Controls, Start-Up, Operation, Service and ... - Climayoreo

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NOTE: “Error” is clamped between –10 and +50 and “Error rate” is clamped between –5 and +5. This “SUM” will be compared against the “Z” calculations in determining whether cooling stages should be added or subtracted. Z Calculation — For the “Z” calculation, the control attempts to determine the entering and the leaving-air temperature of the evaporator coil and based upon the difference between the two during mechanical cooling, determines whether to add or subtract a stage of cooling. This is the adaptive element. The entering-air temperature is referred to as MAT (mixed-air temperature) and the leaving-air temperature of the evaporator coil is referred to as EDT (evaporator discharge temperature). They are found at the local display under the TemperaturesCTRL sub-menu. The main elements to be calculated and used in the calculation of SumZ are: 1) the rise per percent capacity (R.PCT) 2) the amount of expected rise for the next cooling stage addition 3) the amount of expected rise for the next cooling stage subtraction The calculation of “Z” requires two variables, Z.PLU used when adding a stage and Z.MIN used when subtracting a stage. They are calculated with the following formulas: Z.PLU = Z.GN * (10 + (4*(–ADD.R))) * 0.6 Z.MIN = Z.GN * (–10 + (4*(–SUB.R))) * 0.6 Where: Z.GN = configuration used to modify the threshold levels used for staging (ConfigurationCOOLZ.GN) ADD.R = R.PCT * (C.CAP – capacity after adding a cooling stage) SUB.R = R.PCT * (C.CAP – capacity after subtracting a cooling stage) Both of these terms, Z.PLU and Z.MIN, represent a threshold both positive and negative upon which the “SUM” calculation must build up to in order to cause the compressor to stage up or down. Comparing SUM and Z — The “SUM” calculation is compared against Z.PLU and Z.MIN. • If “SUM” rises above Z.PLU, a cooling stage is added. • If “SUM” falls below Z.MIN, a cooling stage is subtracted. There is a variable called SMZ which is described in the reference section and which can simplify the task of watching the demand build up or down over time. It is calculated as follows: If SUM is positive: SMZ = 100*(SUM/Z.PLU) If SUM is negative: SMZ = 100*(SUM/Z.MIN) Mixed Air Temperature Calculation (MAT) — The mixedair temperature is calculated and is a function of the economizer position. Additionally there are some calculations in the control which can zero in over time on the relationship of return and outside air as a function of economizer position. There are two configurations which relate to the calculation of “MAT”. These configurations can be located at the local display under ConfigurationUNIT. ITEM EXPANSION RANGE CCN POINT DEFAULTS UNIT UNIT CONFIGURATION MAT.S MAT Calc Config 0 - 2 MAT_SEL 1 MAT.R Reset MAT Table Entries? Yes/No MATRESET No 52 MAT Calc Config (MAT.S) — This configuration gives the user three options in the processing of the mixed-air temperature (MAT) calculation: • MAT.S = 0 There will be no MAT calculation. • MAT.S = 1 The control will attempt to learn MAT over time. Any time the system is in a vent mode and the economizer stays at a particular position for long enough, MAT = EDT. Using this, the control has an internal table whereby it can more closely determine the true MAT value. • MAT.S = 2 The control will stop learning and use whatever the control has already learned. Using this setting infers that the control has spent some time set to MAT.S = 1. First set MAT.S = 1. Then go into the Service Test mode, turn on the fan and open the economizer to a static position for 5 minutes. Move to several positions (20%,40%,60%,80%). It is important that the difference between return and outside temperature be greater than 5 degrees. (The greater the delta, the better). When done, set MAT.S = 2 and the system has been commissioned. Reset MAT Table Entries? (MAT.R) — This configuration allows the user to reset the internally stored MAT learned configuration data back to the default values. The defaults are set to a linear relationship between the economizer damper position and OAT and RAT in the calculation of MAT. SumZ Overrides — There are a number of overrides to the SumZ algorithm which may add or subtract stages of cooling. • High Temp Cap Override (H.TMP) • Low Temp Cap Override (L.TMP) • Pull Down Cap Override (PULL) • Slow Change Cap Override (SLOW) Economizer Trim Override — The unit may drop stages of cooling when the economizer is performing free cooling and the configuration ConfigurationECONE.TRM is set to Yes. The economizer controls to the same supply air set point as mechanical cooling does for SumZ when E.TRM = Yes. This allows for much tighter temperature control as well as cutting down on the cycling of compressors. For a long cooling session where the outside-air temperature may drop over time, there may be a point at which the economizer has closed down far enough were the unit could remove a cooling stage and open up the economizer further to make up the difference. Mechanical Cooling Lockout (ConfigurationCOOL MC.LO) — This configuration allows a configurable outsideair temperature set point below which mechanical cooling will be completely locked out. DEMAND LIMIT CONTROL — Demand Limit Control may override the cooling algorithm and clamp or shed cooling capacity during run time. The term Demand Limit Control refers to the restriction of the machine capacity to control the amount of power that a machine will use. Demand limit control is intended to interface with an external Loadshed Device either through CCN communications, external switches, or 4 to 20 mA input. The control has the capability of loadshedding and limiting in 3 ways: • Two discrete inputs tied to configurable demand limit set point percentages. • An external 4 to 20 mA input that can reset capacity back linearly to a set point percentage. • CCN loadshed functionality. NOTE: It is also possible to force the demand limit variable (Run StatusCOOLDEM.L).
To use Demand Limiting, select the type of demand limiting to use. This is done with the Demand Limit Select configuration (ConfigurationDMD.LDM.L.S). To view the current demand limiting currently in effect, look at Run StatusCOOLDEM.L. The configurations associated with demand limiting can be viewed at the local display at ConfigurationDMD.L. See Table 39. Demand Limit Select (DM.L.S) — This configuration determines the type of demand limiting. • 0 = NONE — Demand Limiting not configured. • 1 = 2 SWITCHES — This will enable switch input demand limiting using the switch inputs connected to the CEM board. Connections should be made to TB202 terminals 1,2,3, and 4. • 2 = 4 to 20 mA — This will enable the use of a remote 4 to 20 mA demand limit signal. The CEM module must be used. The 4 to 20 mA signal must come from an externally sourced controller and should be connected to TB202 terminals 10 and 11. • 3 = CCN LOADSHED — This will allow for loadshed and red lining through CCN communications. Two-Switch Demand Limiting (DM.L.S = 1) — This type of demand limiting utilizes two discrete inputs: Demand Limit Switch 1 Setpoint (D.L.S1) — Dmd Limit Switch Setpoint 1 (0-100% total capacity) Demand Limit 2 Setpoint (D.L.S2) — Dmd Limit Switch Setpoint 2 (0-100% total capacity) The state of the discrete switch inputs can be found at the local display: InputsGEN.IDL.S1 InputsGEN.IDL.S2 The following table illustrates the demand limiting (Run StatusCOOLDEM.L) that will be in effect based on the logic of the applied switches: Switch Status Run StatusCOOLDEM.L = 1 InputsGEN.IDL.S1 = OFF 100% InputsGEN.IDL.S2 = OFF InputsGEN.IDL.S1= ON InputsGEN.IDL.S2 = OFF ConfigurationDMD.LD.L.S1 InputsGEN.IDL.S1= ON InputsGEN.IDL.S2 = ON ConfigurationDMD.LD.L.S2 InputsGEN.IDL.S1= OFF InputsGEN.IDL.S2 = ON ConfigurationDMD.LD.L.S2 4-20 mA Demand Limiting (DM.L.S = 2) — If the unit has been configured for 4 to 20 mA demand limiting, then the Inputs4-20DML.M value is used to determine the amount of demand limiting in effect (Run StatusCOOLDEM.L). The Demand Limit at 20 mA (D.L.20) configuration must be set. This is the configured demand limit corresponding to a 20 mA input (0 to 100%). The value of percentage reset is determined by a linear interpolation from 0% to “D.L.20”% based on the Inputs 4-20DML.M input value. The following examples illustrate the demand limiting (Run StatusCOOLDEM.L) that will be in effect based on amount of current seen at the 4 to 20 mA input, DML.M. D.L.20 = 80% D.L.20 = 80% D.L.20 = 80% DML.M = 4mA DML.M = 12 mA DML.M = 20mA DEM.L = 100% DEM.L = 90% DEM.L = 80% CCN Loadshed Demand Limiting (DM.L.S = 3) — If the unit has been configured for CCN Loadshed Demand Limiting, then the demand limiting variable (Run StatusCOOL DEM.L) is controlled via CCN commands. 53 The relevant configurations for this type of demand limiting are: Loadshed Group Number (SH.NM) — CCN Loadshed Group number Loadshed Demand Delta (SH.DL) — CCN Loadshed Demand Delta Maximum Loadshed Time (SH.TM) — CCN Maximum Loadshed time The Loadshed Group Number (SH.NM) corresponds to the loadshed supervisory device that resides elsewhere on the CCN network and broadcasts loadshed and redline commands to its associated equipment parts. The SH.NM variable will default to zero which is an invalid group number. This allows the loadshed function to be disabled until configured. Upon reception of a redline command, the machine will be prevented from starting if it is not running. If it is running, then DEM.L is set equal to the current running cooling capacity (Run StatusCOOLC.CAP). Upon reception of a loadshed command, the DEM.L variable is set to the current running cooling capacity (Run Status COOLC.CAP) minus the configured Loadshed Demand Delta (SH.DL). A redline command or loadshed command will stay in effect until a Cancel redline or Cancel loadshed command is received, or until the configurable Maximum Loadshed time (SH.TM) has elapsed. HEAD PRESSURE CONTROL — Condenser head pressure for the 48/50P Series is managed directly by the ComfortLink controls. The controls are able to cycle up to 6 stages of outdoor fans to maintain acceptable head pressure. Fan stages will be turned on or off in reaction to discharge pressure sensors with the pressure converted to the corresponding saturated condensing temperature. An option to allow fan speed control (Motormaster ® ) on the first stage is configured by setting ConfigurationCOOLM.M = Yes. There are three configurations provided for head pressure control that can be found at the local display: ConfigurationCOOLM.M (MotorMaster enable) ConfigurationCOOLSCT.H (Maximum Condensing Temp) ConfigurationCOOLSCT.L (Minimum Condensing Temp) There are up to four outputs provided to control head pressure: OutputsFANSCDF.1 – Condenser Fan Output 1 OutputsFANSCDF.2 – Condenser Fan Output 2 OutputsFANSCDF.3 – Condenser Fan Output 3 OutputsFANSCDF.4 – Condenser Fan Output 4 The specific staging sequence for a unit depends on the 3 factors: the unit size (tonnage), which refrigeration circuits are currently operating, and whether or not MotorMaster is enabled. See Fig. 7 for fan staging sequencing. The condenser fan output controls outdoor fan contactors and outdoor fans for each unit tonnage as shown in Fig. 7. Each stage of fans is also shown. The ComfortLink controller adds or subtracts stages of fans based on SCT.H and SCT.L. When the SCT is above SCT.H for 30 seconds, a fan stage will be added. When the SCT is below SCT.L for 30 seconds, a fan stage will be subtracted. When a condenser fan output is common to both refrigeration circuits, in other words when the fan(s) will affect both circuit A and circuit B, the following logic is used: in order to add a fan stage, the SCT of either circuit must be above SCT.H for 30 seconds and in order to subtract a stage, the SCT of both circuits must be below SCT.L for 30 seconds.
Page 1 and 2: Controls, Start-Up, Operation, Serv
Page 3 and 4: WARNING What to do if you smell gas
Page 5 and 6: and the ENTER keys until the desire
Page 7 and 8: START-UP IMPORTANT: Do not attempt
Page 9 and 10: Table 4 — Fan Performance — 48P
Page 15 and 16: AIRFLOW (cfm) Table 10 — Fan Perf
Page 23 and 24: AIRFLOW (Cfm) LEGEND Table 18 — F
Page 29 and 30: AIRFLOW (cfm) LEGEND Bhp — Brake
Page 31 and 32: HIGH-EFFICIENCY MOTORS Nominal Maxi
Page 33 and 34: 2. Under the Setpoints menu, set th
Page 35 and 36: would use Period 2 and set days Sat
Page 37 and 38: there is a loss of communication be
Page 39 and 40: and when ON, the control sets a cap
Page 41 and 42: System Mode Test — When the syste
Page 43 and 44: Table 31 — Unit Configuration ITE
Page 45 and 46: SETTING UP THE SYSTEM Machine Contr
Page 47 and 48: High SST Alert Delay Time (H.SST)
Page 49 and 50: Table 36 — Cool/Heat Set Point Of
Page 51: Table 38 — Run Status Cool Displa
Page 55 and 56: Size 050, 055, 060 Contactor OFM(s)
Page 57 and 58: Whenever the outdoor ambient temper
Page 59 and 60: Demand Level Low Heat Off Offset (L
Page 61 and 62: Limit Switch Low Temp (SW.L.T) —
Page 63 and 64: STAGE Table 49 — IGC LED Indicato
Page 65 and 66: Table 50 — Static Pressure Contro
Page 67 and 68: Table 53 — Dirty Filter Switch Po
Page 69 and 70: NOTE: If the user wishes to disable
Page 71 and 72: the economizer modulates when attem
Page 73 and 74: P = K * BP.P * (error) I = K * BP.I
Page 75 and 76: its smoke. Closing the economizer (
Page 77 and 78: Table 57 — Indoor Air Quality Con
Page 79 and 80: Table 58 — Humidity Configuration
Page 81 and 82: The default sensor is the return ai
Page 83 and 84: TEMPERATURE COMPENSATED START LOGIC
Page 85 and 86: Sensor Trim Configuration — The T
Page 87 and 88: SUPPLY FAN VFD CONFIGURATION — Th
Page 89 and 90: REMOTE SWITCH LOGIC CONFIGURATION (
Page 91 and 92: Alarms and Alarm History for for an
Page 93 and 94: Transducer Troubleshooting — The
Page 95 and 96: Table 75 — 10K Thermistor vs Resi
Page 97 and 98: TEMP RESISTANCE (F) (Ohms) -25 98,0
Page 99 and 100: PRESSURE (PSIG) Table 80 — Suctio
Page 101 and 102: Table 81 — Discharge Pressure Tra
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Table 82 — Auto View of Run Statu
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Table 84 — Cooling Information Di
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equalize compressor oil levels. If
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Table 91 — Alert and Alarm Codes
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T072 (Evaporator Discharge Reset Se
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This alarm will disable mechanical
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This is the reverse of the Pressuri
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117 a48-8408 Fig. 19 — Typical Po
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OD ENTHALPY SWITCH LOW REMOTE OCCUP
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Fig. 23 — Typical Electric Heat U
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123 Fig. 25 — Typical Gas Heat Se
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125 Fig. 27 — Component Arrangeme
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ACCSY — Accessory ACC’Y — Acc
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Table 93 — Rooftop Control Board
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Table 96 — Control Expansion Modu
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LEGEND IAQ — Indoor Air Quality V
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the motor position to be configured
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TIME EWT LWT SETP Run Status Servic
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Fig. 37 — Door Latch Fig. 38 —
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SUPPLY FAN AND POWER EXHAUST MOTOR
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Routine cleaning of coil surfaces i
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Saturated Discharge Temperature (de
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Gas System Adjustment (48P Only) GA
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APPENDIX A — LOCAL DISPLAY TABLES
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APPENDIX B — CCN TABLES (cont) ST
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APPENDIX B — CCN TABLES (cont) ST
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APPENDIX B — CCN TABLES (cont) SE
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APPENDIX B — CCN TABLES (cont) MA
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APPENDIX B — CCN TABLES (cont) MA
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TESTACTC TESTCOOL TESTFANS TESTHEAT
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APPENDIX C — UNIT STAGING TABLES
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* 41 for Supply Fan Motor VFD, 42 f
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Fig. B — VFD Keypad START UP WITH
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Upload All Parameters — To upload
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To replace the main fan for frame s
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ALARM CODE ALARM NAME IN PANEL 2001
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APPENDIX E — MODE SELECTION PROCE
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CONTROLS SET POINT AND CONFIGURATIO
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Controls, Start-Up, Operation, Service and ... - Climayoreo

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