optional pressure-controlled loop bypass Differential pressure transducer...

  • Page 72: Pump Logic: Single Pump

    Pump Logic: Single Pump Configurations 1 and 4 use the CSM’s single-pump cooling load pump logic. Single-pump logic simply starts the pump when the system starts and stops it when the system stops. Note that the pump is identified as Cooling Load Pump #1 on the Flow screen.
  • Page 73 Natural Lead Pump Implementation Natural lead pump implementation automatically occurs whenever the CSM is in any Off operating state. For a typical chiller system that is shut down daily, a new lead pump is implemented within 24 hours (at most). If your chiller system seldom or never shuts down, you should consider using forced lead pump implementation.

  • Page 74: Pump Logic: Sequenced Constant-Speed Pumps

    Pump Logic: Sequenced Constant-Speed Pumps Configuration 3 uses the CSM’s sequencing pump logic. Sequencing logic can be applied to a group of two to six pumps, which are identified as Cooling Load Pump #1 through Cooling Load Pump #6 on the Flow screen. It operates one or more pumps as required to maintain the differential pressure across the loop at the Loop Differential Pressure Setpoint.

  • Page 75: Figure 37. Example Of Pump Sequence Order Table (Main > Configuration > Load Flow Control)

    Figure 37. Example of Pump Sequence Order Table (Main > Configuration > Load Flow Control) An example of the pump sequence order table is shown in Figure 37. Notice that this system has five pumps and five stages. By comparing rows, you can see that this sequence order is as follows: Pump #2 Pump #1 Pump #3...
  • Page 76 The current pump stage can be viewed on the Flow screen. Interstage Timers The CSM uses a stage-up timer and a stage-down timer to coordinate staging. After any pump stage change or chiller stage change, both timers reset and start counting down. The stage-up timer is set equal to the Pump Stage-Up Delay Time variable (default is 2 minutes), and the stage-down timer is set equal to the Pump Stage-Down Delay Time variable (default is 5 minutes).

  • Page 77: Pump Logic: Multiple Variable-Speed Pumps

    If a pump fails, the CSM does not de-energize that pump’s output when the timer expires—the output will be energized whenever it is part of the current stage. So if the problem goes away, the pump restarts immediately and the Cooling Load Pump #X Fail alarm will automatically be reset.
  • Page 78 Interstage Timers The CSM uses the Stage-Up Delay Time and Stage-Down Delay Time variables for transition between stages. Different stage-up and stage-down delay times may be entered for each pump stage if desired. These stage timers start counting down after the Cooling Load Pump Speed crosses the current Stage-Up/Down % setpoint. Pump stage changes (up or down) will occur when the timer reaches zero.

  • Page 79: Pump Speed Control

    To set up multiple variable-speed pump logic Set the Pump Control Option variable to “Multiple VFD Pumps.” Set the Number of VFD Controlled Pumps variable to the number of pumps to be controlled. Commission Remote I/O Module A on the Device Addressing screen. If more than two pumps are to be controlled commission Remote I/O Modules B, if more than four pumps are to be controlled commission Remote I/O Module C.

  • Page 80: Loop Bypass Valve Control

    Loop Bypass Valve Control The CSM can control the position of a loop bypass valve to maintain the differential pressure at the Loop Differential Pressure Setpoint. This type of control is typically used in primary-only systems, but it can also be effectively used in primary-secondary systems.

  • Page 81: Table 17. Sched (Main > Configuration > Sched)

    BACnet BAS scheduling (priority = 9) Manual (priority = 8). Note: the Manual CSM Control Mode must be set to AUTOMATIC for any of the other scheduling methods to take command. To view the current value of the CSM Control Mode and the priority at which it has been set, go to the System Control screen.

  • Page 82: Weekly Scheduling

    The Internal Schedule Editor Clicking on the Schedule Icon on the Sched screen brings up the schedule editor. From the schedule editor you can select the Weekly, Holiday, Special-event, and Calendar schedules. If you want the CSM to have complete authority over chiller system scheduling, set the BAS Network Schedule Flag to “No BAS Scheduling Allowed”...

  • Page 83: Holiday Scheduling

    Figure 39. Weekly Schedule (Main > Configuration > Sched > Schedule Icon > Weekly) Enter start and stop times by clicking in the row and column where you want an event to occur. Highlighting a stop or start time and clicking on the Delete button will remove that entry. Multiple events can be entered for any and all days. When a weekly schedule is active, the CSM’s system status is “On: Schedule.”...

  • Page 84: Special-Event Scheduling

    Figure 40. Calendar (Main > Configuration > Sched > Schedule Icon > Calendar) Any date box that is shaded red is a holiday date. To designate a date as a holiday, right click on the date box, select NEW, select DATE, enter the date that you want to be a holiday, and click OK. Holiday dates can also be entered in this same way as a DATE RANGE or as a recurring WEEK AND DAY each year.

  • Page 85: Timed Override

    Figure 41. Special Event Schedule (Main>Configuration>Sched>Schedule Icon>Special Events) As shown in Figure 41, the special-event schedule has four adjustable fields: description, priority, period and start/stop times. Start/stop times are edited as described in the weekly schedule section above. When you have finished making changes to the special-events schedule, click the Save button to enter your changes.

  • Page 86: External Time Clock

    External Time Clock If desired, an external clock can be used to schedule chiller system operation. The clock must be connected to the CSM’s external start/stop input (UI-13 of the CSM’s onboard I/O panel). If the switch or relay contact connected to it is closed, the CSM is occupied.

  • Page 87: Table 18. Optimal Start (Main > Configuration > Optimal Start)

    The system starts and operates. When the chilled water supply temperature reaches the System Setpoint, the time that it took is compared with the estimate—if you want to adapt the time. Note: Optimal start control can be used only with systems in which the CSM is controlling the cooling load pump(s). Table 18.

  • Page 88: Figure 42. Optimal Start Time Line

    Figure 42. Optimal Start Time Line Optimal Start Begin Recirculate Period CSM samples temperatures and calculates optimal start time Scheduled start-up time Optimal start window time Optimal Start Optimal start Recirculation Period time increment Today's Optimal Start Time When the Scheduled Start-Up Time minus the Optimal Start Begin Recirculate Period occurs, the CSM enters the Recirculate operating state and starts the cooling load pump(s).
  • Page 89 The CSM subtracts the Optimal Start Time Increment from the scheduled start time to get the Optimal Start Time. If the calculated optimal start time is after the current time, the CSM returns to the Off: Unoccupied state, stops the cooling load pump(s), and waits.

  • Page 90: Bas Communication

    To set up optimal start control Command the Optimal Start Flag to “OS Enabled” If you want the CSM to automatically adapt to your Optimal Start characteristics set the Auto Update Flag CWRT Flag and/or Auto Update OAT Flag to “Yes.” Set the Optimal Start Begin Recirculate Period to the desired time period before the scheduled start time which optimal start-up will run the cooling load pump(s) for a temperature sample.

  • Page 91: Modbus Settings

    Enable (BAS only) BACnet Ethernet The CSM’s network number defines the network connection to a BACnet router. Range = 0 to 65534. Default = 10 Configuration – Network Number Modbus Settings If the CSM was purchased with a Modbus License, the CSM may be integrated into a Modbus BAS. The CSM has been programmed to operate as a Modbus slave device and may be integrated into a serial Modbus RTU or ASCII network using either an RS-485 or RS-232 port connection.

  • Page 92: Physical Alarm Outputs

    Table 22. Configuring Physical Alarm Outputs (Main > Configuration > Alarms) Name Description Horn on Comm Loss Flag If this input = “Horn”, the alarm horn relay (DO-2 on the CSM’s onboard I/O panel) will close whenever a Comm Loss alarm is present.

  • Page 93: E-Mail Alarm Notifications

    Fault-1-E-Mail Address:To These inputs specify the e-mail addresses to which the alarms are sent. A primary (To) address is required; other Fault-1-E-Mail Address: CC addresses are optional. If multiple addresses are used in an entry, use a semicolon (;) between addresses, e.g.: hsmith@aol.com;bjones@msn.com.

  • Page 94: Table 24. Configuring Bacnet Alarm Notification (Main > Configuration > Alarms)

    To have e-mail addresses John.Smith@aol.com and Jane.Doe@msn.com receive all three CSM alarm categories (Faults, Problems, Warnings) at all hours, every day of the week, the operator would configure the following; a) Set Fault 1 E-mail Address To: = John.Smith@aol.com;Jane.Doe@msn.com b) Set Problem 1 E-mail Address To: = John.Smith@aol.com;Jane.Doe@msn.com c) Set Warning 1 E-mail Address To: = John.Smith@aol.com;Jane.Doe@msn.com...

  • Page 95: Bacnet Alarm Notifications

    Fault 1 - Valid Days Defines the days of the week in which routed alarms can be sent as BACnet notifications. Can be set in any combination. Range = Sun, Mon, Tues, Wed, Thurs, Fri, Sat. Default = All days Fault 2 - Valid Days Fault 3 - Valid Days Problem 1 –...
  • Page 96 5, JACE NT and Web Supervisor. The Admin Tool is available at www.mcquay.com, go to Product Information > Controls > Software. Download the AdminTool.zip file to the hard drive of a Windows NT, Windows 2000 or Windows XP computer. Unzip this file and run the enclosed executable file.

  • Page 97: Operator's Guide

    Operator’s Guide This section provides information on the day-to-day operation of the CSM. Each sub-section describes one of the screens under the System Status tab on the Main screen of the CSM’s user interface. The final sub-section, Alarm Monitoring and Control, describes the information under the View Alarms tab of the Main screen.

  • Page 98: Csm Operating State

    Figure 43. System Status (Main > System Status) This section summarizes the most important chiller system information; you can get details about each chiller by using its keypad/display or the Chiller Status screen. CSM Operating State The CSM Operating State variable tells you what state the chiller system is currently in. The chiller system includes everything under the CSM’s supervision;...
  • Page 99 Off: Unoccupied The sub-state name tells you why the CSM is in the Off State. Off: Alarm Sub-state: The Off: Alarm state indicates that a CSM Fault alarm exists. In this state, the CSM cannot start for any reason. To get the CSM out of Off: Alarm, you must clear any Fault alarms that exist. The Off: Alarm state overrides any On state.
  • Page 100 For example, it might send different cooling tower setpoints to the CSM, open two- position bypass valves via digital outputs, and override chiller pumps via digital outputs. Note: McQuay International’s chiller applications group must approve all free cooling strategies. Contact your McQuay representative for information.

  • Page 101: Stage-Up Status

    CAUTION If a BAS is coordinating a free cooling strategy in which it changes cooling tower setpoints as it changes the network command, the CSM should be set up to be Unoccupied during any period when free cooling is possible. If this is not done, chillers could start and operate with extremely low condenser water temperatures.

  • Page 102: System Capacity

    The next-off chiller will be disabled when the next-off active capacity is less than (spare capacity multiplied by spare capacity factor). Decoupled systems have the additional stage-down requirement that the decoupler line flow rate is greater than (next-off chiller’s flow multiplied by decoupler stage down flow rate factor). All stage-downs require that the chiller stage delay time has expired since the last stage-up or stage-down.

  • Page 103: Monitoring Chiller Status

    Figure 45. Condenser Water Temperature Sensor Locations Optional cooling tower bypass Common entering condenser water temperature Common leaving condenser water temperature Leaving condenser water temperature Entering condenser water temperature Chiller #1 Condenser Chiller #2 Condenser a0140 Note: All chillers provide a leaving evaporator water temperature to the CSM. The availability of the other three chiller water temperatures is dependent on chiller type.

  • Page 104: Status (Chiller Run Mode)

    Figure 46. Chiller Status (Main > System Status > Chiller Status) Status (Chiller Run Mode) The chiller status tells you what general state a chiller is currently in. The following chiller status states are possible: • • Start • • PreShutdown •...

  • Page 105: Alarm

    Clear Alarm MicroTech II centrifugal chiller alarms can be cleared from the CSM by commanding the Clear Alarms variable. To clear chiller alarms right-click your mouse on the “Ready” box and then select the “Clear Alarm” command of the dialog box that appears.

  • Page 106: Comp

    Comp # On dual centrifugal chillers, refrigerant pressure and saturated refrigerant temperature data is displayed one compressor at a time. This is also the case for multiple circuit screw and scroll chillers. The Comp # variable tells you which compressor (or circuit) is currently being displayed on the CSM.

  • Page 107: Chilled Water Distribution System Status

    Load limiting prevent the affected chillers from exceeding a certain percentage of their capacity. When no percent-of- capacity load limit is in effect, the load limit sent to each chiller is 100%. When any one is in effect, the load limit is less than 100%.

  • Page 108: Free Cooling Bas Network Override

    Free Cooling BAS Network Override The CSM’s operating state can be overridden by a network command received from a BAS to provide a custom free cooling strategy. The CSM provides the BAS with a Free Cooling data point (see ED 15075-BACnet and ED 15076- Modbus) to allow the BAS to override the normal operation of the CSM in specific instances.

  • Page 109: Clearing Csm Alarms

    None. Clearing Chiller Alarms Each chiller’s alarms may be cleared at the chiller unit controller. MicroTech II centrifugal chiller alarms can also be cleared through the CSM. To clear chiller alarms from the CSM see Clear Alarm on page 105.
  • Page 110 Alarm Alarm Alarm Message Indication Reset Type Priority Comm Loss Between CSM and Communications lost between CSM and Chiller #10 Auto Chiller 10 Comm Loss Between CSM and Communications lost between CSM and Chiller #9 Auto Chiller 9 Comm Loss Between CSM and Communications lost between CSM and Chiller #8 Auto Chiller 8...

  • Page 111: Fault Alarms

    Alarm Alarm Alarm Message Indication Reset Type Priority Common Return Chilled Water Common return chilled water temperature sensor failed Auto Temp Sensor Fail Common Supply Chilled Water Common supply chilled water temperature sensor failed Auto Temp Sensor Fail Chilled Water Loop Chilled water loop differential pressure sensor failed Auto Differential Pressure Sensor...

  • Page 112: Problem Alarms

    No Chilled Water Flow If the Pump Control Option is not equal to “None (Load Flow Control screen), the no chilled water flow alarm occurs whenever all cooling load pumps have failed. A pump is considered “failed” if its digital input is open while its digital output is closed for any continuous period of time equal to the Pump Status Check Delay Time variable (Load Flow Control screen).
  • Page 113 Decoupler Flow Meter Fail If the conditioned analog signal from the flow rate sensor used to determine flow through the decoupler line falls below 1 Vdc (or the current signal from the flow meter falls below 2 mA), the decoupler flow meter fail alarm occurs. As a result, the system continues to operate, but the decoupled sequencing logic is modified to eliminate excess primary water flow as a stage-down precondition.
  • Page 114 Decoupler Temperature Sensor Fail If the temperature sensor in the decoupler line reads out of range (-10 to 135°F, -23.3 to 57.2°C), the decoupler temperature sensor fail alarm occurs. As a result, the system continues to operate, but the decoupled sequencing logic is modified to allow stage-ups only when additional capacity is required, not when additional primary water flow is required.
  • Page 115 Sequencing pump logic acts as though the loop differential pressure is extremely high (1035). Therefore, stage-down control is based on time only, and thus the pump set quickly stages down to stage 1. • Variable speed pump control The variable speed pump control process acts as though the loop differential pressure is extremely high (1035). Therefore, it quickly reduces the pump speed to 0%.

  • Page 116: Warning Alarms

    No Evaporator Flow After Enabling Chiller X Some chillers have a “Waiting For Flow” status condition where the compressors will not run because evaporator flow does not exist. Since chillers may remain in this state indefinitely if flow is never provided, the CSM must recognize this condition and enable different chillers to meet load requirements.
  • Page 117 Stage-Up Inhibiting has Restricted the Enabling of a Chiller If some form of stage-up inhibiting is active while the conditions in the system would normally cause a stage-up to occur, this alarm occurs as a warning. The restriction of capacity this creates is normally expected and desired when using stage- up inhibiting, the associated loss of primary flow in primary-secondary systems my cause unforeseen problems including water flowing backwards through the decoupler line.

  • Page 118: Troubleshooting

    Troubleshooting Using Status LEDs The CSM controller includes a series of LEDs that can be used to determine the status of a variety of normal operating parameters for the unit. They are located on the main circuit board (see Figure 48). From the top of the board to the bottom, these include the following: •...

  • Page 119: Lon Port

    If you can’t ping the CSM, do not try any other forms of Ethernet communications (i.e. the user interface web screens) with the CSM. If you call the McQuay Controls Support Group for support connecting to the CSM, the first thing they may ask you is if you can “ping”...

  • Page 120: Checking The Ip Address And Subnet Mask Of Your Computer

    Checking the IP Address and Subnet Mask of Your Computer The ipconfig command is a command-line utility available on Windows NT 4.0 and Windows 2000 operating systems. Open the DOS prompt and type “ipconfig” or “ipconfig/all” to determine the current IP Address and Subnet Mask of the computer you are trying to connect to the CSM.
  • Page 121 Connect the other end of the cable to a RJ-45 to DB-9 null modem adapter. This adapter can be purchased at www.cdw.com (Part #533740). Assemble this adapter must be pinned out per Table 26. Connect the DB-9 adapter to a serial port (generally COM1 or COM2) of a Windows NT 4.0, 2000 or XP computer. The two devices are now physically connected.

  • Page 122: Figure 50. Ip Address Read From A Hyperterminal Boot Sequence

    Figure 50. IP address read from a HyperTerminal boot sequence Table 26. DB-9 to RJ-45 Null Modem Adapter Pin Assignments DB-9 Female Signal RJ-45 Female Pin Data terminal ready Request to send Transmit data Signal ground Data carrier detect Receive data Clear to send Data set ready Page 122...

  • Page 123: Pinging The Csm From Your Computer

    DB-9 Female Pin Reference RJ-45 Female Pin Reference (view when looking at the pins from the front, see numbers on adapter) Pinging the CSM from Your Computer Packet Internet grouper (ping) is a utility that checks the availability and response time of a network host. It uses the Internet control message protocol (ICMP).

  • Page 124: Checking Internet Explorer Settings

    Figure 51. Performing the “ping” Command at the DOS Prompt Checking Internet Explorer Settings If you can ping the CSM from your computer but cannot bring up the CSM’s user interface on your web browser, verify the following: • The CSM user interface works from your PC with Microsoft Internet Explorer browser version 5.0 or later only (not AOL or Netscape).

  • Page 125: Figure 52. Important Microsoft Internet Explorer Options

    Figure 52. Important Microsoft Internet Explorer Options OM 780-2 Page 125...

  • Page 126: Appendix A: Hardwired Chiller Control

    Optional chiller condenser leaving water temperature (Analog Input) Hardwired chillers are controlled by the CSM the same as a MicroTech II chiller with some exceptions. These differences include limited chiller data, limited alarm information, and the limited Comm Loss control features.

  • Page 127: Chiller % Rla From A Hardwired Chiller

    associated chiller’s Nameplate Rated Load Amps. This value is used to calculate % RLA by measuring (not used if chiller supplies % RLA) the amps used by the chiller. Default = 150 Amps. Current Transducer High Signal Amps If % RLA is sent from the chiller unit controller this property is not used. This input tells the CSM the amps associated with the high range of the current transducer’s (CT) output signal (20 mA).

  • Page 128: Hardwired Chiller - Load Limiting Control

    Hardwired Chiller - Load Limiting Control The CSM can limit the loading of each chiller in the system from 100% to 40% by sending it a capacity limit. The CSM generates the load limit for each chiller based on a demand limiting, soft load, or load-balancing function (see the Load Limiting Control section for details).

  • Page 129: Hardwired Chiller Unit Controller Settings

    Figure 54. Hardwired Chiller Leaving Water Temperature Setpoint Reset (English) CSM Maximum System Setpoint= 54°F Minimum System Setpoint= 44°F 0–10 Vdc: 0–20 mA: Hardwired Signal to Chiller Figure 55. Hardwired Chiller Leaving Water Temperature Setpoint Reset (SI) CSM Maximum System Setpoint= 12°C CSM Minimum System Setpoint = 7°C 0–10 Vdc: 0–20 mA:...

  • Page 130: Hardwired Chiller Sequence Of Operation

    The chiller was recently disabled and the chiller’s timers (Start-to-Start and/or Stop-to-Start) prevents the chiller from starting. On MicroTech II chillers, the CSM receives a “chiller enable” signal from the chiller telling the CSM the chiller is ready to run. No such signal is available to the CSM on hardwired chillers. The CSM’s Stop-to-Start Timer (see Table 27) is used by the CSM to keep track of chiller availability on hardwired chillers.

  • Page 131: Chiller Shutdown

    All chillers will typically have one alarm output signal. Chillers with multiple compressors (i.e. the McQuay MicroTech 200 series dual compressor centrifugal chiller) may have two alarm output signals. If a chiller has two alarm outputs the Number Of Chiller Alarm Outputs (see Table 27) property must be set to 2.

  • Page 132: Chiller Problem Alarms

    Fault (Check Unit for Details) If the chiller’s alarm output relay is switched (steady), the “Fault (Check Unit for Details)” alarm will occur. Upon receipt of this generic alarm, the CSM sets the chiller unavailable and disables it (if enabled). The chiller will not be enabled again by the CSM until the chiller’s alarm output relay changes to a non-fault state.

  • Page 133: Chiller Data

    Misc screen Chiller Data Hardwired chillers have less information available at the CSM user interface or offered to a BAS than MicroTech II chillers communicating with the CSM on the dedicated L network. Chiller alarm descriptions are also limited ORKS (see Table 29).

  • Page 134: Index

    Index decoupler temperature sensor fail alarm, 114 demand-limiting, 45, 107, 128 Admin Tool, 7, 11, 96 alarm notification, 91 AUTO, 19 entering condenser water temp sensor warning alarm, 117 Automatic Sequence Order, 35 entering condenser water temperature sensor fail, 112 Ethernet, 11, 12, 13, 14, 16, 18, 90, 119, 123 Ethernet Port, 118 evaporator water flow status, 106...
  • Page 135 run time, 34, 35, 36, 67, 72, 106, 107 Neuron ID, 23, 24 Next-OFF Active Capacity, 101 Next-OFF Chiller, 101 Saturated Refrigerant Temperatures, 106 Next-ON Chiller, 101 schedule editor, 82 no chilled water flow alarm, 112 secondary pumps, 24 Number of Chillers Running, 101 Security Administrator, 20, 21 Sequence Number, 34 Serial Port, 118...
  • Page 136 This document contains the most current product information as of this printing. For the most up–to-date product information, please go to www.mcquay.com. © 2005 McQuay International (800) 432-1342 www.mcquay.com...

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