Temperature/Pressure Controller User Manual
Contents
1. S S S P1 M1 M1 Fan System P1 P2 Po po M2 BALTIGUARD PLUS Fan S S S System VFD on pony motor S VFD 1 VFD 2 M1 main motor across the line VFD 2 M1 M2 D4 Units Having 3 Main Fan Motors of Equal Size Configuration ST01 ST02 ST03 ST04 ST05 ST06 ST07 S S 1 Speed S 2 M1 a se Be M1 M2 M2 M3 S S S S S i S M1 low M1 high M1 high M1 high 2 ppegd 3 M1 low a M2 low M2low M2high M2 high M3 low M3low M3low M3 high S VFD S VFD 1 VFD 2 S S S S S ENERGY MISER s S Py P1 M1 M1 M1 Fan System P1 P2 P2 P2 M2 M2 P3 P3 P3 M3 BALTIGUARD PLUS S S S S Fan System s VFD 1 M1 M1 M1 s pe VFD on pony motor VFD 2 VFD 2 M2 M2 main motor across the line VFD 3 VFD 3 VFD 3 M3 E Sequence of Operation All Units 1 The system input contact wired between TC7 and TC8 closes and the controller processes the Leaving Water Temperature LWT for Cooling Towers Leaving Fluid Temperature LFT for Closed Circuit Cooling Towers or Discharge Pressure DCP for Evaporative Condensers 2 When the LWT LFT DCP rises above the Upper Deadband UDB Stage 1 STO1 will cycle on after 10 seconds 3 If the LWT LFT DCP remains between the UDB and High Limit HL each additional stage cycles on in ascending order after the Minimum Stage Time MST for the previous stage expires 4 If the LWT LFT DCP rises above the HL each additional stage cycles on after the Override Time ORT for the previous stage expires 5 When the LWT2. VED Variable Frequency Drive C1 Units Having 1 Main Fan Motor Configuration ST01 1 Speed M1 2 Speed M1 low ENERGY MISER Fan System P1 BALTIGUARD PLUS Fan System VFD on pony motor VFD main motor across the line Value SP DB 2 SP DB 2 SP ORM x DB SP ORM x DB ST02 M1 high M1 M1 C2 Units Having 2 Main Motors of Equal Size Configuration ST01 ST02 ST03 ST04 M1 1 Speed M1 M2 3 M1 low M1 high M1 high i WIT IOW M2low M2low MZ high P1 M1 M1 i ENERGY MISER Fan System P1 P2 po M2 TM BALTIGUARD PLUS Fan System VED 1 M4 M1 VFD on pony motor VED 2 VED 2 M2 z3 main motor across the line Excludes Series V units with 2 motors and 1 casing section C3 Units Having 2 Main Fan Motors of Different Size M1 smaller M2 larger Configuration ST02 ST03 ST04 ST05 ST06 M1 1 Speed M1 M2 M2 M1 low M1 high M1 high ASPRpN M1 low M2low M2 low M2low M2high P1 M1 M1 ENERGY MISER Fan System P1 P2 P2 po M2 TM amis Hs era VED 1 VED 1 VED 1 M1 F S AA VFD 2 M1 M2 M2 main motor across the line C4 Units Having 3 Main Fan Motors Configuration ST01 ST02 ST03 ST04 ST05 ST06 M1 1 Speed M1 my M2 M3 M1 low M1 low M1 high Mt high M1 high 2 Speed M1 low M2 low M2 low M2low M2high M2 high M3 low M38low M3low M3 high P1 P1 M1 M1 M1 ENERGY MISER Fan System P1 po P2 P2 M2 M2 P3 P3 P3 M3 BALTIGUARD PLUS Fan System VFD 1 M1 M1 M1 VFD on po
3. enabling and disabling the pony motor the main motor will be enabled and disabled respectively e Pony motor should be enabled when the user would like to operate the pony motor and disable the VFD on the main motor Screen J Pump Status Closed Circuit Cooling Towers and Evaporative Condensers only Spray Pump Status OFF Spray Pump Status OFF Dry Mode PressF0 WET WetMode Presso DRY e Spray Pump Status indicates whether the motor is stopped or running e In Wet Mode the spray pump is used as the first stage for heat rejection In Dry Mode the spray pump is not used and only the fan motors are running Screen K Program Information Frog No wat ELC Rey 0 00 OlRey 0 00 e Program number is the current operating logic of the controller e ELC Rev is the current operating revision of the controller e OI Rev is the current operating revision of the operator interface panel Screen L PID Status VFD only PID parameters Page Down PID Output o0 e PID Output is the value that the controller sends to the analog output 4 20mA Screen M PID Control VFD only Gain Hint Integral Haat e The Gain is the amount by which the controller will increase the output when the leaving water temperature is above the UDB e To change this value press the FO key 12 e The allowable range is 0 1000 recommended starting value 100 e Integral is the frequency by which the controller increases the output when the leaving wate
4. Baltimore Aircoil Company Controller Operating Instructions TABLE OF CONTENTS PSs OVET VIC Wern an a eS O Orin sea A E E dasa E E EA NAARS 1 By System Variables case e E EE E A E EA T AE A EE A A E R E R 2 C Stages of Capacity Cooling TOWETS serieen eoni E E aa Eeen 3 D Stages of Capacity Closed Circuit Cooling Towers and Evaporative Condensers ccceseeeees 5 Es Sequence Of Operation miaran ieren aerae aia Ei e Ae oa E E aa AEE E r Eei eiea 7 F Operator Interface OVervie Weti o seveed ages e a aunts ucduateiseaasu sees dts a a a 9 G Operator Menuss Creenssa iierteecaiasadsiyencdtaaecade statics A E usenet Mkazsagesoegsactelgeaaunag even TAE 10 A Overview Al Installation The controller has been factory installed into the BAC Enclosed Controls Refer to your submittal for descrip tions of components included in your package A2 Temperature or Pressure Sensor A two wire 4 20mA temperature or pressure sensor must be field wired into Enclosed Control terminals TC5 and TC6 per your submittal wiring diagrams for automated control The temperature sensor must be installed at the following locations e Open Cooling Towers Leaving water piping e Closed Circuit Cooling Towers Leaving fluid piping e Evaporative Condensers Compressor discharge piping A flashing red LED on the user interface indicates that the sensor input is either open or out of range A3 System Input Remote A system input remote signal must
5. LFT DCP is between the Lower Deadband LDB and Upper Deadband UDB the number of stages currently operating remains unchanged 6 If the LWT LFT DCP is between the LDB and lower limit LL each additional stage cycles off in descending order only if the MST has expired 7 If the LWT LFT DCP falls below the LL each additional stage cycles off in descending order after the ORT for the previous stage has expired NOTE The MST and ORT are reset each time a stage is cycled on or off Operation Flow Diagram All Units System off All stages are off Temperature or Pressure rises LWT LET DCP rises Stages cycle on in ascending order after between UDB and HL ee min default for previous stage Stages cycle on in ascending order after ORT 1 min default for the previous stage expires LWT LFT DCP rises above HL Temperature or pressure falls Stages cycle off in descending order after Between LBD and LL MST 15 min default for previous stage expires Stages cycle off in descending order after Below LL ORT 1 min default for the previous stage expires See pages 3 6 for Stage descriptions F Operator Interface Overview F1 Changing Screens e When viewing the main screen use the Pg Dn Down button to begin scroll screens If the screen does not change press the Pg Dn Down button multiple times until it changes e Press the Up Pg Up button to return to the previous screen e If the backlight is turned off pres
6. be wired between TC7 and TC8 The controller will operate only when this circuit is closed A4 Startup Confirm that the facility power lines have been properly wired to the BAC Enclosed Controls per the submittal drawings and confirm that all field wiring has been completed Close the Main Circuit Breaker to apply power to the Enclosed Controls Once the system input remote contact closes digital input X0 the controller will operate the unit according to Section E Sequence of Operation BAC recommends that the PID Autotune function see User Interface screens for your unit be performed when controlling a VFD This function automatically sets the Gain Integral and Differential per system settings The Autotune function monitors VFD operation for a period of 20 minutes and adjusts accordingly Additional adjustments may be required as the load varies B System Variables B1 User Adjustable Variables ariable Description Default Range Set Point e Value at which desired leaving water temperature LWT is maintained LWT must be above upper deadband UDB or below lower deadband LDB for 10 seconds before any action is taken Set Point e Value at which desired leaving fluid temperature LFT is maintained e LFT must be above UDB or below LDB for 10 seconds before any action is taken Set Point e Value at which desired discharge pressure DCP is maintained DCP must be above UDB or below LDB for 10 seconds before any action is ta
7. ken SP Open Cooling Towers SP Closed Circuit Cooling Towers SP Evaporative Condensers Deadband Range e Range in which no action occurs Deadband range is DB 2 above and below the set point Minimum Stage Time e Minimum period of time that the stage operates before cycling e Timer begins when stage cycles on or off Minimum On Time e Minimum period of time that the spray pump motor operates before cycling e Timer begins when spray pump cycles on Stage Override Time e Minimum period of time that the stage operates before cycling overridden above HL and below LL Stage Override Multiplier See high limit HL and low limit LL descriptions for details Gain Used for manual tuning of PID only O 1000 Integral Used for manual tuning of PID only O 1000 Differential Used for manual tuning of PID only 0 100 B2 Internal Variables Description Variable UDB Upper Deadband e Value at which stages turn on for increased capacity LDB Lower Deadband e Value at which stages turn off for decreased capacity High Limit HL e Value above set point which will cause immediate increase in stages for increased capacity Low Limit LL e Value below set point which will cause immediate decrease in stages for decreased capacity C Stages of Capacity Open Cooling Towers Legend M Main fan motor across the line P Pony fan motor across the line High High speed winding Low Low speed winding
8. ny motor VFD 2 VFD 2 M2 M2 main motor across the line VFD 3 VFD 3 VFD3 M3 D Stages of Capacity Closed Circuit Cooling Towers and Evaporative Condensers Legend Soinissa All spray pump motors M Main fan motor across the line P Pony fan motor across the line High High speed winding Low Low speed winding VFD Variable Frequency Drive D1 Units having 1 Main Fan Motor Configuration ST01 ST02 ST03 S 1 Speed S M1 s S S eopeee gt M1 low M1 high S VFD VFD1 ENERGY MISER Fan System S 3 gt y P1 M1 BALTIGUARD PLUS Fan System VFD on pony motor S gt 3 VFD1 M1 main motor across the line D2 Units Having 2 Main Fan Motors of Equal Size Configuration ST01 ST02 ST03 ST04 ST05 s S 1 Speed S M1 M1 M2 s S S S 2 Speed S M1 low M1 low M1 high M1 high M2 low M2 low M2 high S VFD S VFD1 VFD2 7 n n a7 5 l G co SOO ENERGY MISER Fan System S P1 M1 M1 P2 P2 M2 BALTIGUARD PLUS Fan System S S S VFD on pony motor S VFD1 M1 M1 main motor across the line VFD2 VFD2 M2 Excludes Series V Units with 2 motors and 1 casing section D3 Units Having 2 Main Fan Motors of Different Size M1 smaller M2 larger Configuration ST01 ST02 ST03 ST04 ST05 ST06 S S S 1 Speed S M1 M1 M2 M2 S S S S S 2 Speed S M1 low M1 high M1 high Milow M2low M2iw M2low M2high S VFD S VFD 1 VFD 2 7 ee eee a en S S So ENERGY MISER
9. of the leaving fluid from the unit e Set Point is the temperature the controller will attempt to maintain by cycling the cooling tower motor s e To change the set point press the FO key Screen C Discharge Pressure Monitoring Evaporative Condensers only Discharge pressure 0 0 Set Point Hit t e Discharge Pressure is the current value in PSIG of the compressor discharge e Set Point is the pressure the controller will attempt to maintain by cycling the cooling tower fan e To change the set point press the FO key Screen D Controller Status Remote Signal OFF Sensor Status OK e RemoteSignal is the run enable signal required by the controller to turn the motor on field wired between TC7 and TC8 Once the system input contact closes the controller will cycle the cooling tower motor s to maintain the set point e Sensor Status indicates when the remote sensor signal is being received by the controller If the sensor signal fails open the Alarm light on the operator interface will flash and the controller will shut down the motor s Screen E Control Data Dead band Time Over ride mutipier e Deadband is the range above and below the set point within which no action is taken see LDB and UDB calculations on page 3 For example a deadband of 5 signals the controller to cycle on the next stage at 2 5 above the set point and to cycle off the highest stage 2 5 below the set point e Override Multiplier ORM is used to e
10. r temperature is above the UDB e To change this value press the F1 key e The allowable range is 0 1000 recommended starting value 50 Screen N PID Setpoints Differential aait Deadband at e The Differential is the rate at which the controller changes the output based on how quickly the leaving water temperature rises above or falls below the set point e The Differential remains active in changing the output until the leaving water temperature falls below the LDB e To change this value press the FO key e The Deadband is the range in which no action is taken by the controller e The range is split above and below the set point e The controller will not begin to increase the output until the leaving water temperature is above the UBD and will continue applying output until the leaving water temperature is below the LDB e To change this value press the F1 key Screen O PID Autotune VFD only PID Autotune C e The controller has a PID Autotune feature e By pressing the F1 key from this screen the controller will enter a 20 minute adjustment cycle of the output in response to set point deviation e This process will automatically determine values for the Gain Integral and Differential e The circle on the screen will be shaded and the text Autotune Active will flash e Autotune can be stopped at any point by pressing the F2 key Any values written to the Gain Integral and Differential will be re
11. s any key to turn it on before you can scroll screens F2 Changing Set Points Any numeric value that is displayed in a box is user adjustable 1 Press the respective function key in order to change default values a For default values and parameter function keys see section F3 Operator Menu Screens 2 After pressing the appropriate function key use the Left and Right arrow keys to align the cursor to the position of the value you want to change 3 Enter the number and then move to the next position with the arrow keys if required 4 Press the Enter key to accept the selected value 5 You can press the Esc key at any time to cancel the set point change If you attempt to enter a value that is out of range the message OUT OF RANGE will briefly appear on the screen 10 G Operator Menu Screens The order in which the following screens appear may vary depending on your Evaporative Cooling Equipment Screen A Water Temperature Monitoring Cooling Towers only Leaving Water Temp 0 0 Set Point Hit Leaving Water Temperature is the current value in F of the leaving fluid from the cooling tower e Set Point is the temperature the controller will attempt to maintain by cycling the cooling tower motor s e To change the set point press the FO key Screen B Fluid Temperature Monitoring Closed Circuit Cooling Towers only Leaving Fluid Temp 0 0 Set Point Hig Leaving fluid temperature is the current value in F
12. stablish the high and low limit overrides HL and LL respectively e Time is the time in minutes that the LWT LFT DCP must be greater than the high limit HL or less than the low limit LL to override the Minimum Stage Time MST Screen F Fan Control Cooling Towers only Minimum Stage Time minutes e Minimum Stage Time MST is the minimum period in minutes for which each stage operates after cycling on or off e To change the value press the FO key Screen G Fan and Pump Control Closed Circuit Cooling Towers and Evaporative Condensers only Minimum Stage Time minutes Min on time pump minutes e Minimum Stage Time MST is the minimum period in minutes for which each stage operates after cycling on or off e To change the value press the FO key e Minimum on time pump MOT is the minimum period in minutes for which the spray pump motor runs once it cycles on e The spray pump will never cycle more frequently than the MST allows e To change the value press the F1 key Screen H Motor Status Motor Status Motor Status OFF ON e Motor status indicates whether the fan motor is stopped or running 11 Screen I Pony Status ENERGY MISER Fan System with VFD on main motor only Pony Status OFF ENABLED Pony Status OFF DISABLED Disable Pony Motor Press Fo Enable Pony Motor Press FO e Pony Status indicates whether the pony motor is stopped or running e Press FO to enable or disable the pony motor e When
13. tained Screen P I O Status HO Y xO YO I Yl I Yi e An open circle indicates an open input or output turned off while a dark circle indicates a closed input or output turned on e Digital inputs X0 X1 e Digital outputs YO Y1 on base module YO through Y7 on the first expansion module YO and Y1 on the second expansion module 13 14 Screen Q I O Status cont d 20 Y2 Yag Yel 23 25 Outputs Y20 through Y25 on the screen correspond to outputs YO through Y5 on the first expansion module The circle next to the corresponding digital I O will be dark when the controller is reading that the I O is active If the controller is not reading an input as active and you have confirmed the appropriate voltage with a multimeter then the input is no longer functioning properly All digital outputs are Normally Open relay contacts If the controller is showing the output to be active and you do not measure the appropriate voltage level with a multimeter then the output is not functioning properly Screen R I O Status cont d Y26 30 Ye Y3 e Outputs Y26 and Y27 on the screen correspond to outputs Y6 and Y7 on the first expansion module e Outputs Y30 and Y31 on the screen correspond to outputs YO and Y1 on the second expansion module
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