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Troubleshooting

Chilled Water System Optimizer v2

CARRIER CORPORATION ©2019

Installation and Start-up Guide

28

All rights reserved

If you have problems mounting, wiring, or addressing the controller or the Chilled Water System Optimizer, contact
Carrier Control Systems Support.

NOTE

To help you troubleshoot, obtain a Module Status (Modstat) from the controller and review the System Error

and Warning details.

Controller LED's

The

Module Status

LED can display the following error codes.

Error
Code...

Indicates...

Possible solutions

0

The control program or
driver has not been
downloaded.

Download All Content to the controller.

1

A control program error Obtain a Module Status Report (Modstat) and look for error conditions. See

To get the controller's serial number below for instructions on obtaining a
Modstat.

If you cannot determine the error from the Modstat, contact Carrier Control
Systems Support.

2

The controller's
memory is full

In the i-Vu® interface, reduce the amount of trend data being stored in the
controller.
In SiteBuilder, reduce the amount of control programs.

3

A setup error

Verify:



The address has been set on the rotary switches. See Addressing the
controller.



The address is unique on the network



DIP switches are set correctly

4

A system error

Obtain a Module Status Report (Modstat) and look for error messages. See
To get the controller's serial number below for instructions on obtaining a
Modstat.

If you cannot determine the error from the Modstat, contact Carrier Control
Systems Support.

8

Factory defaults are
being restored

The number 8 should display only during the short restoring period. If this
number displays continuously or flashes intermittently with another number,
try each of the following:



Turn the controller's power off, then on.



Format the controller. See

Restore factory defaults

(page 29) below.



Download the controller.



Replace the controller.

Other LED's show the status of certain functions.

Troubleshooting

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Содержание OPN-OPT-OL

Страница 1: ...m O Op pt ti im mi iz ze er r v v2 2 I In ns st ta al ll la at ti io on n a an nd d S St ta ar rt t u up p G Gu ui id de e CARRIER CORPORATION 2019 A member of the United Technologies Corporation fami...

Страница 2: ...ur local Carrier office Important changes are listed in Document revision history at the end of this document CARRIER CORPORATION 2019 All rights reserved throughout the world i Vu is a registered tra...

Страница 3: ...party device 17 Communicating through the Local Access port with a USB Link 18 To communicate using PuTTY 19 Installing the controller into an i Vu Control System 21 To configure third party protocol...

Страница 4: ...Water Setpoint Reset Output Limit Settings 55 Electric Metering Combined kW of Monitored Equipment 56 Appendix B The Chilled Water System Optimizer Commissioning view of the Properties page 58 General...

Страница 5: ...of both the chilled water plant equipment and the chilled water consumers This results in an overall reduction in energy use and electrical demand You can select from the following protocols BACnet IP...

Страница 6: ...time clock keeps track of time in event of power failure Battery 10 year Lithium CR123A battery ensures the following data is retained for a maximum of 720 hours during power outages Time Graphics Co...

Страница 7: ...removable screw type terminal blocks Overall dimensions A B 7 1 2 in 19 1 cm 11 5 16 in 28 7 cm Mounting dimensions C D E F 5 in 12 7 cm 10 7 8 in 27 6 cm 1 1 4 in 3 2 cm 1 4 in 6 cm Mount with 6 32 b...

Страница 8: ...secondary pumps and tertiary pumps are part of the chilled water system including variable air handling unit fans Condenser water side systems with multiple cooling towers and condenser water pumps d...

Страница 9: ...unctions most efficiently and provides increased energy savings if all pumps and fans have variable frequency drives and as more power inputs are measured though it is not necessary Control Inputs Pow...

Страница 10: ...CARRIER CORPORATION 2019 Installation and Start up Guide 6 All rights reserved Safety considerations WARNING Disconnect electrical power to the controller before wiring it Failure to follow this warn...

Страница 11: ...al Do not touch components or leads Handle the board by its edges Isolate from high voltage or electrostatic discharge Ensure that you are properly grounded Screw the controller into an enclosed panel...

Страница 12: ...Connect the transformer wires to the screw terminal connector 5 Apply power to the power supply 6 Measure the voltage at the controller s power input terminals to verify that the voltage is within the...

Страница 13: ...controller address is also used to autogenerate the BACnet device instance name for the router See Configuring BACnet device instance and network number To set the controller address on the Open netw...

Страница 14: ...IP Broadcast Management Devices BBMDs See To set up BACnet Broadcast Management Devices To obtain an IP address using DHCP 1 Turn the controller s power off 2 Set the IP Addr DIP switch DHCP to On 3 T...

Страница 15: ...chiark greenend org uk sgtatham putty download html 2 Connect the laptop to the local access port of the router ZS sensor or an SPT sensor using the USB Link cable s USB Link Connect to Local Access...

Страница 16: ...o take an action type number of the action then press Enter 9 If you changed a value type 1 then press Enter to restart the controller 10 Close PuTTY 11 Verify that you can communicate with the contro...

Страница 17: ...communication Local Access Enhanced Access Rnet 115 2 kbps Configuration System start up and troubleshooting The Config Mode DIP switch Console must be Off down position to use Port S2 Port S2 suppor...

Страница 18: ...e Tens 10 s switch to the tens digit of the address and set the Ones 1 s switch to the ones digit EXAMPLE If the controller s address is 25 point the arrow on the Tens 10 s switch to 2 and the arrow o...

Страница 19: ...ifications 328 feet 100 meters Use one of the following CAT5 or higher Ethernet cables A cross over cable to connect the controller directly to the third party device A straight through cable to conne...

Страница 20: ...Check the communications wiring for shorts and grounds 3 Set the Router Config Mode DIP switch Console to Off down position 4 Wire the controller s Port S2 to the third party device then set the S2 ju...

Страница 21: ...le or disable with a jumper Make sure that only devices at the end of a network have termination enabled EXAMPLE If an EIA 485 2 wire network s characteristic impedance is 120 Ohms terminate one pair...

Страница 22: ...ter and the USB Link Purchase a USB isolator online from a third party manufacturer Plug the isolator into your computer s USB port and then plug the USB Link cable into the isolator PREREQUISITES For...

Страница 23: ...5 or later system But if needed you can get the latest driver from http www silabs com products mcu Pages USBtoUARTBridgeVCPDrivers aspx Install the driver before you connect the USB Link to your comp...

Страница 24: ...To find the port number select Start Control Panel System Device Manager Ports Com LPT The COM port number is beside Silicon Labs CP210x USB to UART Bridge Speed baud 115200 Data Bits 8 Stop Bits 1 Pa...

Страница 25: ...appears 5 Enter a name for your control program in Display Name and select the controller in the Controller drop down list NOTES You can change the control program s Reference Name if needed 6 Do one...

Страница 26: ...ce a Master 8 Accept all other default settings 9 Click Accept NOTE You can configure the controller for either Modbus RTU or Modbus IP not both at the same time Modbus over IP network 1 Verify the Po...

Страница 27: ...ng shipment 1 Verify the Archive Valid LED is lit then set this field to 0 2 After you install the controller and apply power enter a number greater than 0 TouchScreen Control TouchScreen Schedule Edi...

Страница 28: ...ates in 3 seconds the driver automatically throttles the broadcasts to 1 per second Also if the object s value updates excessively for 30 seconds an alarm is sent to the i Vu application listing all o...

Страница 29: ...ociated with this Notification Class Recipient Description Name that appears in the Recipients table Recipient Type Use Address static binding for either of the following Third party BACnet device rec...

Страница 30: ...pe from this controller Notification Class Do not change this field Custom Translation Tables You can set up a translation table that an analog input will use to translate the raw data from a non line...

Страница 31: ...9 Installation and Start up Guide 27 All rights reserved Protocols On the Protocols page you can enable or disable Telnet diagnostics This allows you to write to a text file the communication between...

Страница 32: ...er Control Systems Support 2 The controller s memory is full In the i Vu interface reduce the amount of trend data being stored in the controller In SiteBuilder reduce the amount of control programs 3...

Страница 33: ...ng data on Port S1 Battery low The battery is low To restore factory defaults CAUTION This erases all archived information and user configuration settings You will have to reconfigure all custom setti...

Страница 34: ...rchive function to restore data when the power returns A low battery is indicated by the Battery low LED or a low battery alarm in the i Vu application You can purchase replacement batteries from any...

Страница 35: ...hilled Water Supply Setpoint Value Link the Analog Network Input in the chiller program to the BACnet Analog Value Status in the optimization program NOTE The chilled water supply setpoint signal is r...

Страница 36: ...o set a condenser water setpoint value and then verify response in the tower manager program You may need to tune PID properties and tower ramp rates NOTE It is important that the condenser water setp...

Страница 37: ...chedule present value is locked to On NOTE In order to lock the Schedule microblock from the Properties page you must select Show Service Config view 4 Verify the outdoor air conditions are met OAT mu...

Страница 38: ...agger Reset Enable Conditions page 65 Verify Lead Lag Stagger routine for optimization is Off NOTE Stagger reset should only be On after both the Chilled Water Optimizer Reset and the Condenser Water...

Страница 39: ...ropriately to match the system s operating requirements 2 The pause status displays Pause Hold is OFF If it is on then determine which condition is causing it to display ON and correct as necessary 3...

Страница 40: ...ith Minimum Reset 1 deg Maximum Reset 2 deg Reset Increment Coarse Gain 5 Reset Increment Fine Gain 0 NOTE Adjust if required 8 Bias for reset of CHWS temperature setpoint for warmer temperatures are...

Страница 41: ...ction Since the first reset raises the supply temperature then the second reset lowers the chilled water supply temperature 3 Third and successive responses The program will repeat the above process a...

Страница 42: ...from the chilled water setpoint change The effect of this change must propagate through all the devices in the system until it is stable You may need to tune some chiller programs or properties to get...

Страница 43: ...temperature could be running cooler than expected This could be any one of the following reasons It is the best temperature for optimum energy use The system power flows or tonnage inputs are turbule...

Страница 44: ...eg EXAMPLE Your default Resting temperature Condenser Water Optimizer Operation Overview Notes Condenser Water Supply Setpoint Range Based on OA Wet Bulb Temperature the condenser water supply tempera...

Страница 45: ...degrees Setpoint when the optimizer is off Minimum Wet Bulb Approach 5 degrees Setpoint at highest reset coolest condenser water temperature when the tower fans are running faster NOTE You may need to...

Страница 46: ...he program recognizes it is resetting in the wrong direction Since the first reset lowers the supply temperature then the second reset raises the condenser water supply temperature 3 Third and success...

Страница 47: ...ser water setpoint change The effects of the setpoint change must propagate through the entire condenser water system until all devices in the system become stable You may need to tune certain tower o...

Страница 48: ...ent then raise the reset gain If most often at the Maximum Increment then lower the reset gain Optional Add Bias for cooler Condenser Water Supply Temperatures After the program has been running a whi...

Страница 49: ...you must configure Currently the controller implements DAB for the following variables 0 1 Plant ON 1 CH1 kW 1 CH1 ON 2 CH2 kW 3 CH3 kW 3 CH3 ON 4 CH4 kW 4 CH4 ON 5 CH5 kW 6 CH6 kW 6 CH6 ON 7 CH7 kW...

Страница 50: ...EMOTE INPUT 17 CWS STPT TEMP REMOTE INPUT 17 CWS TEMP REMOTE INPUT 17 Optimized CWS Reset Heartbeat ANO Minutes NOTE Recommended but not required Outdoor Air Humidity Outdoor Air Temperature You can i...

Страница 51: ...ent options to view and configure properties and points You can select from the following views Status only Displays the current values or state of points and properties applicable to monitoring the c...

Страница 52: ...s operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful in...

Страница 53: ...and ranges for the properties At the top of the Properties page there is a quick overview of system statuses ENABLED DISABLED Optimizer ENABLED DISABLED Chilled Water Supply Reset __ __ degrees Setpoi...

Страница 54: ...Total Chilled Condenser Water System kW Displays the current value of all the monitored energy loads Total Building Cooling Load Tons Displays the current value of all the monitored chilled water sys...

Страница 55: ...vaporator so the temperature difference will not drop too low This prevents the chiller from cycling off on low load too often and helps to stabilize chiller operation The optimization program will no...

Страница 56: ...set is only enabled when both Chilled Water Reset and Condenser Water Reset are running Stagger Reset alternates between the chilled water reset and the condenser water reset calculations When on the...

Страница 57: ...an kW ton Displays value Total Chilled Water System kW ton Displays value Section 1 Chilled Water System Optimizer Enable conditions Navigation i Vu Properties Control Program Chilled Water Temperatur...

Страница 58: ...tatus Manual Quick Cool Down of Chilled Water Supply Quick Cool Down is __ Displays OFF or ON status Condenser Water Temperature Optimizer Reset Navigation i Vu Properties Control Program Condenser Wa...

Страница 59: ...am Condenser Water Temperature Optimizer Reset Section 2 Manual Overrides of Condenser Water Reset and other Settings Point Name Description Manual Pause Hold of Condenser Water Reset Pause Hold is __...

Страница 60: ...e evaluation period The following time period values are displayed in this format ___ __ Kw on ___ hh mm on __ __ __ mm dd yy day of the week since __ __ hh mm on __ __ __ mm dd yy day of the week Dai...

Страница 61: ...tatus only view of the Properties page Chilled Water System Optimizer v2 CARRIER CORPORATION 2019 Installation and Start up Guide 57 All rights reserved Point Name Description Yearly Usage Year To Dat...

Страница 62: ...1 Set the CHWS Optimizer ON Switch to DISABLED 3 Condenser Water Temperature Optimizer Reset Section 1 Set the CWS Optimizer ON Switch to DISABLED At the top of the Properties page there is a quick o...

Страница 63: ...bled is checked D D Unlocked checked Enabled checked Outdoor Air Humidity Allows using another controller s relative humidity value over the network The remote controller must be equipped with a netwo...

Страница 64: ...BLED DISABLED 2 AND is the Plant ON via the Plant ON binary network input This input runs the optimization program only when the plant is appropriately enabled and running AND is at least one chiller...

Страница 65: ...imizer Reset if Load is __ of capacity D R 90 60 to 90 hysteresis of __ D R 5 5 to 10 6 AND is the Chilled Water Temperature Difference return supply across the chiller evaporator great enough Set a m...

Страница 66: ...r operation OFF 1 If the comm is lost for _ __ mm ss or more Time since loss of comm _ __ mm ss Displays status D R 1 00 mm ss 0 00 to 5 00 mm ss 2 OR if __ or more comm losses occur D R 3 2 to 5 with...

Страница 67: ...Range The following are statuses displayed from the linked network points See Device Address Binding page 45 Total Chiller kW Displays value Total Chilled Water Pump kW Displays value If Amp network...

Страница 68: ...Is the CH1 power input above in Amps OR kW Default is kW D R kW Amps kW If Amps The chiller voltage is ___ volts Enter value If Amps Power Factor is ___ Enter value CH1 Nominal Capacity is ___ tons En...

Страница 69: ...Reset are running Stagger Reset alternates between the chilled water reset and the condenser water reset calculations When on the program first resets the chilled water supply temperature and calcula...

Страница 70: ...e changed within 2 minutes after each new setpoint is determined If the operator delays changing the setpoint then the optimizer begins losing effectiveness in saving energy The optimizer calculates t...

Страница 71: ...r is calculating next setpoint NEW SETPOINT optimizer has new setpoint and is ready for acceptance WAITING TURN setpoint calculation is waiting when stagger is ON PAUSE IS ON displays when pause is ON...

Страница 72: ...MOTE INPUT Displays value Allows lockout if Lock at value is checked Allows communication if Enabled is checked D D Unlocked checked Enabled checked 16 CHWS TEMP REMOTE INPUT Displays value Allows loc...

Страница 73: ...n i Vu Properties Control Program Chilled Water Temperature Optimizer Reset Section 1 Chilled Water System Optimizer Enable Conditions Point Name Description Range 1 CHWS Optimizer ON Switch Displays...

Страница 74: ...n happen as the chilled water supply temperature rises faster than the chilled water return temperature This could create low load conditions across the chiller and could cycle off too often The chill...

Страница 75: ...ure difference and encourages chiller stability Input your preferred low temperature trip point and delay NOTE This low temperature trip point should be below the pause trip point since the pause is t...

Страница 76: ...ys value D R 4 00 mm ss 2 00 to 10 00 mm ss 3 OR Pause Reset if Building Relative Humidity is __ D R 60 50 to 100 with hysteresis of __ D R 2 2 to 10 for __ __ mm ss Present output is False for __ __...

Страница 77: ...tput is False for __ __ mm ss Displays value D R 1 00 mm ss 1 00 to 3 00 mm ss Building Occupancy Status ___ Mode Displays status Total Cool Request _ __ Displays value 2 OR Drop chws temperature if c...

Страница 78: ...ncy Cool Down Response Time in Minutes 3 min to 30 max __ minutes Current interval time is _ __ minutes and _ __ seconds Displays values Use Emergency Cool Down Response Time __ NOTE You can use this...

Страница 79: ...ed by the equipment NOTE The deg designation does not indicate actual degrees but the 0 10 output range of the algorithm that is converted into an actual temperature EXAMPLE The 0 10 deg reset range m...

Страница 80: ...ls down by the same amount each Response Time set in the following section The cool down continues until minimum reset is reached To turn off Quick Cool Down select Off and the program begins again st...

Страница 81: ...fting the output too much Input settings 0 no smoothing 1 automatic minimal smoothing Up to 100 maximum smoothing or dampening D R 50 0 to 100 System Response time in minutes 3 min to 30 max __ minute...

Страница 82: ...hange to determine if it saves energy Minimum Reset Increment __ deg output units 0 10 The minimum allowed output increment for each response interval EXAMPLE If you set this value to 1 0 deg the prog...

Страница 83: ...ain between 0 and 10 D R Off Off On Fine gain for bias for reset toward warmer CHWS temps 0 min to 10 max This adds another fine adjustment to the small bias above increases bias for warmer temperatur...

Страница 84: ...h Section 2 Manual Overrides of Condenser Water Reset and other Settings page 83 First Reset Each response period the program determines the next reset signal that best lowers energy demand The 0 10 d...

Страница 85: ...NABLED Optimized Condenser Water Supply Setpoint AV wetb approach BAV Displays value Lock the CWS temperature setpoint output Locks above setpoint to a specific value D R Off Off On To __ degrees real...

Страница 86: ...f Lock at value is checked Allows communication if Enabled is checked D D Unlocked unchecked Enabled checked Section 1 Condenser Water System Optimizer Enable Conditions Navigation i Vu Properties Con...

Страница 87: ...Off Off REINITIALIZE Pause CWS reset algorithm holds logic at current state and output Select PAUSE to manually pause the condenser water supply reset When you no longer need the pause select OFF to...

Страница 88: ...perature increment is too small then the system won t experience enough temperature change to determine if it saves energy The program measures the decrease or possible increase in kW ton from this fi...

Страница 89: ...e may be between 5 and 10 minutes Towers next to the mechanical room may be between 3 and 5 minutes D R 8 minutes 3 to 30 minutes Minimum and Maximum Reset Increments Algorithm Reset Gain Each respons...

Страница 90: ...less than the minimum increment and no more than the maximum increment D R 5 1 to 10 Reset Increment Fine Gain 0 min to 10 max A fine gain that is added to each increment It can be combined with the a...

Страница 91: ...of 5 F D R 8 F 7 to 9 F Resting Use CWS Setpoint __ degrees The default temperature or resting condenser water temperature setpoint when the optimization program is off D R 75 F 72 to 78 F Instead of...

Страница 92: ...between these points If the low limit temperature profile is not known set the same low limit temperature for each Low CWS Temp Setpoint limit at 20 Chiller capacity __ degrees D R 57 F 55 to 78 F Low...

Страница 93: ...Current High Approach is Displays value Current Setpoint is Displays value Current Low Approach is Displays value Current Low Limit is Displays value Electric Metering Combined kW of Monitored Equipme...

Страница 94: ...__ __ __ mm dd yy day of the week Daily Peak Demand Today Displays values and times in the above format Previous Day Displays values and times in the above format Monthly Peak Demand Month To Date Dis...

Страница 95: ...stem CW Setpoint X System CW Setpoint ANO This value is optimized CW setpoint value and is pushed down to the incumbent control system CW Setpoint Heartbeat O CW setpoint comm verification signal to i...

Страница 96: ...rimary secondary tertiary Condenser water pumps Max 20 CW pump power X Power per pump ANI Optimizer supports a maximum of 10 kW inputs and 10 amp inputs Cooling tower fans Max 20 Cooling tower fan pow...

Страница 97: ...raphics and download for i Vu v7 Manual Intervention to accommodate Union or other worker requirements Converted optimizer enable chilled water reset enable condenser water reset enable and pauses to...

Страница 98: ......

Страница 99: ......

Страница 100: ...CARRIER CORPORATION 2019 A member of the United Technologies Corporation family Stock symbol UTX Catalog No 11 808 574 01 6 25 2019...

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