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EVAPCO SAGE Operation & Maintenance Instructions Manual

Water & energy conservation control system
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Operation & Maintenance Instructions
FOR SAGE WATER & ENERGY CONSERVATION CONTROL SYSTEM
For EVAPCO Authorized Parts and Service, Contact Your Local EVAPCO Representative
EVAPCO, Inc. – World Headquarters & Research/Development Center
PHONE: (410) 756-2600 • FAX: (410) 756-6450 • E-MAIL: SageSupport@evapco.com
EVAPCO North America
EVAPCO, Inc.
World Headquarters
PO Box 1300
Westminster, MD 21158, USA
Phone: (410) 756-2600
Fax: (410) 756-6450
Email: marketing@evapco.com
EVAPCO East
5151 Allendale Lane
Taneytown, MD 21787, USA
Phone: (410) 756-2600
Fax: (410) 756-6450
Email: marketing@evapco.com
EVAPCO Midwest
1723 York Road
Greenup, IL 62428, USA
Phone: (217) 923-3431
Fax: (217) 923-3300
Email: evapcomw@evapcomw.com
EVAPCO West
1900 West Almond Avenue
Madera, CA 93637, USA
Phone: (559) 673-2207
Fax: (559) 673-2378
Email: contact@evapcowest.com
EVAPCO Iowa
925 Quality Drive
Lake View, IA 51450, USA
Phone: (712) 657-3223
Fax: (712) 657-3226
EVAPCO Iowa
Sales & Engineering
215 1st Street, NE
Medford, MN 55049, USA
Phone: (507) 446-8005
Fax: (507) 446-8239
Email: evapcomn@evapcomn.com
EVAPCO Northwest
5775 S.W. Jean Road, Suite 210
Lake Oswego, OR 97035, USA
Phone: (503) 639-2137
Fax: (503) 639-1800
EVAPCO, Inc. • P.O. Box 1300 • Westminster, MD 21158 USA
EVAPCO Newton
701 East Jourdan Street
Newton, IL 62448, USA
Phone: (618) 783-3433
Fax: (618) 783-3499
Email: evapcomw@evapcomw.com
Refrigeration Valves & Systems
Corporation (RVS)
A wholly owned subsidiary of EVAPCO, Inc.
1520 Crosswind Drive
Bryan, TX 77808, USA
Phone: (979) 778-0095
Fax: (979) 778-0030
Email: rvs@rvscorp.com
EvapTech, Inc.
A wholly owned subsidiary of EVAPCO, Inc.
8331 Nieman Road
Lenexa, KS 66214, USA
Phone: (913) 322-5165
Fax: (913) 322-5166
Email: marketing@evaptech.com
Tower Components, Inc.
A wholly owned subsidiary of EVAPCO, Inc.
5960 US Highway 64 East
Ramseur, NC 27316, USA
Phone: (336) 824 2102
Fax: (336) 824-2190
Email: mail@towercomponentsinc.com
EVAPCO-BLCT Dry Cooling, Inc.
1011 US Highway 22 West
Bridgewater, NJ 08807, USA
Phone: (908) 379-2665
E-mail: info@evapco-blct.com
EVAPCO South America
EVAPCO SEMCO
Equipamentos de Refrigeracao Ltda.
Rua Alexandre Dumas, 1601 – 2 andar
04717-004 Sao Paulo – SP – Brazil
Phone: (55) 11-5184-0067
EVAPCO Europe
EVAPCO Europe BVBA
European Headquarters
Industrieterrein Oost 4010
3700 Tongeren, Belgium
Phone: (32) 12-395029
Fax: (32) 12-238527
Email: evapco.europe@evapco.be
EVAPCO Europe, S.r.l.
Via Ciro Menotti 10
I-20017 Passirana di Rho
Milan, Italy
Phone: (39) 02-939-9041
Fax: (39) 02-935-00840
Email: evapcoeurope@evapco.it
EVAPCO Europe, S.r.l.
Via Dosso 2
23020 Piateda Sondrio, Italy
EVAPCO Europe, GmbH
Meerbuscher Straβe 64-78
Haus 5
40670 Meerbusch, Germany
Phone: (49) 2159-69560
Fax: (49) 2159-695611
Email: info@evapco.de
Flex coil a/s
A subsidiary of EVAPCO, Inc.
Knøsgårdvej 115
DK-9440 Aabybro Denmark
Phone: (45) 9824 4999
Fax: (45) 9824 4990
Email: info@flexcoil.dk
EVAPCO S.A. (Pty.) Ltd.
A licensed manufacturer of EVAPCO, Inc.
18 Quality Road
Isando 1600
Republic of South Africa
Phone: (27) 11-392-6630
Fax: (27) 11-392-6615
Email: evapco@icon.co.za
EVAPCO Egypt Engineering Industries Co.
A licensed manufacturer of EVAPCO, Inc.
5 Al Nasr Road St.
Nasr City, Cairo, Egypt
Phone A: (20) 2-290-7483
Phone B: (20) 2-291-3610
Fax A: (20) 2-404-4667
Fax B: (20) 2-290-0892
Email: Primacool@link.net / Shady@primacool.net
EVAPCO Asia/Pacific
EVAPCO Asia/Pacific Headquarters
1159 Luoning Road
Baoshan Industrial Zone
Shanghai, 200949 P.R. China
Phone: (86) 21-6687-7786
Fax: (86) 21-6687-7008
Email: marketing@evapcochina.com
Evapco (Shanghai) Refrigeration
Equipment Co., Ltd.
1159 Luoning Road
Baoshan Industrial Zone
Shanghai, 200949 P.R. China
Phone: (86) 21-6687-7786
Fax: (86) 21-6687-7008
Email: marketing@evapcochina.com
Beijing EVAPCO Refrigeration Equipment
Co., Ltd.
Yan Qi Industrial District, Huai Rou
Beijing, 101407 P.R. China
Phone: (86) 10 6166-7238
Fax: (86) 10 6166-7395
Email: evapcobj@evapcochina.com
Evapco Australia Pty Ltd
34-42 Melbourne Road
Riverstone, NSW Australia 2765
Phone: (61) 2 9627-3322
Fax: (61) 2 9627-1715
Email: sales@evapco.com.au
Evapco Composites Sdn. Bhd
No. 70 (Lot 1289) Jalan Industri 2/3
Rawang Integrated Industrial Park
Rawang. Selangor, 48000 Malaysia
Phone: (60) 3 6092-2209
Fax: (60) 3 6092-2210
EvapTech Asia Pacific Sdn. Bhd
A wholly owned subsidiary of EvapTech, Inc.
IOI Business Park, 2/F Unit 21
Persiaran Puchong Jaya Selatan
Bandar Puchong Jaya,
47170 Puchong, Selangor, Malaysia
Phone: (60-3) 8070-7255
Fax: (60-3) 8070-5731
Email: marketing-ap@evaptech.com

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  • Page 1 Operation & Maintenance Instructions FOR SAGE WATER & ENERGY CONSERVATION CONTROL SYSTEM For EVAPCO Authorized Parts and Service, Contact Your Local EVAPCO Representative EVAPCO, Inc. – World Headquarters & Research/Development Center EVAPCO, Inc. • P.O. Box 1300 • Westminster, MD 21158 USA PHONE: (410) 756-2600 •...

  • Page 2: Table Of Contents

    Operation and Maintenance Instructions Table of Contents Introduction .................................... 3 Sage Water and Energy Conservation Control System ..................... 3 Installation and Wiring ................................4 Safety ....................................4 Panel Installation Considerations ............................4 Temperature Sensor Installation ............................4 Wiring Considerations ................................ 5 Operation and Servicing ..............................

  • Page 3: Introduction

    This bulletin includes a description of the screens and parameters that are available through the Human Machine Interface (HMI) located on the front of the Sage Control System. Also included in this bulletin are the functions of the Sage Control System, common terminology, and a troubleshooting guide. Please note that the screens displayed on your Sage Control System HMI may vary slightly from the images shown in this document.

  • Page 4: Installation And Wiring

    Placement of the Sage Control System should be in close proximity to the fluid cooler unit to reduce the wire lengths required. If the Sage Control System is within sight of the fluid cooler unit, the Sage Control System may be used as the main electrical disconnect for the basin heater(s), fan motor(s), and spray pump motor(s) for the fluid cooler unit.

  • Page 5: Wiring Considerations

    All wiring in and out of the Sage Control System should be with copper conductors and wire lengths must be kept as short as possible. Consult the detailed wiring diagram for field wiring connections of each device. Applicable electrical codes for the location should be followed during the sizing and installation of the field wiring.
  • Page 6 The Sage Control System is supplied with air filters that must be inspected monthly for cleanliness. Filters must be replaced when they appear dirty or at least every 4 months. It is recommended that filters be replaced prior to peak ambient conditions to ensure the highest level of cooling.

  • Page 7: Operator Interface Screens

    The Welcome Screen (Figure 2) appears while the Sage Control System is in its startup state. After the Sage Control System has started up, the Sage Home Screen (Figure 3) will be displayed. If there is no interaction with the HMI within fifteen minutes, the Welcome Screen will reappear.

  • Page 8: Sage Faceplate

    Sage Faceplate Located at the bottom of most screens is the Sage Faceplate (Figure 4). The left side of the faceplate shows the current logged in user as well as the on/off status of all pumps and fans. The Control parameter indicates if the Sage Control System is set to receive commands locally or from a BAS.

  • Page 9: Sage Home Screen

    Operation and Maintenance Instructions Sage Home Screen The Sage Home Screen displays an overview of the current operation of the fluid cooler unit. The Ambient Outside air temperature, Average Return (inlet) fluid temperature, Average Supply (outlet) fluid temperature, Active (leaving water) control setpoint, and current VFD speed (in percent) are shown.
  • Page 10 Sage Control System’s with multiple cells that a corresponding label is placed on the other fluid cooler unit to make it easier for users to correlate the Sage Control System. This makes it easier for users to identify each cell in the control system.

  • Page 11: Main Menu Screen

    Cell End View Screen To view information for a specific cell, touch the individual cell on the Sage Home Screen. This will open the Cell End View Screen. Navigation to this screen is also available via the Main Menu Screen.
  • Page 12 The VFD status of the selected cell will be displayed on the right side of the screen. Reference the table below to identify what each VFD status represents. Figure 12: The Cell End View Screen. Page 12 www.evapco.com SageSupport@evapco.com...

  • Page 13: Login Button

    To prevent unauthorized access, users must login to obtain access to screens in which system performance or settings may be changed. Sage Control System passwords may only be changed onsite by Evapco personnel. The Sage Control System supports both Operator and Service levels of password protection which are detailed below:...

  • Page 14: Logout Button

    Pressing the Logout Button on the Main Menu Screen will immediately log the user out of the system. Always logout before leaving the Sage Control System to prevent unauthorized access. The system will automatically log out the user after 10 minutes of inactivity.

  • Page 15: Digital Status Screen

    The Digital Status Screen shows the current state of all digital inputs and/or outputs. A quick overview of the status of all external components connected to the Sage Control System is shown on this screen. Note: All digital outputs are delayed being energized by 30 seconds after a power cycle.

  • Page 16: Analog Input Status Screen

    The Analog Input Status Screen shows the current value of all analog inputs. A quick overview of the values of all temperature sensors connected to the Sage Control System is shown on this screen. Figure 17: The Analog Input Status Screen.
  • Page 17 Complete the previous steps but now with a 20 mA signal. Once you have calibrated all the necessary analog inputs, press and hold the Update button until the Updated text becomes visible under the Update button (Figure 21). Page 17 www.evapco.com SageSupport@evapco.com...

  • Page 18: Alarm Setup Screen

    Alarm History Screen. For a description of each alarm, please see the Alarm Event Description section of this document. To view active alarms, refer to the Alarm Display Screen. Figure 22: The Alarm Setup Screens. Page 18 www.evapco.com SageSupport@evapco.com...

  • Page 19: Alarm Display Screen

    Alarm Display Screen All active alarms can be viewed on the Active Alarm Display Screen (Figure 23) by pressing the Alarm button on the Sage Faceplate at the bottom of every screen. Any user can acknowledge all currently active alarms without logging in. The function to acknowledge all alarms can also be triggered by the BAS communications if the Sage Control System is set for remote control.
  • Page 20 For a description of each alarm and possible causes for each alarm, please see the Alarm Event Description section of this document. Figure 24: Toggle Switch Between Alarm Screens. Figure 25: The Active Alarm Display Screen. Page 20 www.evapco.com SageSupport@evapco.com...
  • Page 21 If the user has changed the name of a cell, the table on the right side of the alarm screen shows the name of the cell in the alarm table and what the name of the cell has been changed to. This is used to properly identify which cell the alarm is associated with in multi-cell Sage Control Systems. Figure 26: Cell Alarm Naming Table Page 21 www.evapco.com...

  • Page 22: Bump Test Screen

    3. In the Setup Options Screen, ensure that the fluid cooler unit standby status is Disabled. 4. In the Unit Operation Screen, place the fluid cooler unit in Auto. 5. Press the Bump Button next to each device. Page 22 www.evapco.com SageSupport@evapco.com...

  • Page 23: Setup Options Screen

    Sage Control System. Enabling an accessory that is not installed or wired to the Sage Control System will cause the fluid cooler unit to not function correctly. Also, Page 23 www.evapco.com...
  • Page 24 Spray Pump Flow Switch: The flow switch(es) may be enabled or disabled from the Setup Options Screen. If a spray pump is energized and a flow switch detects no flow, an alarm will activate, and the spray pump will turn off. The Sage Control System will then try to restart the spray pump(s) two more times after a short delay between each attempt.

  • Page 25: Control Setpoints Screen

    Louver De-Icing Sequence Basin Water Temperature: The Basin Water Temperature below which the automatic Louver De-icing sequence will be triggered by the Sage Control System. The Louver De-icing sequence will only run if the Louver De-icing routine is enabled on the Setup Options Screen.

  • Page 26: Motor Runtimes Screen

    Motor Runtimes Screen The Motor Runtime Screen is only available to users that are logged into the Sage Control System. This screen displays the runtime hours for all fan motors and spray pumps. To reset any counter, press the appropriate Reset Button.
  • Page 27 Manual Operation: In Manual, the user controls if the fan motor(s) and spray pump(s) are on or off. If a fan motor is Enabled, the user can change the VFD speed. Note that the Sage Control System will not automatically maintain an Active Control Temperature setpoint in this mode.

  • Page 28: Set Time And Backup Screen

    35. If no text is shown, the save did not register. System settings may also be reset to the factory settings at any time by touching Restore in the row indicated by the text Factory Backup. Figure 35: A saved or restored is indicated by the text flashed on the screen. Page 28 www.evapco.com SageSupport@evapco.com...
  • Page 29 If the incoming power is out longer than the designated time, the Sage Control System will be in an off state upon restart. Once the Sage Control System senses the supply fluid temperature is above the Active Control Temperature setpoint, it will begin increasing the capacity of the fluid cooler unit until it meets the required load.

  • Page 30: Priority Selection Screen

    Energy Savings Priority: With this setting, the Sage Control System will operate in the manner in which the least amount of electricity is consumed by the fluid cooler unit. Note: there may be a point at which it is more energy efficient to shutoff a spray pump and increase the fan motor power.

  • Page 31: Bms & Network Screen

    To access the BMS & Network Screen the user needs be logged in at the Service level and the status of the system needs to be disabled in the Setup Options Screen. All Sage controllers can communicate with BMS via Modbus RTU, Modbus TCP/IP, BACnet MS/TP, and BACnet IP.

  • Page 32: Advanced Unit Setup Screen

    BMS controller within 30 seconds after the value has changed to a one. Once the bit has been changed to zero, then the Sage Controller will change the bit back to one after 5 seconds. If the bit does not have a zero written to it after 30 seconds, then an alarm will energize, and the Loss of Network Comms response will go into effect.
  • Page 33 35°F. At 35°F, the spray pump(s) will turn off and the basin heater(s) will energize. Once the basin heater(s) energize, the spray pump(s) will not run until the basin temperature reaches the Pump Cut In Temperature (42°F). Page 33 www.evapco.com SageSupport@evapco.com...

  • Page 34: Digital Output Test Screen

    Digital Output Test. CAUTION: Safety alarms are disabled when Digital Output Test is enabled. DO NOT keep any outputs enabled for an extended period or damage could be caused to devices. Page 34 www.evapco.com SageSupport@evapco.com...

  • Page 35: Terminology

    The need for the Hot Start Routine will be determined by Evapco during start-up.

  • Page 36: Troubleshooting

    For Remote control, ensure a start signal is being transmitted (see Sage Faceplate).  Verify the Sage Control System is set to the desired control mode (see Setup Options Sage Control System is not set in Screen for Local/Remote settings).
  • Page 37 (see Unit Operation Screen).  This is a preprogramed function that must be enabled by the user. Check the Sage Home Louver De-icing routine is being Screen or the remote signal (if equipped) to executed Fan Spinning Backward see how long the Louver De-icing sequence will last.
  • Page 38 Problem Possible Cause Remedy  This is a preprogramed function. Check the Sage Home Screen or the BAS setpoint (if Cycle Pump routine is active connected) to see how long the Cycle Pump routine will continue.  Once energized in Auto control, a spray pump...
  • Page 39 System Stuck in Local  If user wants BMS Heartbeat enabled, then BMS Heartbeat Mode or Off check that the BMS Heartbeat bit is being changed to 0 every 30 seconds on the customer’s BMS side. Page 39 www.evapco.com SageSupport@evapco.com...
  • Page 40 Raise the high inlet water temperature alarm Temperature Alarm* the user setpoint. setpoint.  Notification only. High Outlet Water The outlet fluid temperature is  Raise the high outlet water temperature Temperature Alarm* above the user setpoint. alarm setpoint. Page 40 www.evapco.com SageSupport@evapco.com...
  • Page 41  Ensure the EWLC is operating correctly.  Inspect the EWLC standpipe for damage.  If the basin is drained, but the alarm is still active, ensure the water make-up is disabled (see Setup Options Screen). Page 41 www.evapco.com SageSupport@evapco.com...
  • Page 42 Check that the BAS heartbeat Modbus bit is PLC and BMS System mode, the BMS heartbeat is set to 1 from the Sage system and the BAS Comms. Loss: Moved to enabled and “move to local system is changing it to 0 within 30 seconds.

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