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Operating & Maintenance Manual

OMM 1008-1

Group:

Chiller

Part Number:

332830001

Effective:

November 17, 2010

Supersedes:

April 2010

Magnitude™ Magnetic Bearing Chillers

Model WMC 145SBS – 400DBS

OITS Software Version: 2.01.01

Control Software Version: WMCU3UU02B

Содержание Magnitude WMC 145SBS - 400DBS

Страница 1: ...ual OMM 1008 1 Group Chiller Part Number 332830001 Effective November 17 2010 Supersedes April 2010 Magnitude Magnetic Bearing Chillers Model WMC 145SBS 400DBS OITS Software Version 2 01 01 Control So...

Страница 2: ...u Screens 55 Menu Matrix 56 Compressor Controller Menu Screens 72 Menu Matrix 72 BAS Interface 74 Sequence of Operation 74 Operating the Chiller Control System 75 Interface Panel On Off 75 Start Stop...

Страница 3: ...the panel NOTICE This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with this instruction manual may cause interference to radio communica...

Страница 4: ...ls of security protection against unauthorized changing of setpoints and other control parameters Plain language warning and fault diagnostics to inform operators of most warning or fault conditions W...

Страница 5: ...F and it has a dead band of 2 0 degrees F nothing will happen until the measured temperature is less than 42 F or more than 46 F DIN Digital input usually followed by a number designating the number o...

Страница 6: ...er temperature It is calculated by taking readings of the temperature every few seconds and subtracting them from the previous value over a rolling one minute interval ms Milli second Maximum Saturate...

Страница 7: ...ssor or fan and stopping the last compressor or fan The Delta T is the dead band on either side the setpoint in which no action is taken Stage Up Delay The time delay from the start of the first compr...

Страница 8: ...g operation The operator can monitor all operating conditions by using the unit mounted OITS In addition to providing all normal operating controls the MicroTech II control system monitors equipment p...

Страница 9: ...ate independently from the chiller control the breaker has no effect The unit controller s function is acquiring and processing data relating to the chiller operation and issueing instructions to vari...

Страница 10: ...power while the chiller is running can cause severe compressor damage The necessary procedure for reconnecting power from the generator back to the utility grid is show below These procedures are not...

Страница 11: ...tory 3 For the pCo2 controller the pLAN address can be confirmed by viewing the DIP switch positions and comparing to the table above Bin rows There are six Binary DIP Switches Up is On indicated by 1...

Страница 12: ...ion Setup 1 With no communication connections between chillers disconnect control power and set the pLan address as shown in Table 1 2 With all manual switches off turn on control power to each chille...

Страница 13: ...e is reduced the amount of power to pump a given amount of gas also is reduced The reduction can result in significant energy savings However as with most centrifugal chiller applications a tower bypa...

Страница 14: ...ol panel located adjacent to the Interface Panel has switches inside the panel for stopping the entire unit or individual compressors When the UNIT switch is placed in the OFF position the chiller wil...

Страница 15: ...g commands and entries into the control system Settings can also be made directly into the unit controller The OITS can also display controller data and information on a series of graphic screens A si...

Страница 16: ...where a particular screen is located 2 Knowing what is contained in a menu screen and how to read that information or how to change a setpoint contained in the menu screen Navigating The menus are ar...

Страница 17: ...ay from a data screen to a menu screen Menu selections are then made using the arrow keys according to labels on the right side of the display the arrows are ignored When the last menu item is selecte...

Страница 18: ...ription Load Output OFF Output ON 1 Evaporator Water Pump 1 Pump Contactor Pump OFF Pump ON 2 Evaporator Water Pump 2 Pump Contactor Pump OFF Pump ON 3 Condenser Water Pump 1 Pump Contactor Pump OFF P...

Страница 19: ...20 to 80 N T Maximum Amps 100 40 to 100 N T Soft Load OFF OFF ON D M Begin Amp Limit 40 20 to 100 N M Soft Load Ramp 5 min 1 to 60 min D M Maximum Rate 0 5 F min 0 1 to 5 0 F min D M Minimum Rate 0 1...

Страница 20: ...N M Stage Up 80 0 to 100 N M Valve Control Range Min 10 0 to 100 N M Valve Control Range Max 90 0 to 100 N M Valve Type NC To Tower NC NO N M Minimum Start Position 0 0 to 100 N M Minimum Position 60...

Страница 21: ...t AND leaving water reset is based on entering water Reset mode is set to No Reset Manual Reset mode goes back to Entering Water Warnings The following alarms only generate a warning message to the op...

Страница 22: ...oint Max Reset Delta T setpoint when the evaporator return leaving water temperature delta varies from the Start Reset Delta T setpoint to 0 The Active Leaving Water variable is set equal to the Cool...

Страница 23: ...s unavailable Inputs and outputs are as follows Table 9 Compressor Controller Analog Inputs Description Signal Source Range 1 2 Spare 3 Motor Current 0 to 5 VDC 0 to 125 RLA Table 10 Compressor Contro...

Страница 24: ...for 30 sec Annunciation Starter Fault Starter Fault Digital Input Fault AND Compressor State START INTLOK RUN or UNLOAD Rapid Stop Leaving Evaporator Water Temperature Sensor Fault Sensor shorted or...

Страница 25: ...on run hours 3 The above two modes can be combined so that there are two or more groups where all compressors in the first group are started based on number of starts hours before any in the second g...

Страница 26: ...loading or unloading ensues considering any capacity overrides that may be in effect Capacity Overrides The conditions described in the following subparagraphs override normal capacity control when th...

Страница 27: ...LWT Rate The maximum rate at which the leaving water temperature can drop chiller mode COOL is limited at all times by the Maximum Rate setpoint If the rate exceeds this setpoint capacity increases is...

Страница 28: ...ne Rectifier SCR temperature Speed Line currents Guide vane position Soft Start Controller the soft start controller limits current inrush by temporarily inserting a charging resistor between the ac l...

Страница 29: ...STAGE STARTER COOLING TOWER SECOND STAGE STARTER COOLING TOWER THIRD STAGE STARTER COOLING TOWER FOURTH STAGE STARTER NOTE10 H A O C3 NOTE10 H A O NOTE10 NOTE10 79 78 77 74 73 REMOTE ON OFF NOTE5 54...

Страница 30: ...oil rated condenser water pump relay CP1 2 is to be wired as shown Units with free cooling must have condenser water above 60 F before starting 10 Optional customer supplied 115 VAC 25 VA maximum coil...

Страница 31: ...EACH GROUP OF SETPOINTS HAVE SETTING AND RANGE EXPLAINED ON SCREEN HISTORY PRESS HISTORY PRESS VIEW SET SCREENS HOME SCREEN VIEW SCREEN COMPRESSOR STATE COMPRESSOR I O UNIT I O EVAPORATOR CONDENSER V...

Страница 32: ...he device or signal that created the STATE The possible combinations are in the following table Table 15 UNIT STATUS Combinations MODES STATES SOURCES COOL OFF Manual Switch SHUTDOWN Note 1 Remote Swi...

Страница 33: ...ence NOTES 1 Timer countdown values will be shown where xxx is shown below 2 Vanes or Speed is shown in the RUN state to indicate if the capacity is controlled by speed from the VFD or by vane control...

Страница 34: ...that will toggle between the two compressors data allowing the STATE and I O detail screens to be viewed for either compressor Pressing the UNIT I O button displays the unit inputs and outputs as desc...

Страница 35: ...sor State screen is basically a compilation of the events that the chiller sequences through at startup A green light light gray in the figure indicates that a particular sequence requirement has been...

Страница 36: ...d corner of the Detail View Screen This button will toggle compressor data from 1 compressor to 2 compressor Figure 15 Unit Input Output Screen The screen shown in Figure 15 to the left gives the stat...

Страница 37: ...with equipment of this type MicroTech II provides an extremely simple method for accomplishing this NOTE If the Interface Panel is unavailable the unit controller can be used to change setpoints Appro...

Страница 38: ...tons in the second from right column are pressed to select a particular setpoint The selected setpoint will appear in blue on the screen and a description of it with the range of available settings wi...

Страница 39: ...transaction Some setpoints are text rather than numeric values For example LWT Reset Type can be None or 4 20 ma The selection can be made by toggling between choices using the UP or Down button If da...

Страница 40: ...considered fully open Interlock Timer 4 10 sec 10 to 240 seconds M Maximum time allowed before interlock confirmation from compressor Stop Start Timer 3 3 min 3 to 20 min M Time from when compressor...

Страница 41: ...s Active only if ST SP7 at start Surge Temperature Limit 7 50 F 2 to 45 F T At start Surge Temp ST is compared to this SP Alarm at ST 2x SP High Discharge Temp Stop 6 190 F 120 to 240 F T Max discharg...

Страница 42: ...ondenser EWT at which initial valve position is set to Setpoint 6 Minimum Start Position 8 10 0 to 100 M Initial position of valve when condenser EWT is at or below Setpoint 7 Stage Down 7 20 0 to 100...

Страница 43: ...M Temperature for fan stage 4 on Stage Differential Lift 7 6 0 psi 1 0 to 20 0 psi M Fan staging deadband with Setpoint 1 Lift Stage Differential Temp 6 3 0 F 1 0 to 10 0 F M Fan staging deadband with...

Страница 44: ...ntrol 1 Tower Fan Staging Only NONE This is not a recommended control strategy The following settings are used for the Tower Fan Staging Only mode SP setpoint a TOWER SETPOINT Screen i SP1 Select TEMP...

Страница 45: ...SP7 Select STAGE DIFFERENTIAL in PSI Start with default of 6 PSI ii SP12 15 Start with default setpoints The number of STAGE ON setpoints used must be the same as SP3 2 VALVE SETPOINT Screen a SP1 Sel...

Страница 46: ...for fan staging and bypass valve field wiring connection points 3 Tower staging with bypass valve controlled by fan stage VALVE STAGE This mode is similar to 2 above except that the bypass valve setpo...

Страница 47: ...ow setpoint Soft Load Ramp Time 7 5 min 1 to 60 min M Time period to go from initial load point RLA set in SP 5 to 100 RLA Initial Soft Load Amp Limit 6 40 10 to 100 M Initial amps as of RLA uses SP4...

Страница 48: ...ciency Pump Standby M Ditto No 9 Max Comp ON 6 1 1 16 M Total number of compressors minus standby BAS Protocol 5 MODBUS None Local BACnet LonWorks MODBUS Remote M Sets BAS Standard Protocol to be used...

Страница 49: ...a T above which Return reset begins LWT Reset Type 5 NONE NONE RETURN 4 20mA M Select reset type NONE for none RETURN for resetting chilled water based on the entering water or 4 20 mA for external an...

Страница 50: ...nch Pounds or Metric units of measure on the OITS SELECT LANGUAGE allows toggling between the available languages The language can be set separately for display or history which is used for alarm and...

Страница 51: ...right hand scale The screen can display history for 8 hour 2 hour or 20 minute periods by pressing 8 2 or 1 3 respectively Pressing NOW for any time period will start the display for the current time...

Страница 52: ...ws Faults shutdowns Red Problems limit alarms Yellow Warnings notifications Dark Blue Download Data This screen is also used to download the Trend History Figure 27 selected by date or the Alarm Histo...

Страница 53: ...splayed Note that the alarms are color coded red for FAULT equipment protection control that causes a rapid compressor shutdown yellow for PROBLEM limit alarm that will inhibit loading or load or unlo...

Страница 54: ...the number 100 for operator 2001 for manager level and press Enter to enter the password The screen will automatically revert back to the previous Set screen This screen will appear automatically when...

Страница 55: ...n to a menu screen Menu selections are then made using the arrow keys according to labels on the right side of the display the arrows are ignored When the last menu item is selected the display change...

Страница 56: ...iquid Line 000 0 o F Lift Press 000 0psi VIEW UNIT TOWER 2 Bypass Valve XXX VFD Speed XXX VIEW COMP 2 psi Cond Press 000 0 Evap Press 000 0 Lift Press 000 0 VIEW COMP 2 2 psi Cond Press 000 0 Evap Pre...

Страница 57: ...T 10 0 o F SET COMP SPs 5 Nom Capacity 0100T SET COMP 2 SPs 5 Nom Capacity 0100T SET ALARM LMTs 5 Evap Freeze 34 0 F Cond Freeze 34 0 F SET TOWER SPs 5 Valve Sp type Valve DB type SET UNIT SPs 6 Soft...

Страница 58: ...be OFF COOL SHUTDOWN and ALARM as determined from the Unit State variable the Unit Mode setpoint and the presence of a unit shutdown alarm Compressor states can be OFF START HOLD LOAD UNLOAD SHUTDN an...

Страница 59: ...Tower Control None VIEW UNIT TOWER 2 Bypass Valve XXX VFD Speed XXX The Bypass Valve value is None in place of XXX if the Valve VFD Control setpoint None or VFD Stage The VFD Speed value shall be None...

Страница 60: ...COMP N 6 psi F SatEvap XXX X XXX X SatCond XXX X XX X VIEW COMP N 7 Hours XXXXX Starts XXXXX The following menus are found only on the compressor controllers and contain detailed information on the co...

Страница 61: ...54 Ver 00136 Ok SCR On VIEW COMP N 14 Psi IGV 020 0 DisC 082 6 024 9 Suct 081 9 00000Alr Intr 000 0 VIEW COMP N 15 Temps Suct 89 4 Cav 093 9 SCR 090 8 Ent 077 4 Disc 090 7 Lev 077 4 VIEW COMP N 16 Mot...

Страница 62: ...etpoint Unit Mode settings can be COOL or TEST as determined from the Unit Mode setpoint TEST mode is not be selectable from the 4x20 display keypad although it may be displayed if already set Source...

Страница 63: ...mp 1 will be started even in event of a failure If 2 Only is selected only pump 2 will be started If Auto is desired the unit will try to balance operating hours on each pump by starting the pump with...

Страница 64: ...s Id 001 Units IP Baud Rate 19200 SET UNIT SPs 15 EX Val Std Values Pos 450 L76 0psi Enthalpy Sp 85 0 F Set Compressor Setpoints NOTE In the following SET COMP screens the N field indicates which comp...

Страница 65: ...chilled water temperature StageSequence is set for each compressor In NORMAL or STANDBY Mode all compressors can have the same number or a number from 1 up to the total number of compressors Sequence...

Страница 66: ...he cumulative time to zero For VFD Set Point YES Load pulsing has exceeded the Full Load set point as described above AND the VFD speed 100 OR The Vanes Open digital input is On AND the VFD speed 100...

Страница 67: ...si HiDschT Load 170 F HiDschT Stop 190 F SET ALARM LMTS 3 WMC Compressor Oilless Design blank mask page SET ALARM LMTS 4 Surge Slp Str 20 F Surge Tmp Run 12 F MtrCurrThrshld 05 CAUTION Only trained co...

Страница 68: ...s 5 Valve SP XXX F Valve SP XXX psi Valve DB XX X F Valve DB XXX Xpsi SET TOWER SPs 6 ValveStartPosition Min 010 060 F Max 100 090 F SET TOWER SPs 7 Valve Control Range Min 010 Max 100 SET TOWER SPs 8...

Страница 69: ...setpoint Lift Bypass valve position is the Stage Down setpoint only if Valve VFD Control setpoint Valve Stage VFD Speed is the Stage Down setpoint only if Valve VFD Control setpoint VFD Stage OR Valv...

Страница 70: ...ition analog output of full scale is updated according to the following equation New Position Old Position Increment 10 Valve Stage Mode This mode is only operational when the Valve VFD Control setpoi...

Страница 71: ...to select units of measure directly from the keypad Systems available are F psi unit controller compressor controller touch screen C kPa touch screen only Security Two four digit passwords provide OP...

Страница 72: ...Sat Evap 000 0 000 0 Sat Cond 000 0 000 0 VIEW COMP 1 State OFF RLA 000 Evap LWT 054 0 o F VIEW EVAPORATOR Suct SH 000 0 o F Approach 00 0o F VIEW CONDENSER Disch SH 000 0 o F Approach 00 0o F Subcool...

Страница 73: ...n Start Start 40 min SET ALARM LMTs 3 WMC Compressor Oilless Design blank mask page SET COMP SPs 4 Full Load 300 sec Name Plate RLA 085 SET ALARM LMTs 4 Surge Slp Str 20 o F Surge Tmp Run 06o F MtrCur...

Страница 74: ...e unit controller of the chiller with the Next On compressor when there are two chillers will start the evaporator pump and determine if there is load based on the water temperature This is determined...

Страница 75: ...The setpoint of Nominal Capacity is used for defining the point to unload a compressor on a single or two chiller system With each compressor having its Nominal Capacity defined then the network which...

Страница 76: ...alarm is wired in it too will be energized There are three types of alarms FAULT equipment protection alarms that shut a unit or compressor off Problem limit alarms that limit compressor loading in r...

Страница 77: ...sion erosion sliming scaling or algae formation It is recommended that the service of a reliable water treatment company be used McQuay International assumes no responsibility for the results of untre...

Страница 78: ...8 Routine Maintenance Refrigerant Cycle Maintenance of the refrigerant cycle includes maintaining a log of the operating conditions and checking that the unit has the proper refrigerant charge At ever...

Страница 79: ...to their weight One method follows After draining water remove all but two head bolts at roughly 10 and 2 o clock Loosen the remaining two bolts to enable the head to be separated from the tube sheet...

Страница 80: ...be leak tested to determine the location of the leak Leak Testing In the case of loss of the entire refrigerant charge the unit must be checked for leaks prior to charging the complete system This ca...

Страница 81: ...If the system is under a vacuum stand the refrigerant drum with the connection up and open the drum and break the vacuum with refrigerant gas to a saturated pressure above freezing 4 With a system gas...

Страница 82: ...Alarm Relay X Pump Interlocks X III Condenser A Performance Evaluation O B Test Water Quality X C Clean Condenser Tubes X D Eddy current Test Tube Wall Thickness X E Seasonal Protection X IV Evaporato...

Страница 83: ...enance Contract For further information concerning the many services available contact your local McQuay Factory Service office Operator Schools Training courses for Magnitude Centrifugal Maintenance...

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Страница 86: ...mcquay com All McQuay equipment is sold pursuant to McQuay s Standard Terms and Conditions of Sale and Limited Product Warranty All McQuay equipment is sold pursuant to McQuay s Standard Terms and Con...

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