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Smardt Air Cooled Chiller O&M - Coward Environmental Systems

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1. A A SS E DESIGNED BY DESING DATE APPROVED BY P Kennedy 21 01 08 Eng Manager TS REFERENCE NO TITLE Electrical Control Schematic Kiltech 700003 1800 Tram Carada Hwy A SHEET Derval Qc Carada HPT HT TESTA en FED coer S46 0003 02 rl 1 OF 1 2 3 4 cp 8 Figure 3 Controls Wiring Diagram With Dp Transmitters 18 Smardt Air Cooled Chiller IOM Manual COPYRIGHT 2007 KILTECH INC Lon BacNet Converter To Bachet MSTP or dolio Feb Lon FT 10 Network qH TD B GND Cb E E VDCIF N 2AVAC SUPPLY O GND C TD A b RS485 232 Converter 19200 Baud A 10 8 P qo ro a voc rb ver qH T B X cNo cp TEMPERATURE INPUTS CHW RETURN T RS485 232 Converter 19200 Baud Tc h CHWSuPPLY T DIGITAL INPUTS daloe eno e D 24vDC e Lor RS485 232 Converter 19200 Baud ry cw FLO F5 COND SAFETY 24VDC gt AA e IEEE cer dH T B GND cp o n E Bod py crap status H2avog 4 20mA INPUTS 2 msns HED B O D 7 EN TOWER VFD Hz O Deres stars AD q CHW DIFF PRESS q 8 2 E N N J17 COMPRESSOR 1 LAS Tomo pres Q T 1 0 CARD AB5 Q LA BASLOADUMI Y cc o o E q m EEE U 3333 DIGITAL OUTPUTS jJ 1 Xf Als Q AUN SET POINT RESET a e R8 5 Q CHILLER RUN PP wc DD ae d D EEN 222 Refrigerant level Al6 q O NO ORT s sensor 4 20mA AIT C CY O rez Style Car OUTSIDE AIR TEMP q C Cas
2. q E w f ne a EJ 15A FUSE 1 0 CARD 0 10V OUTPUTS O E cm Ln CTFANVEO y Q P o woman CAPACITY Compr Lock Relay o E cw pump speso C RCS Ethernet Connection LUV ss peen Kw I For remote web access AO C O lt OQ LT LLI O R NLO CW PUMP ENABLE A047 EXV CONTROL Cl 4 aca s HOTGAS VALVE C 5 O HLO CHW PUMP ENABLE RS 3 3 MISC LOOP oP I O RC3 3333 A page gt gt gt No2 D En 1 N VFD ENABLE 4v J s a a a E a M a 1A Y c2 gE cz i mn D FE o1 D Rt COMPRESSOR ENABLE OPTIONAL HOT GAS CONTROLLER DK d ca D i max A VALVE DANFOSS VALVE 2B G AIR COOLED SPECIAL OPTION W C ONLY 115 230VAC 0 36 0 21A d EN d 12VDC LSA q Weidmuller q 992889 0012 POWERPAX EXV CONTROLLER M mex dee q 2A R Th intonation corra is f deeming Brac x s ELECTRONIC HOTGAS nr vechten ce Bhs STRICTLY CONFIDENTIAL and p sa Q 2B G lo be R DT oct racer m an unha bas cert VALVE iecur wen consoni of VB TECH ho DWG UNITS IN METRIC m A0 istNovt07 D C PK RELEASE ISSUE EEDE EE Es EE el DESIGNED BY DESING DATE APPROVED BY APPR DATE SIZE SCALE 11 01 07 A3 N T S F P Kennedy 21 01 08 REFERENCE NO TITLE Electrical Control Schematic Kiltech 700003 Eng Manager 1800 Trans Canada Hwy DWG NO ISSUE SHEET 8 2 3 I PS 5 6 7 19 Figure 4 Controls Wiring Diagram No Dp Transmitters Smardt A
3. gt gt gt gt gt gt gt gt gt gt AO 5 HotGas Valve Output 0 10V oOlololo ojojlojolo oljo H 1 Y 1 1 3BBE gt o AO 6 Selectable Loop 0 10V CIOWOHJOVW C O O OOOOOCPC OOOPOOOCPCOO OOP OO OOOH AO OOAD OOOH Touch Screen Power Supply Figure 5 Field Wiring Terminations Smardt Air Cooled Chiller IOM Manual DI 1 BAS Enable Input Normally Open Close to enable chiller DI 2 Chw Flow Input Chiller Faults if opens while running DI 5 HP LP Safety Switch External manual reset high pressure switch Power to Touch Panel 20 COMMISSIONING Smardt Factory Service start up is offered on all units sold for installation in Canada and the U S Start up must be performed by a Smardt Authorized Service Contractor to initiate the stardard Limited Product Warranty Start up only by Smardt Factory Service or an authorized Smardt Service Representative will be covered in the Limited Product Warranty Plan for a two week lead time to notify Smardt of startup and submit the Smardt Request Start Up Form If you are requesting a factory supervised start up please submit the Smardt request for Start Up Form A copy of the Smardt Request Start Up form can be found in Appendix A of this document NOTE Smardt requires equipment to be commissioned according to a detailed procedure and by a Smardt and Turboc
4. DCBwOvrVomge 2 O0 3 Motor High Current Warning L 4 Motor High Current Fault 8 3008 BN odd ERN odi Be Locked 8 Bearing Warning Active 128 0x0080 _ Bl mm Ke current 65536 Compressor motor fault registers are located in registers 40088 to 40093 If the bearing fault register is equal to zero then the compressor has no faults Modbus Defintion Rev09 AS amp KILTECH Example Program Usage Starting and Stopping the Chiller Modbus Communications Definition To start the chiller via the modbus communication protocol the following sequence is applicable Read Chiller Fault Register 40017 No Unable to Start Chiller Wait for error to clear or start next chiller Yes y Read Chiller operating mode Register 40007 Mode Desired Mode No gt Write Correct Mode to chiller Yes y BAS enable chilled condenser water pumps to chiller l Write 1 to Chiller Enable Register 40001 To stop the chiller write 0 to enable register 40001 Changing the Chiller Set point To change the chiller set point via the modbus communication protocol the set point temperature must be multiplied by a factor of ten and then sent to register 40002 Example Desired BAS set point 45 0 F Value to write to chiller controller 45 x10 450 Modbus Defintion Rev09 2235
5. Failed To Start When Requested Check Pressure Sensors Check Expansion Valve Control Check Pressure rations vs Demand Compressor s driving Out Of Surge Operator Intervention Check Circuit Check For Refrigerant Leaks Check Refrigerant Monitor Operation Check Circuit Yes oo Many Start Per Set Time Frame hiller Ramping up too Quick causign excessive cycling Process Load Too Low for Given Chiller Capacity Process Loop Extremely Sma Install inertia Tank Page 4 of 12 K KILTECH Faults Cont Go To I O 10 Module Comms Los Yes Section Active No CHW Pump Fail Active No CW Pump Fail Active No S Burst Disc Active Settings Operation To Determine Cause Of High Pressures KTS 000001 Rev 1 Troubleshooting Guide Troubleshooting Guide Yes Check Auxilary Pump Contacts and Pump operation Yes Check Auxilary Pump Contacts and Pump operation Yes Check Burst Disc Operation Check Chiller Settings and Page 5 of 12 K KILTECH Troubleshooting Guide Compressor Checks Go To Compressor Section Compressor Section Is Main Power Applied To Compressor with Compressor I O Card LED On No Turn ON Mains Power to Compressor Yes Is Controller Communicating with Compressors No Ensure Correct Communication Settings In The Controller Yes Recheck Communication Settings In The Compressor N
6. Power Up to Running peusijgeise jou mopy ILS 1103 ues JossaudWwod 3 V 1S NMOd TINA esop ejeJ HOOI JosseJduio snonunuoo 99899 104 MOJ ULIYUOO JUN YOJIMS MOI HEJS 9sop eea dund Jeje palo J9SHO ulod jes lt duie JO Hurem lieg buijoog sesojo eje snjejs pea Jeju SHUI pes Mo oq 9Je sdua JOJOW eAup x99u jul Jy Jsuejs Jduioo YIBUD ejqissod s Ing Jasa smes yne duos Y93949 yiqejeAe JduJ00 JO 6M JLVIS ddl Buluuny 0 dn 198mog 74 a1nbi4 99508 _ 9100 HUD JosseJduo 3 Je 0J U0 uoneJqieo Duueeg soD IN 0 8010 JOJOW AB 1959 JossaJdWo jose ony JLVIS 3101 ales UMOP jnus se WO 39506 0 OE dn joog 25 Smardt Air Cooled Chiller IOM Manual Temperature Pull Down and Normal Running oJjuo9 aAjea ssed q seb Joy pue joJuoo aunsseJd Jesuepuoo Jojuoo AXT sdoo 0 409 Buiuuni EIS sy Buibeys uey emoj puewap pue zulo jas Moled LAAT JI JO peuun sJosserdwog uibejs spasox puewep JI pappe sJossaJdW0d ajo 00L pds pue uo siduuoo e JI sasojo ejal Ajoedeo WNWIXeN 0 suossasdwioo euijuo e ssoJoe enba AB pue peeds ejejnpo uui uo Buruunu st 1 ll uo 31W1S TVINHON NAS JLYLS WEY TY Buluuni s Josseidwos pause uOnIpuos ju Buluuny eu oy pue umog Ind 3 njeladula g aunbi4 suonipuoo ney pue WJeje 10 Jemod pue seJnsseJd sdue tu s s Buuoyuou yes asojo BJaJ SULE
7. amp KILTECH Modbus Communications Definition Setting a Chiller Demand Limit On occasion it may be necessary to demand limit the chiller such as in a case where loading shedding is required to avoid peak demand charges A demand limit may be applied to the chiller by writing a value between 25 and 100 to register 40005 Setting the capacity limit register to a value to 50 will cause the chiller capacity to limited at 50 Note this value is initialized on boot to 100 if this value is changed via BAS it should be set back to 100 once the limit period required has expired failing to do will cause the chiller to be locked into a limit state Changing the Chiller Operational Mode The Kiltech controller is programmed to operate the chiller in one of three modes e HVAC Heat Mode 0 e HVAC Cool Mode 1 e Saturated Suction Temperature Mode 2 To set the chiller to a different operating mode the chiller must be stopped then a new mode may be written to register 40007 setting the outside air Temperature and Relative Humidity If the Kiltech chiller controller is setup to control the cooling tower fan and or variable speed condenser water pump the controller requires measurement of the outside air temperature and relative humidity The outside air temperature and relative humidity may be hard wired to the controllers I O or supplied via the communication bus via the BAS To set the outside air temperature via the modbus netwo
8. Jo abejs 10 dwnd Ja em Jasuspuod dnuejs oi sasojo ejaJ pa 009 Jie sue Jesuapuoo o dund Jesuepuoo els snes Buluuny ywli ulbe s speeoxe puewap Jl pappe sJossaJduoo ao Ja joJjuoo uo spuedep JosseJduioo pea pexij JO UIYOBU auununi 1S9m0 WEIS 0 JosseJduioo asooy ues 0 siduoo jo Jequinu ejes juiod jes oj dues mos ui peoe d siosseudwo4 ALVLS NMOJ Tid panels suosseJduo suoneJedo 118 9 91d d w a D A91I5 1 N9eQpaa uni JosseJdui0 26 Smardt Air Cooled Chiller IOM Manual it Fault Avoidance Im th an Alarm L ing wi Runn onina lP O uibejs uey Jamo puewep pue julo Jes Moleg 147 J HO peuun sioss iduio ues speeox puewep JI pappe JosseJduJoo ajo 0 sJosseJduioo ulljuo B SSOJIE enbe Ab pue peeds eje npo 31VW1S IVINHON NA Buluuni s 0sseJduJo e9uepioAy neJ yw wejy ue uy Buruuny g aniya Bunopuow uonipuoo 1 ne J uJe v onun eA BA ssed q seb joy pue o nuos alnssald jesuepuoo oJuo9 AX3 sdoo jo guo9 Buiuuni peijdde 1959 7 8 0 26 JO Ju PUEWSP anulu OS E pueulep 94526 le uueje ainssaid aBleyosip payors J IILO JI ejduiex3 Deuoes sem wee USYM puewep au Jo 08 1e palidde s yu puewap lnului og e sdwe yde Jo eunsseud eBueuposip ypy si uueje JI JossaJduio e dois Buiuuni sjosseJduioo sJosseJduioo Buluuru 1e 0 puewap Josseidwoo eonpes yu e uy BUIUUNH Bids
9. with a query to a Slave Chiller Controller The Slave which is constantly monitoring the network for Queries will recognize only the Queries addressed to it and will respond either by performing an action setting a value for example or by returning a response Only the Master can initiate a query Slave 1 Slave 2 Slave 3 Slave n TIIT Master Response In the MODBUS protocol the master can address individual slaves or using a special Broadcast address can initiate a broadcast message to all slaves The SPR and Integra products do not support the broadcast address For extra information please see http www modbus org on the web Modbus Defintion Rev09 aA lt KILTECHI Modbus Communications Definition Modbus Message Format The MODBUS protocol defines the format for the master s query and the slave s response The query contains the device or broadcast address a function code defining the requested action any data to be sent and an error checking field The response contains fields confirming the action taken any data to be returned and an error checking field If an error occurred in receipt of the message or if the slave is unable to perform the requested action the slave will construct an error message and send it as its response Query The example illustrates a request for a single 16 bit Modbus Register slave Function Start Start Number Number Er
10. Refrigerants fluids and expendable items such as filters are not covered by this warranty This parts warranty and any optional extended warranties are granted only to the original user and become void if payment for the goods is in default To obtain assistance under this limited warranty please contact the selling agency To obtain information or to gain factory assistance contact Smardt Inc Warranty Claims Department 1800 Trans Canada Highway Dorval Quebec H9P 1H7 Canada Telephone 514 426 8989 This warranty constitutes the customer s sole remedy It is given in lieu of all other warranties express or implied There is no implied warranty of merchantability or fitness for a particular purpose In no event and under no circumstances shall the Company be liable for incidental or consequential damages whether the theory be breach of this or any other warranty negligence or strict tort EXTENDED For a negotiated price the standard warranty will be increased to five 5 years from start up Smardt s warrant y ies is valid if the following conditions are met Smardt Air Cooled Chiller IOM Manual 40 1 the failure occurred within the period stated in this Clause paragraph B above ii the warranty claim is made within thirty 30 calendar days from the alleged defect occurrence iii the Articles are used for the purpose and within the specification they were designed and intended for and within any limitation specified by S
11. and the chiller Fully inspect the chiller before accepting delivery from shipping company Detail any damage that may have occurred during shipping Advise Smarat Inc immediately of any shipping damage and make sure this is noted on the transport companies delivery sheets Before opening any refrigerant valves fit a set of refrigerant gages to the evaporator and condenser of the chiller and make sure there is pressure in both heat exchangers If there is no pressure this may indicate a leak has been created during transport If no pressure is recorded on one of the heat exchangers leave them both isolated and investigate source of leak Verify the chiller foundations are correct for the unit size and weight use a level to validate the chiller foundation is level with not more than a 1 4 pitch in any direction Install the chiller and any field supplied vibration spring mounts in place in accordance with Smardt S unit placement guidelines Install electrical power to the chiller in accordance with local electrical codes and regulations Install building automation wiring to the chiller Smardt Air Cooled Chiller IOM Manual 11 Inspect all electrical wiring on the chiller for correctness and terminal torque Supply and install refrigerant relief piping vent lines Evacuate chiller to 500microns or less and hold there for at least 2hours Charge the chiller with refrigerant to the nameplate amount Install water piping to chi
12. during a low load period and consider the desired cycle time for the compressor If the chiller plant has a reasonable turndown the water volume should be two to three times the chilled water gom flow rate If the system components do not provide the required water volume add a storage tank Variable Water Flow A large range of Smardt chillers are well suited to installations where the chilled water and condenser water flow rates are changed in the chiller relative to the instantaneous building load and outdoor conditions When applying Smardt chillers into variable volume variable speed pumping applications the designer must make sure Smardt Inc are met Smardt Air Cooled Chiller IOM Manual 14 These are Water flow shall not be altered at a rate greater than 10 per minute The water flow rates shall not exceed the minimum and maximum flows detailed in the chiller selection sheet When operating at reduced flow rates on open water systems it should be noted that this may increase the tubing cleaning frequency requirement This is especially true for the condenser water loop where rapid tube fouling where rapid tube fouling may occur at low flow rates which can significantly increase the chiller power consumption yielding an inefficient chiller plant Variable speed pumping is a design feature of the Smardt air cooled chiller reducing the water flower through the evaporator as the load decreases This feature will function successfu
13. measured temperature This difference is the amount of sub cooling Design spec 9 15 F 5 8 C Superheat Measurement Procedure Connect the service manifold Note the corresponding saturation temperature of the refrigerant at the pressure indicated In order to have superheat the measured value must be greater than the saturation temperature Smardt Air Cooled Chiller IOM Manual 38 With a temperature probe measure the temperature on the suction line Calculate the difference between the saturated temperature and the measured temperature This difference is the amount of superheat Design spec 0 5 F 0 3 C Soldering Procedure When components in the refrigeration system require replacement soldering or sweating will be required to either remove or replace the components To protect the internal pipe work the use of industrial grade nitrogen must be used at all times during any procedure where a naked flame is applied to the pipe work The use of nitrogen prevents copper oxide formation in the internal pipe work during the soldering process This keeps the internal pipe work clean and free of contamination Connect the gauge manifold set Connect the common gauge line yellow hose to the nitrogen regulator Set the regulator to provide a positive pressure of 5 psig Open the nitrogen cylinder and manifold set to purge the area to be soldered Nitrogen displaces any oxygen present in the pipe work During the s
14. recovery cylinder Once the system pressure is approximately 10 kPa the system can be opened up to atmosphere and the necessary repairs carried out Smardt Air Cooled Chiller IOM Manual 35 Once the system is open for inspection turn the water pumps off or isolate flow if the system is parallel with other chillers If the water circuits are not shut down condensation will occur in the refrigeration pipe work leading to longer than normal evacuation times due to the presence of moisture in the system Refrigerant Leak Testing Leak testing can be performed by the following means Electronic leak detector Soapy water Both of the above methods are adequate to locate leaks Once the leak is isolated the system should be shut down and the affected component s repaired Machine not operating no charge Connect the service manifold set to the chiller Connect gauge set up to the R134A refrigerant cylinder and add a trace gas only required if electronic detection device is used Connect the gauge set up to an industrial grade nitrogen cylinder and increase the pressure in the system to 1500 kPa Carry out leak detection Once the leak has been repaired pressurize the system with nitrogen and leave undisturbed for 24 hours Check the pressure gauge noting any change in pressure and ambient temperatures from the previous day There may be slight pressure changes if the ambient temperature has changed dramatically If the pressure i
15. the Smardt chiller should receive instruction with regard to the following points at regular intervals a minimum of once a year Risks involved in dealing with refrigeration units Safety stipulations Conduct in the event of accidents and malfunctions Measures in the event of accidents and malfunctions Operator s obligations for safety equipment consists of To provide equipment to protect against the effects of refrigerants and coolants To store fully operational personal safety equipment outside of the at risk areas within easy reach Personal safety equipment consists of Protective gloves made from leather Protective goggles for use with chemicals RISK of SUFFOCATION R 134a is ASPHYXIATING Common name of the substance 1 1 1 2 tetrafluoroethane Chemical name CF3 CH2F In the event that refrigerant escapes please observe the following Have first aid equipment on hand Have emergency shower on hand Wear self contained breathing apparatus R134a is asphyxiating Smardt Air Cooled Chiller IOM Manual 5 In the event that refrigerant escapes please observe the following Ensure that everyone leaves the danger area immediately Follow first aid measures relevant to refrigerant Inform the local safety personnel Only enter rooms where refrigerant has escaped if wearing the appropriate safety equipment Ventilate rooms in which refrigerant has escaped Ventilate the hazardous area K Stop
16. the gas escaping Ensure that the refrigerant does not escape into the sewage system or into the environment If the refrigerant concentration is more than 0 25 kg m Wear self contained breathing apparatus Ensure that at least one person with the necessary safety equipment is standing by to come to your aid If the following are possible without putting yourself at further risk Switch off the Smardt chilling the master switch Close the valves on the suction and liquid pipes Observe instructions on the safety data sheet In case of contact with refrigerant observe the following Cause Symptoms Measures Gaseous refrigerant has Rinse with plenty of clean water come into contact with the Eye irritation immediately Consult a doctor eyes immediately Extreme eye irritation watery Rinse with plenty of clean water eyes redness and swollen immediately Consult a doctor eyelids immediately Liquid refrigerant has come into contact with the eyes Gaseous refrigerant has come into contact No risk with the skin Rinse with plenty of clean water immediately Consult a doctor immediately Liquid refrigerant has come Frostbite with burn like skin into contact with the skin problems redness blistering Take person out into the fresh air l immediately Consult a doctor i unconsciousness Risk of E Inhalation of gaseous suffocation immediately refrigerant i If patient stops breathing artificial resuscitation Infor
17. the message and compare the calculated value to the value received in the error check bytes If the two values are not equal the message should be discarded The error check calculation is started by first pre loading a 16 bit register to all 1 s i e Hex FFFF each successive 8 bit byte of the message 1s applied to the current contents of the register Note only the eight bits of data in each character are used for generating the CRC start bits stop bits and the parity bit 1f one 1s used are not included in the error check bytes During generation of the error check bytes each 8 bit character 1s exclusive OR ed with the register contents The result 1s shifted in the direction of the least significant bit LSB with a zero filled into the most significant bit MSB position The LSB prior to the shift is extracted and examined If the LSB was a 1 the register 1s then exclusive OR ed with a pre set fixed value If the LSB was a 0 no exclusive OR takes place This process is repeated until eight shifts have been performed After the last eighth shift the next 8 bit byte is exclusive OR ed with the register s current value and the process repeated The final contents of the register after all the bytes of the message have been applied is the error check value In the following pseudo code ErrorWord is a 16 bit value representing the error check values BEGIN ErrorWord Hex FFFF FOR Each byte in message ErrorWord ErrorW
18. to maintain maximum unit performance and efficiency Recirculation of air or restricting air flow must be avoided Snow and debris near or on the chiller must be removed insure maximum unit performance Make sure that sides and service clearances are respected The condenser and evaporator connections are grooved type stubs Victaulic Shurjoint or other equivalent for interconnection to the external water circuits All external piping must be adequately supported and aligned to prevent strain and distortion on the chiller headers and couplings 6 feet Single unit pit installation 8 feet no deeper than height of unit Units side by side floor 12 feet between units 6 level feet on other sides Units side by side pit 16 feet between units 8 installation no deeper than feet on other sides height of unit Table 2 Placement clearances Do Not Install conduits that will in any way block service access to controls valves or refrigerant driers Do Not Obstruct area of fan expulsion Smardt Air Cooled Chiller IOM Manual 10 INSTALLATION OVERVIEW For convenience Table 3 details responsibilities that are generally associated with the installation of a Smardt air cooled chiller Requirement Smardt Supplied Smardt supplied Field Field supplied Field Installed Smardt Installed installed Delivery Inspection Shall be performed by the purchaser of the chiller Rigging Safety chains Clevis connectors Lifting bea
19. uou ne payesauab JejoJjuoo Ja 49 29 Smardt Air Cooled Chiller IOM Manual MAINTENANCE Maintenance Maintenance of the Smardt line of oil free chillers may be divided into four categories 1 Compressor maintenance 2 Heat exchanger maintenance 3 Electrical maintenance 4 Valves and control components maintenance Compressor While the compressor requires minimal attention as it has very few moving parts thanks to the magnetic bearing there are still a couple things to look for Periodically a full leak test of the compressor should be performed this includes powering down the compressor and checking the o rings around inverter cooling plate See Turbocor compressor service manual for more information Once every five years the DC bus capacitors must be replaced During routine maintenance manually check the inlet guide vanes moving freely from 0 to 110 Check the suction and discharge temperature pressure sensors on the compressor are correct against a calibrated gage or temperature sensor Download all compressor fault and event logs and identify any repeat errors Heat Exchanger Condenser Coils The most common routine maintenance procedure required on the Smardt chiller is that of cleaning the heat exchangers The most common problem with air cooled condensers is dirt accumulation on the heat exchange surface The degree of dirt accumulation on the condensers fins will lay heavily upon where the unit is install
20. 0 an invalid value 1540 1560 1580 Slave Device n error occurred when the Instrument 1540 1560 attempted to store an update to it s configuration Illegal Data Attempt to access an invalid address or 1000 2000 Address an attempt to read or write part of a 1540 1560 floating point value 1580 Modbus Defintion Rev09 e l2 Modbus Communications Definition K KILTECH Product Specific Information Modbus Register List Variable Name Data Type Modbus Register nviChillerEnable snvt switch 0 1 40001 nviCoolSetpt snvt_temp_p 40002 nvoOnOff snvt switch 0 1 40003 nvoActiveSetpt snvt temp p 40004 nviCapacityLim snvt lev percent 40005 nviEntChWTemp snvt temp p 40006 nviMode snvt hvac mode 40007 nviHeatSetpt snvt temp p 40008 nvoActualCapacity snvt lev percent 40009 nvoCapacityLim snvt lev percent 40010 nvoLvgCHWTemp snvt temp p 4001 1 nvoEntCHWTemp snvt temp p 40012 nvoEntCndWTemp snvt_temp_p 40013 nvoLvgCndWTemp snvt_temp_p 40014 nvoLigRef Temp snvt temp p 40015 nvoAlarmDescr snvt chlr type 40016 nvoChillerStat snvt chlr status 40017 nviOutdoorTemp snvt temp p 40018 nvoOutdoorTemp snvt temp p 40019 nviOutdoorRH snvt lev percent 40020 nvoOutdoorRH snvt lev percent 40021 nvoChlrPwr snvt power kilo total power 40022 nviChlrPwrLim snvt power kilo total power limit 40023 nvoChlrPwrLim snvt power kilo 40024 nvoEntCndWSeipt snvt_temp_p 40025 nvo
21. 20mA Variable speed control signal for condenser fan Signal is generated from condenser control loop NotUsed S o Chiller Design kW 4 20mA Output indicates current percentage of chiller capacity The design kW is defined as the electrical power consumption and the full load design point of the chiller Refrigerant SH level control Output to control an electronic expansion valve output 4 20mA from a refrigerant level sensor or suction super heat measurement Control output is generated from chiller controllers EXV control loop Smardt Air Cooled Chiller IOM Manual 22 Hot gas valve 0 10VDC Output to control an electronic hot gas bypass valve The hot gas valve is used for three purposes they are Low load capacity control pressure ratio assistance for starting compressors and high discharge pressure avoidance Selectable Loop Output 0 10VDC The selectable output loop is a PID loop that has a selection for the controlled variable Possible controlled variables are SST SDT_Circuit_1 SDT Circuit 2 and Temperature input 7 A common use for this output is a condenser bypass valve to control the absolute minimum condensing temperature in cold start situations AA AAA Condenser VFD feed back Monitors cooling tower variable speed drive actual speed BAS load limit Input to limit the demand output control to the compressors 4mA input no demand limiting 20mA full demand limiting to 25 Set point reset I
22. ActiveEntCndWSeipt snvt_temp_p 40026 nvoChlrState snvt state 16 40027 nvoRpm 1 snvt rpm 40028 nvoRpm 2 snvt rpm 40029 nvoRpm 3 snvt rpm 40030 nvoRpm 4 snvt rpm 40031 nvoRpm 5 snvt rpm 40032 nvoRpm 6 snvt rpm 40033 nvoDrvPwr 1 snvt power kilo 40034 nvoDrvPwr 2 snvt power kilo 40035 nvoDrvPwr 3 snvt power kilo 40036 nvoDrvPwr 4 snvt power kilo 40037 nvoDrvPwr 5 snvt power kilo 40038 nvoDrvPwr 6 snvt power kilo 40039 nvoDrvRunHours 1 snvt time hour 40040 nvoDrvRunHours 2 snvt time hour 40041 nvoDrvRunHours 3 snvt time hour 40042 nvoDrvRunHours 4 snvt time hour 40043 Modbus Defintion Rev09 2162 K KILTECH nvoDrvRunHours 5 nvoDrvRunHours 6 nvolgvPosition 1 nvolgvPosition 2 nvolgvPosition 3 nvolgvPosition 4 nvolgvPosition 5 nvolgvPosition 6 nvoPressure Suction 1 nvoPressure Suction 2 nvoPressure Suction 3 nvoPressure Suction 4 nvoPressure Suction 5 nvoPressure Suction 6 nvoPressure Discharge 1 nvoPressure Discharge 2 nvoPressure Discharge 3 nvoPressure Discharge 4 nvoPressure Discharge 5 nvoPressure Discharge 6 nvoComp State 1 nvoComp State 2 nvoComp State 3 nvoComp State 4 nvoComp State 5 nvoComp State 6 nvoCCAlarm State 1 nvoCCAlarm State 2 nvoCCAlarm State 3 nvoCCAlarm State 4 nvoCCAlarm State 5 nvoCCAlarm State 6 nvoCCFault State 1 nvoCCFault State 2 nvoCCFault State 3 nvoCCFault State 4 nvoCCFault State 5 nvoCCFault State 6 nvoBRG State 1 nvoBRG State 2
23. BOVE FANS INTAKE INTAKE CLEARANCE CLEARANCE CONTROL POWER 2000 AIR INTAKE FIGURE 1 CLEARANCE FOR AIRFLOW AND SERVICE CLEARANCE 2000 AIR INTAKE CLEARANCE UNOBSTRUCTED AIRFLOW BOTH SIDES AND ABOVE FANS SPREADER BAR T KEEP SAFE CLEARANCE BETWEEN WIRING RIGGING CABLE AND COILS E 2387 Kl REI B RM AE 3 0 OPTIONAL WATER CONNECTION POSITION FIGURE 2 RIGGING e OFF WICTAULIC CONNECTIONS Figure 1 Rigging Diagram chiller dimensions and clearances Values shown are typical Refer to Smarat for product specific values Local codes may apply ensure clearances comply with local codes standards UNIT PLACEMENT Install the chiller set on approved anti vibration mounts Each corner should be supported on vibration eliminators and steel plate or suitably isolated from the plant room floor Generally waffle pads are considered suitable as the Smardt chiller is virtually vibration free The chiller should be protected from excessive ground or pipe borne vibration from external sources such as pumps Once installed remove the rigging equipment and check for longitudinal and transverse alignment Add shims if necessary to level the unit along both axes Smardt Air Cooled Chiller IOM Manual 9 Clearance Adequate clearance around the chiller set is essential to facilitate maintenance and service Required minimum clearances are tabulated in Table 2 Space above the fans must be free of obstruction as
24. Chiller Model To Match I O definition Page 3 of 12 K KILTECH Faults Go To Fault Section Fault Present Low LVGCHW Fault Active No Low SUCP Fault Active No High DISP Fault Active No High Amps Fault Active No igh Evap Delta Fault No CHW Flow Fault Active No Yes Yes Yes Yes Yes Yes Check Leaving Chiller Water Temperature Sensor Check Ramp Up Settings Ramping Up Too Quick For Load Check Pressure Sensors Check Expansion Valve Control Check Pressure rations vs Demand Compressor s driving Out Of Surge Check Pressure Sensors Check Expansion Valve Control Check Pressure rations vs Demand Compressor s driving Out Of Surge Check Expansion Valve Control Pumping Liquid Check Pressure rations vs Demand Compressor s driving Out Of Surge Check Leaving and Return Chiller Water Temperature Calibration Check Flows Per Design Check Chilled Water Flows Per Design Check Chilled Water Flow Switch and Circuit KTS 000001 Rev 1 Troubleshooting Guide Troubleshooting Guide CW Flow Fualt Active ail Start Fault Active HP Switch Fault Active Emergency Switch _ Fault Active Gas Switch Fault Active Max Starts Exceeded Active Yes Check Condenser Water Flows Per Design Yes Yes Yes Yes Check Condenser Water Flow Switch and Circuit Check Compressor s
25. Chiller Running Not Making Set Point Chiller Running Not Demand Increasing From Chiller Control No Are Any Alarms Active Yes Determine Alarm Type and Investigate Cause Check External BAS Load Limiting or Set Point Reset Yes No Pressure Ratio Too Low To Allow s The Actual K No Is Actual Speed Yes Equal To the Close To Or At Compressors To Load Up To Desired KW Desired KW Surge Speed Motor Power No Yes Settee katie Yes Investigate Correct Compressor Issue or pan Operational Condition Active Are Any Compressors Yes Offline Or In Correct Compressor Issue and Reset Fault No Check Compressor Staging If Taking too long to Load up Compressors Meeting Requested Capacity Load Too Great For Chiller KTS 000001 Rev 1_Troubleshooting Guide Page 9 of 12
26. JIVIS NHY IV d TYWHON NOY Qq3sVva IO NAVY TV 27 Smardt Air Cooled Chiller IOM Manual UMO MUS EWJON QL oJnBiJ Bunoyuow uonipuo2o 1ne ule v 0 0 Jas sindino doo 0 u09 ue pue aajea Buiuunu dois suado ejg Suey JO dund salem Jesuepuog suado eja suado Keja snje s Apeds Jol UD snje s uiuuny suado ejaJ 490 J9 UI cODHOUOS 0 PUBLUSP JossaJdu100 19S LVLS 310 J1Y1S NMOGLNHS En aanjeJedws HO INUS gt MT x BuiuunJ 1oss iduioo euo Huljood JO IEI ON Normal shut down 28 Smardt Air Cooled Chiller IOM Manual JUL 0193808 ajgembjuo 3lvis NA 13534 1 1NVW3O1NV NO ONLLIVM Abnormal Shut Down Fault Present 0 Jes sindino sdoo jojjuoo uey pue eA eA Buluuni do s suado eja sue 1o dwnd seem Jesuepuog suedo ejal snjejs Buluuny HO sle sJossaJduioo uuo spuo ss 06 gt 31W1S NMOOLNHS Juasald Jne umog mus jeuuouqyv yy nBigd BuLopuow uollipuo5 yne 4 WUe y suedo ejal snje s Apea JolllUD S so0 5 e 91 smejs 1ne d suado eje l 350l1 lul JossadWo 0 0 puewep 1oss iduio3 Jas 31V1S LNV En mz See pasoj9 U9 IAS dTdH eUI JoJo pejeJeueb jeuISJUI JOSsaJdulo9 o anp paddo s syossaudwod Ny i n n m s rVno h Wyyn sJ0J19 09 SWLUOD JossaJduio a ee nF y lt m Buiyo e
27. MODEL Full color touch panel graphical chiller control system Kiltech Inc KCT 1000 Smardt Air Cooled Chiller IOM Manual 16 Features Benefits e Enhanced energy efficiency capabilities utilizing the latest compressor optimization technologies e Remote monitoring via web to obtain real time energy performance data and system interrogation e Panel mount 10 4 TFT Color Touch Screen Displays available e Modular Input Output devices allowing for simple expansion eUser friendly navigation and trending capabilities eEngineered solution allows for quick and simple installation and commissioning e Live updates system configuration functionality e Variable speed condenser controls e In built stepper motor controls for EXV s e Continuous data logging 1 year of data stored on device in easy to use csv format e Logging of 32 000 chiller and compressor faults and events KICTECH Gao Ga Specifications SMARDT Operating System e Custom real time O S e Memory Up to 256 Mb application specific Graphic Terminal e Colour SVGA TFT LCD with resistive type touc EPN e Resolution 800 x 600 e Luminance 400 nits suitable for exterior use Power Supply e 24VAC 50 60Hz e 25vA max Inputs and Outputs e Thermistor Inputs 10K NTC Qty 8 e Digital Inputs Voltage Free Qty 8 e Analogue Inputs 4 20mA or 0 10V Qty 8 e Digital Outputs Relay Qty 8 Phys
28. Modbus Compressor 6 Mode Default Modbus HAUL HDE ULL Input Output Scaling Setup Entering Chw Offset Default 0 0 R Leaving Chw Offset Default 0 0 R Entering Cw Offset Default 0 0 R Leaving Cw Offset Default 0 0 R Outside Air Temp Offset Default 0 0 R Liquid Temp Offset Default 0 0 R Refrigerant Level Default 0 0 Outside Air Temp Al Default 0 0 R Stepper Drive Setup Output Mode Default EXV Max Steps Default 6000 Additional Site or Commissioning Notes Site Notes WU DUI Tempeature 7 Offset Default 0 0 R Tower VFD Al Default 0 0Hz Chw Pump Al Default 0 0Hz Cw Pump Al Default 0 0Hz BAS Limit Al Default 0 0 Setpoint Reset Default 0 0 R AOA RH Al Default 0 0 Step Rate per Sec Default 100 DEU NOTICE This form must be completed signed and received by Smardt to initiate product warranty SMARDT INCIDENT REPORT PROCEDURE INCIDENT REPORT Incident Report No Incident Date Sales Order No Customer Name INCIDENT REPORT RMA No Site Name PO No Chiller Serial No Compressor Serial No if failed Information for shaded boxes to be provided by Smardt Please attach any photos taken of the failed component or any information downloaded from the compressor to this report Incident description SMARDT Chiller Type Chiller Application Chiller Location INCIDENT REPORT B LJ Plant room Number of compressor
29. Oil Free Centrifugal Chiller Air Cooled Chiller Manual Installation Operation amp Maintenance Manual IOM AC February 2008 TABLE OF CONTENTS PRODUCT DESCRIPTION weten detectado 4 PURPOSE OF THIS DOCUMENT la ddr 4 DEFINITION OF ACRONYM Susini test rene Di br neen enabelen dai is alisios ad 4 REFRIGERANT SAFETY GUIDELINES 5 STORAGE AND FANDEN Goes das 7 A 7 ELECTRICAL SAFE Von a 7 RIGGING sa ida ida 8 A E Od ne edn Pet 8 FOUND AOM etend us ME ANNIS AA DURO E D E UD CIN M ED 8 PIE TING METHOD steet al godere rc eiii 8 A LM MU EMEN A 10 INSTALLATION OVERVIEW t L 11 STORAGE aid pe EET EPI e S E EUER US S uu A Sau DER E SD u Su S s 12 CHIEEED WATER SYSTEM etste ee A eta Ive a vetet etes 13 PRESSURE DROP E Nri ZENTREN 13 CHILLED VVATERIPUMES erre aida 14 WATER VO EO NE dicas 14 VARIABLE WATER FLOW ai tia ss 14 OPERATINSG LIMIT Gua u aasawa Qam tiana kaha mA Suha kapa in aQ it Dn Dada 15 FEON ne l ua uu au aaa O es 15 CONTROL WIRING REFERENGE O ua aa Q S awa Du i Sa u auqa a 16 CE PPA u REED 16 ELECTRICAL WIRE eos ia MEC EM DAE LI LP E eU EE Uus 16 HELIO dM DEI M E Lo a Al a sta E i iri i 16 COMPONENTS CONIROLS uu uu xn leu e peu u u u Roads 16 COMMISSIONING coins identico dedos Uo sese voro ida 21 CONTROLS VO POINT FUNCTIONALITY S coats ter in Deseo an edu pido
30. Rc aa vede dtt 21 SERVICE AND MAINTENANCE nie EE EE COE ER ER EU DUE CU EUER PE e CUEEA ciaa 23 SEQUENCE OF OPERATION discite ae id 23 EL unupa MM MUN QM AM M MEI IU EE 23 POWER UP TO RUNNING ae pedes ta neds aca 25 RUNNING WITH AN ALARM LIMIT FAULT AVOIDANCE sana 27 NORMALSHUT A E Ld I M LER LN M ES 28 ABNORMAL SHUT DOWN FAULT PRESENT nono n ccoo no cnnnn cnn nn ocn nn cnn nana erneer 29 MAINTENANCE Sunat D irritada 30 COMPRESSOR eama S L L sal 30 HEAT EXCHANGER CONDENSER COoOILS n nanara 30 HEAT EXCHANGER EVAPORATOR BARREL nn kreere ener n re 30 EVAPORATOR BARREL FREEZE PROTECTION WHILE OFFLINE DURING WINTER MONTHS 31 MAINTENANCE INSPECTION Sa dE 31 TROUBLESHOOTING sucias aiii 33 AUS A O E nanan 33 SERVICE PROCEDURE 9d AA SQ S u sait AA 35 Smardt Air Cooled Chiller IOM Manual 2 CONNECTING REFRIGERANT GAUGES cuina A iia 35 REMOVING REFRIGERAN Titania ados 35 REFRIGERANT LEAK TESTING dodo 36 MACHINE NOT OPERATING NO CHARGE cccccccccccccccccececececucccutececececueauuacaeaeaeseeteteeeeceneneneneneneaeaeaeness 36 DEHYDRATION PROCEDURE CHILLER DEHYDRATION ccecccccececececececccccacececececceueaeaenenenentaeavaeaeaeters 36 CHARGING THE REFRIGERATION SYSTEM 555 ado 38 CHECK SUB COOLING SUB COOLING MEASUREMENT PROCEDURE cscecececccecccccececececeneuceueneneneneas 38
31. SUPERHEAT MEASUREMENT PROCEDURFE rde r r rr rr ante 38 SOLDERING PROCEDURE sat di tn ansa kont Sub huy dA La DE ED Od Ey Es 39 CHECKING IGM OPERATION uz uz ou T u triada 39 CHECKING ELECTRONIC EXPANSION VALVE OPERATION a rr REEL ar rr eerie eiiis 39 INCIDENT REPORT PROCEDURE 40 WARRANT Nedereind delen ua a io 40 APPENDICES z gt gt gt ua uu Qu aa T a 42 For product support issues corrections or enquiries contact Product Support productsupport Smardt com Smardt Inc 1800 Trans Canada Hwy Dorval QC Canada H9P 1H7 Tel 1514 426 8989 Fax 1 514 426 5757 This publication contains information proprietary and confidential to Smardt Inc Smardt Any reproduction disclosure or unauthorized use of this publication is expressly prohibited without written approval from Smardt Smardt reserves the right to make changes without notice in product or component design as warranted by evolution in user needs or progress in engineering of manufacturing technology Smardt has exercised its best efforts to ensure that the information contained in the manual is correct However no warranty or reliability or accuracy is given with respect to the information and Smardt is not and shall not be responsible or liable for the correctness or suitability of the information or for any effort or omission All
32. al refrigerant charge cannot be added to the chiller use an approved refrigerant pump to attain the minimum charge The machine will require restarting and the gas charge added during operation NOTE The Turbocor compressors rely upon liquid refrigerant for the cooling of their mechanical electro mechanical and electronic components Therefore in order to bring the system to the correct operational refrigerant charge it may be necessary to connect the charging lines onto the bypass port on the operational compressor and provide liquid to it during is operation This will ensure adequate cooling for the compressor while completing the charging of the system Determine the operational refrigerant charge to ensure system does not become over charged During this procedure it may be necessary to bypass some control functions in order to maintain chiller operation and thereby reach the desired refrigerant charge Check Sub cooling Sub cooling Measurement Procedure Set up the service manifold however connect the discharge hose red to the liquid line upstream of the electronic expansion valve EXV Note the corresponding saturation temperature of the refrigerant at the pressure indicated In order to have sub cooling the measured value must be less than the saturation temperature With a temperature probe measure the temperature on the liquid line upstream of the EXV Calculate the difference between the saturated temperature and the
33. brand names and product names used in the manual are trademarks registered trademarks or trade names of their respective holders Smardt Air Cooled Chiller IOM Manual 3 INTRODUCTION Product Description The Smardt air cooled range offers the a small footprint the quietest operation and the highest air cooled operating efficiencies on the market Condenser coils use a W configuration to optimize heat rejection and footprint Coils are baked and double coated as standard with sealed edges as standard to extend the coil s protection from environmental corrosion All Smardt chillers are designed to optimize the performance of oil free centrifugal compressors from Danfoss Turbocor Compressors Inc This chiller will deliver a high level of reliability outstanding part load efficiency and the overall lowest cost of ownership in the marketplace Purpose of this Document The purpose of this manual is to inform contractors building owners and engineers of installation sequence of operation and service requirements for the Smardt oil free air cooled centrifugal chiller It is intended that this document be used with the applicable installation and wiring drawings The air cooled centrifugal chiller consists of an evaporator condenser coils twin turbine centrifugal compressor s compressor controller s and interconnecting refrigerant piping The chiller set is a packaged unit requiring connection to the chilled water circuit main electri
34. cal supply and integration with the building automation system if applicable Definition of Acronyms BMS Building Management System EXV Electronic Expansion Valve HP LP High Pressure Low Pressure MCA Minimum Circuit Ampacity MOCP Maximum Over Current Protection CCS Chiller Control System RH Relative Humidity VFD Variable Frequency Drive Smardt Air Cooled Chiller IOM Manual 4 REFRIGERANT SAFETY GUIDELINES Safety precautions must be observed during installation start up and service of the chiller due to the presence of refrigerant charge and low voltage hazards Only qualified personnel should install start up and service this equipment This instruction manual contains the generally valid safety regulations that are of the most importance to the operator of refrigeration units Always ensure that the Smarat chiller is operated by qualified staff only Provide suitable fully operational fire extinguishing equipment Environmentally friendly handling Observe the instructions on handling and storing refrigerant see safety data sheet Ensure that refrigerant does not escape into the air the ground or the sewage system Ensure that installation set up maintenance and cleaning are only carried out by certified companies that specialize in refrigeration units Smardt recommends having the service department install set up service and clean the system Safe handling staff Staff involved with operation of
35. cations Definition Connection Diagram Interconnection Diagram during RS 485 Transfer Slave Chiller Control 1 RS485 Comms to PLC RX O RX RX RX Comm Comm Slave Chiller Control 2 RX RX Comm Termination resistor of 150ohm applied to last slave on RS485 network Above Sample connection diagram between multiple controllers and master plc amp KILTECH MORELA 2n S04 PE Left Connection points found on rear of touch panel Connection points to BAS System Modbus Defintion Rev09 3 lt IC ILT C en Modbus Communications Definition Communication related parameters Before Kiltech Chiller controller can communicate with a master controller the serial communication parameters must be setup via the touch panel Communication parameters are found in the Chiller Commissioning Screen a service password is required to gain access to this page See Kiltech Chiller Control Manual Baud Rate possible settings 9600 19200 amp 38400 Stop Bits possible settings 1 or 2 Modbus Slave Address to 64 The modbus RS485 parity is fixed at none The inverter uses RTS signal when operating with RS 485 transfer switching the transfer direction for sending and receiving Modbus Messages amp the Modbus Protocol Communication on a MODBUS Network is initiated started by a Master BAS
36. chnician start the chiller STORAGE If the Smardt chiller is to be stored before installation please take note of the following Store the chiller in a clean dry warm location free from air borne debris Do not remove protective covers over water connections or air coils Do not remove any protective covering over electrical panels Every three months attach a set of refrigeration gages to the evaporator and condenser and check the dry nitrogen holding charge pressure If this drops greater than 5PSI call a qualified service technician to investigate a possible leak Smardt Air Cooled Chiller IOM Manual 12 CHILLED WATER SYSTEM Pressure Drop Table 14 0 12 0 10 0 am _ W031 1B 44N _ a W502 2B 22N zi W058 2B 44F a W062 2B 33N me x W074 3B 22N _e W084 3B 22N 4 0 2 0 0 0 100 200 300 400 500 600 700 800 GPM Table 4 Pressure Drop Table Smardt Air Cooled Chiller IOM Manual 13 Chilled Water Pumps Make all connections prior to filling with water Run a preliminary leak check before insulating the pipes and filling with water Smardt recommends consulting with local authorities to comply with safety and building codes Additional considerations should be made when designing the piping system All piping systems should include temperature and pressure measures at the evaporator Make these connections prior to filling with water Water pressure should be maintained throug
37. e Transmission lime NEN Start of Query Query received start of Response Response received by slave by master Parity Checking If parity checking is enabled either Even or Odd Parity is specified the quantity of 1 s will be counted in the data portion of each of the eight bits in the character The parity bit will then be set to a 0 or 1 to result in an Even or Odd total of 1s Note that parity checking can only detect an error if an odd number of bits are picked up or dropped in a Character frame during transmission if for example two 1 s are corrupted to 0 s the parity check will not find the error If No Parity checking is specified no parity bit is transmitted and no parity check can be made An additional stop bit is transmitted to fill out the character frame when 2 stop bits are selected If No Parity checking is specified and one stop bit is selected the character is effectively shortened by one bit Modbus Defintion Rev09 8 amp KILTECH Modbus Communications Definition CRC Checking The error check bytes of the MODBUS messages contain a Cyclical Redundancy Check CRC value that 1s used to check the content of the entire message The error check bytes must always be present to comply with the MODBUS protocol there is no option to disable it The error check bytes represent a 16 bit binary value calculated by the transmitting device The receiving device must recalculate the CRC during receipt of
38. e in the query OR ed with Hex 80 indicating the slave either does not recognize the query or could not carry out the action requested Error Code 8 bit value indicating the nature of the exception detected See Exception Codes in the section Product Information for a list of SPR and Integra supported codes Modbus Defintion Rev09 6 lt ITECH Modbus Communications Definition Error Check Lo The bottom least significant eight bits of a 16 bit number representing the error check value Error Check Hi The top most significant eight bits of a 16 bit number representing the error check value Modbus RTU Mode Transmission In RTU Remote Terminal Unit mode each 8 bit byte in a message contains two 4 bit hexadecimal characters The main advantage of this mode 1s that it s greater character density allows better data throughput than ASCII for the same baud rate however each message must be transmitted in a continuous stream The format for each byte in RTU mode is Coding System 8 bit binary hexadecimal 0 9 A F Two hexadecimal characters contained in each 8 bit field of the message Bits per Byte 1 start bit 8 data bits least significant bit sent first 1 parity bit for even odd parity no parity bit for no parity 1 stop bit if parity is used 2 stop bits if no parity Error Check Field Cyclical Redundancy Check CRC MODBUS Message Timing RTU Mode A MODBUS message has defined beginning and e
39. eck BAS Replace I O Module Program Schedule s Input Open at terminals Yes Check Circuit Check with Multimeter O No Digital Inputs Faulty Check BAS Replace I O Module Program Schedule Yes Is Chilled Water Pump running Is Digital Input 2 CH W Flow Open No N Is Digital Input 3 Yes C W Flow Open Is Condenser Water Pump running No N Go To Detailed I O Checks KTS 000001 Rev 1 Troubleshooting Guide Page 7 of 12 K KILTECH Troubleshooting Guide I O Module Detailed Checks Detailed I O Checks mergency Stop Input Closed Yes Check External Emergency Stop Circuit No A Check Burst Disc 1 Circuit rbd Dise 1 Yes Operation of Chiller to Determine Input Closed Casa NO AR Check Burst Disc 2 Circuit Dursting Dise 2 Yes Operation of Chiller to Determine Input Closed Cause No Check Circuit Operation Of S praia Yes Refrigerant Monitor And Leak P Test Chiller If required NO High Low Yes Check Circuit Operation of Pressure Input Closed Chiller And Operation Of Chiller To Determine Cause No Analogue Input Set Yes Point reset Active Check Scaling Of Analogue Input In Commissioning Settings No Check BAS Settings Analogue Input Set Point reset Active MISCO SONUS uem O Appear OK KTS 000001 Rev 1 Troubleshooting Guide Page 8 of 12 K KILTECH Troubleshooting Guide
40. ections Turbocor service manual Check electrical terminals are tight Y Check for signs of hotspots discoloration on power cables Check amperages as per design v Check DC Bus voltage Y Check capacitor mid bus voltage Y Replace capacitor set Y Check operation of all system safety devices and y interlocks Check all communications cables are secure and tight Check all electronic modules are secure Y Check physical condition of all exposed Printed Circuit Boards PCB s Check all exposed PCB s for dust build up and clean if y necessary Check calibration pressure temperature sensors Y Y Refrigeration Check operation of IGV assembly Check system refrigeration charge Check superheat level control if applicable Check system and motor cooling liquid line to ensure sufficient subcooling Check operating conditions external to the compressor Clean inspect motor cooling strainers if service has taken place As Required Table 7 Frequency of Maintenance Turbocor compressor Smardt Air Cooled Chiller IOM Manual 32 TROUBLESHOOTING The performance of the chiller set is largely dependent on the correct operation of the water circuits and the refrigeration system When evaluating the refrigeration system it is important to check the operation of the water circuits first Failure to do this may lead to misdiagnosis of the refrigeration circuit Ensure that the chiller has sufficient water flows in both the evaporator and conden
41. ed Dirt acts an insulator on the heat exchange surface decreasing the condensers ability to reject heat to the air moving over it the result of this is higher than normal condensing pressure low performance and discharge pressure faults The condenser should be cleaned using high pressure air within limits too high of a pressure may also damage the fins or with water spray and chemical cleaning agent see Smardt bulletin for list of approved cleaning chemicals It is important to keep monthly logs of the chillers operation recording the load of the chiller outside air temperature discharge pressure and the power input of the chiller Any major changes in condenser approach or discharge pressure should be noted and a coil cleaning should promptly follow Heat Exchanger Evaporator Barrel In most cases the evaporator is part of a closed water circuit and therefore should not accumulate as much scale or sludge as a comparable water cooled condenser Proper water treatment is also very important to maintaining the condition of the evaporator heat transfer surfaces Maintaining monthly operational logs of the chiller and monitoring the evaporator approach temperature will give a good indication when the evaporator may require cleaning Smardt Air Cooled Chiller IOM Manual 30 If the evaporator does require cleaning Smardt suggests the mechanical cleaning method The mechanical method removes sludge and loose material from the evaporato
42. etpoint Default 5 4 R Deadband Default 0 2 R Proportional Band Default 18 R Integral Gain Default 2500 Derivative Gain Default 5000 Max Slew Rate Default 2 Condenser Loop Controls Control Mode Default Cw in Temp Dead Band Default 0 5 R Proportional Band Default 27 R Integral Gain Default 3500 Derivative Gain Default 5000 Max Slew Rate Default 5 Startup Timer Default 100 sec Startup Output Default 25 Ramp Per Minute Default 5 Expansion Valve Control Control Mode Default Cond Level Dead Band Default 0 10 R Proportional Band Default 50 R Integral Gain Default 1500 Derivative Gain Default 3000 JUN ULL DULL Lookward Time Default 120 sec Startup Timer Default 100 sec Startup Output Default 15 Ramp Per Minute Default 3 Min Output Default 1096 Max Output Default 10096 Setpoint Reset Mode Default Al 5 Reset Temp Low Default 6 0 R Reset Temp High Default 0 0 R Min Output Default 0 Max Output Default 10096 Min Setpoint Default 65 F Start Setpoint Default 78 8 F Condenser Variables Min Temp Limit Default 65 F Max Temp Limit Default 85 F Max Output Default 100 Startup Output Default 25 Ramp Per Minute Default 5 Min Output Default 0 Max Output Default 100 Setpoint Default 50 F HAUL WU He Wu Max Slew Rate Default 25 Startup Timer Default 180 sec Hot Gas Valve Cont
43. f Monitors chilled water flow status through chiller Smardt Air Cooled Chiller IOM Manual 21 barrel If status turns false while chiller is running a no chilled water flow fault is generated and chiller is stopped Monitors condenser status such as overload for Condenser status condenser fan or VFD fault contact If not required Bridge connection Not Used No function Monitors digital input for a closure of an external HP or LP switch A chiller fault is stopped on a Hp LP safety I ee he pressure safety cutout fault if input circuit is closed Monitors chilled water pump status May be Chilled Water pump status connected to auxiliary contact of chilled water pump contactor or VFD status Not Used None Not Used Pilot relay used to enable an external 2 4 or 6 pole relay connected to each of the Turbocor Compressor Enable compressor interlocks Relay closes when chiller is set to run and opens when there is a chiller fault or BAS enable is set to false Relay enables and disables a variable speed fan Condenser VFD Enable Stage 1 output is enabled when chiller starts to run and fans condensing temperature is above the minimum temperature limit setting in controller Relay is enabled whenever the chiller has a Chiller faulted compressor or chiller fault active Relay is enabled whenever the chiller is in a Chiller Running E running state smnVnnIIs A Analogue Outputs Condenser VFD 4
44. for commissioning will be chargable for normal labor and expenses Date of Pre Commissioning Po Requested Date of Start Up Po General Electrical and Controls Other checks Power wiring matches nameplate Installation Location Remote condenser valves installed Chiller mounted on a level surface Interlock wiring completed Drain and purge valves operational i Refrigerant charged and leak free BMS System operational Manually rotated fan blades No visible equipment damage Wire size conforms to system LRA Pressure cut ins outs checked Insulation in good condition Minimum circuit conforms to specs Heat load is ready for start up Service clearances per requirements Maximum fuse conforms to specs All piping installed and supported Disconnect installed and checked Chilled Water Circuit Condenser Water Circuit Design Specs Piping is insulated to chiller Piping is complete to the chiller Design set point degrees F System cleaned and flushed System cleaned and flushed Design chilled water flow rate System pressure checked amp no leaks System pressure checked amp no leaks Chilled water system is vented Water system is vented Design condenser flow rate Flow switch installed and functional Flow switch installed and functional Certifications Required AD Ur Strainers cleaned after flush Strainers cleaned after flush Service clearances per requirements Service clearances per requirements Glycol concentration checked Glyc
45. hage Discharge valve closed Check valve position Restriction in pipe work Correct pipe work High evaporator pressure Chilled water temperature too Check temperature sensor high Pressure sensor faulty Check for excessive water flow IGV failure Replace transducer Check operation refer procedure Low refrigerant temperature Insufficient refrigerant charge Check refrigerant charge cutout Replace sensor Faulty sensor Water temperature too low Water Check set points flow blocked Find repair blockage Drive temperature too high No motor cooling Check pipe work valves Insufficient sub cooling Faulty Check compressor solenoids sensor refer service manual Check refrigerant charge Check liquid line for restrictions Replace sensor Table 8 Fault Diagnosis Chart For additional information on troubleshooting see Appendix C for the Kiltech Trouble Shooting Guide Smardt Air Cooled Chiller IOM Manual 34 SERVICE PROCEDURES The following tools are required for servicing the chiller Allen key set up to 14mm Torx screwdriver 25 Manifold set Thermometer 1000VDC Multimeter Computer with Turbocor Monitoring Software Grounding wrist strap Connecting Refrigerant Gauges It is extremely important that the manifold set is free of moisture and dust It is also important that the gauge set is not contaminated with other refrigerants or oil When performing any service procedure that re
46. hiller Series A280 A310 A540 A560 A580 A610 A770 A840 Number of 1 1 2 2 2 08 8 8 compressors 2 3 3 Numberoffans 4 6 Total length L m 3 74 12 4 89 16 4 89 16 6 04 19 7 20 23 7 60 24 7 60 24 8 75 28 ft in 3 0 0 1 0 7 1 1 1 1 9 Ww s 3000 3500 4500 4500 4500 5351 5450 6350 Weidht ko lbs 6600 7700 9900 9900 9900 11770 11990 13970 Center of gravity 2 10 6 3 45 11 3 45 11 4 30 14 4 40 14 mir di CG m ft in 11 2 85 9 4 4 4 1 5 5 25 17 3 3 figs a a a eo e o ls lugs 4 4 4 4 MCA A 140 180 190 220 280 330 280 330 280 330 330 380 390 430 450 470 Chiller MOP A 225 300 300 350 450 500 450 500 Wut m om 2520 ange aem aen aem unm wiring 2 0 2 0 2 x 2 0 2 x 2 0 2 x 2 0 2 x 3 0 2 x 3 0 2 x 3 0 gpm 127 285 159 317 190 476 270 587 301 713 333 713 856 412 856 Number of passes 2 2 2 2 3 3 2 2 Water conn size Vict 4 4 5 5 S m ft in 2 0 6 7 2 0 6 7 3 4 11 2 2 2 3 8 12 6 3 8 12 6 3 8 12 6 May differ for specific chiller model consult specific chiller documentation Based on 90 C copper wire Table 1 Physical Data Includes full refrigerant charge water circuits empty Weights may vary with individual tube count Smardt Air Cooled Chiller IOM Manual 8 ESE HEAT EXCHANGER SERVICE ACCESS EITHER END UNOBSTRUCTED AIRFLOW BOTH SIDES Be ATO 2000 AIR AND A
47. hout the system install regulating valves or comparable pressure maintenance For efficiency design piping system with a minimum number of elevation changes and turns to maximize performance Install a strainer before the pump at the supply water line to prohibit debris from entering the pump Piping made to and from the chillers water connections and pressure relief valves must be made in such a way that weight and strain is removed from the chillers connections All chilled water piping up to chillers connections should be adequately insulated Strainers with 20mesh filters should be installed upstream of the evaporator and condenser Adequate valving should be supplied to permit draining of water from the evaporator and condenser Install vibration eliminators to reduce transmission to the building Install air valves at the high points and drains at low points Additionally shutoff valves should be installed for unit servicing Protect water temperature from freezing by protecting water piping Allow a vapor barrier on the outside of the insulation to protect from pipe condensation within the insulation Note If glycol or propylene are used as an addition of freeze protection this will cause a pressure drop that may result in the loss of performance Only use glycols designated for use in building cooling systems Water Volume When designing the chilled water system consider the minimum cooling load the minimum plant capacity
48. ical Dimensions e Analogue Outputs 0 10VDC Qty 6 e Enclosure 16 x 24 e EXV Output Bipolar Stepper Motor e Colour White enamel gloss Drive e Category Nema 1 BAS Protocols e Weight 45 Lbs e Modbus TCP IP module Environment e Modbus RTU RS485 module e Operating range 0 50 C 32 e LonTalk FT 10 module 122 F e BacNet MSTP module e Storage range 10 70 C 14 e BacNet IP module 158 F e Relative humidity 5 95 RH non condensing Smardt Air Cooled Chiller IOM Manual 17 VIS V COPYRIGHT 2007 KILTECH INC Ta BacNet MSTP or Lon FT 10 Network D FROM FUSED MVAC O MVAC SUPPLY GD G 1A 480V or 2 E RS485 232 Converter 19200 Baud TEMPERATURE INPUTS Li DIGITAL INPUTS d DIFF PRESS TRANS 8 2 8 VERIS PW SERIES 37 DIGITAL OUTPUTS EELS att x DIFF PRESS TRANS 1 318 Md pe Wed Wd i 115 830VAC 2 dai f 1 Compr Lock Relay 036 021A pr ee set Ja m S0 60Fz CED gt L ES rv SET Weldrruller rm Freak T 992889 0012 z KILTECH CONTROL PCB REV 700003 OPTIONAL HOT GAS CONTROLLER i AIR COOLED SPECIAL OPTION W C ONLY 119 230WAC 360214 Selz ELECTRONIC EXPANSION VALVE DANFOSS VALVE POWERPAX EXV CONTROLLER a UNITS IN METRIC mm A0 istNovt07 DC PK RELEASE ISSUE Ponor sa mes omme REV pare ev aer Eco DESCRIPTION OF CHANGE
49. ice of the equipment When AC power is first removed from the compressor the capacitors store enough energy to cause injury It is essential to allow sufficient time for the capacitors to discharge before proceeding Only a qualified electrician should work on low voltage electronic equipment AN Wait at least 10 minutes after isolating power before opening compressor access covers Smardt Air Cooled Chiller IOM Manual T RIGGING Care must be exercised at all times when rigging or handling the chiller set to prevent personal injury and protect the chiller from damage Handling Do not drop the unit or allow the unit to absorb shock Do not push or pull on the unit Do not let the unit fall during installation Foundation Before installing the chiller set ensure that the supporting floor meets the load bearing requirements Smardt is not responsible for the load bearing capacity of the floor Lifting Method Four to six lifting lugs are provided on both sides of the frame The chillers high center of gravity must be considered when rigging to ensure that the chiller is secure and balanced when suspended A spreader bar l beam combination shall be used to safely position the chiller set into its final location and prevent any damage to the coils The typical rigging details are shown below in Figure 1 Smardt is not responsible for the rigging and placement of the unit Arrangements can be made through a local equipment mover C
50. igh Error Check Low The following response from the slave would indicate a successful write Starting Address High 00 1 1 0 Starting Address Low 00 0 00 Number of Registers High 00 Number of Registers Low 01 Error Check High Error Check Low Modbus Defintion Rev09 11 lt IC ILT E CH Modbus Communications Definition Exception Codes Whenever a Kiltech Chiller Control product receives a MODBUS message with valid parity and error check but which contains some other error e g a request to set a register to an illegal value or a request for part of a floating point variable an Exception code will be generated The message format Is shown in the message Formats section Exceptions are indicated by a value in the function code field of the response greater than Hex 80 obtained by OR ing the original function code in the query with Hex 80 For example if a function code of Hex 34 and exception code 2 were present in an exception response this indicates that a function 4 query Read Holding Registers has resulted in an illegal data address error The error codes and the corresponding types of error returned by the models covered in this guide are given in the following table MODBUS name Description Reported by Exception Illegal Function Function The function code Is not supported by 1000 2000 2000 the product 1540 1560 1580 Attempt to set a floating point variable to 1000 200
51. ion Pressure Fault 4 0x0004 4 High Discharge Pressure Fault 8 0x0008 6 HighRotor Temperature Fault 32 0x0020 8 HighPressure Ratio Fault 128 0x0080 9 Generic Motor or Bearing Fault 256 0x0100 14 Not Used 16348 65536 Compressor fault registers are located in registers 40076 to 40081 If the fault register 1s equal to zero then the compressor has no faults Modbus Defintion Rev09 21 lt KILT ECH Modbus Communications Definition Compressor Magnetic Bearing Faults The Turbocor compressor has eight defined magnetic bearing faults each fault is represented as a different bit in a 16bit register Fault Description Integer Value Bearing Calibration Failed I 0x0001 2 startup Check Failed L 2 0102 3 Thrust Bearing Displacement Over Limit 4 0x0004 4 Thrust Bearing Over Current Fault 8 0x0008 64 00040 6 Front Bearing Over Current Fault Rear Bearing Displacement Over Limit 4 8 Rear Bearing Over Current Fault 0x0080 Compressor bearing fault registers are located in registers 40082 to 40087 If the bearing fault register is equal to zero then the compressor has no faults Compressor Motor Faults The Turbocor compressor has sixteen defined motor faults each fault is represented as a different bit in a 16bit register Fault Description Integer Value 1 Motor Single phase over current 1 Ox0001
52. ir Cooled Chiller IOM Manual FUSE 6A DIO EEE ZE SES E E N _ DI 3 Condenser status Bridge if not used DI 4 Not Used DI 6 Chilled Water Pump Running Status RLY 1 Compressor Interlock Relay RLY 2 Stage 1 Fans RLY 3 Stage 2 Fans RLY 4 Stage 3 Fans RLY 5 Stage 4 Fans RLY 6 Stage 5 Fans RLY 7 Chiller Faulted relay RLY 8 Chiller Running relay E Al 1 Tower Condenser Fan VFD Feedback 4 20mA gt m d N Al 2 Spare No function gt de T Q Al 3 Spare No function A amp T A Al 4 BAS Load Limiter 0 100 4 20mA gt on n e Al 5 BAS Set point reset 4 20mA 0 5VDC 0 10VDC gt T e Al 6 Refrigerant Level Sensor 4 20mA 0 5VDC 0 10VDC gt EN T Al 7 Remote outside air temperature 4 20mA 0 5VDC 0 10VDC A jo do oo Al 8 Remote outside air RH 4 20mA 0 5 VDC 0 10VDC AO 1 Tower Condenser Fan VFD Speed Signal 0 10V AO 2 Spare No Function AO 3 Chiller Percent Electrical Power Used 0 10V AO 4 Refrigerant Level Control Output 0 10V
53. is not a condition that shuts down the chiller but 1t will cause the capacity to be limited Fault Description Integer Value Low Chilled Water Temp 0x0001 2 Low suction pressure alarm 2 0x0002 High discharge pressure alarm 0x0004 4 8 Over current alarm 0x0008 High evaporator delta temp alarm 0x0010 Over network set capacity limit alarm 0x0020 7 Over network set power limit 0x0040 Modbus Defintion Rev09 18 amp KILTECH Modbus Communications Definition Chiller Fault Codes Active chiller faults are read from register 40017 Faults are represented in bit format each bit representing a different chiller fault The chiller controller will attempt to reset each fault automatically approx four minutes after the chiller is shutdown due to fault condition except in the case where the maximum number of starts per day has been exceeded A chiller that has stopped on fault goes through the following sequence before been able to restart CHILLER RUNNING i CHILLER FAULTED Time out 60sec Pumps Continue to run All Compressors stop SHUT DOWN STATE z Time out 180sec FAULT STATE 180 Seconds d Time out 20sec IDLE STATE 200 Seconds 20 Seconds START UP Fault Description Integer Value 1 Low Chilled Water Temp 01 0x0001 Low suction pressure fault i 0x0002 3 High d
54. ischarge pressure fault 0x0004 Over current fault 0x0008 4 5 High evaporator delta temp fault 6 Nochilled water flow fault 32 0x0020 8 _ Chillerfailedtostartfault 128 0x0080 9 External HP LP pressure cutout safety fault 256 Ox0100 14 No Compressors Available to Run 16348 65536 For more details on bit description please see section Program Examples Modbus Defintion Rev09 19 lt KIUT CH Modbus Communications Definition Chiller Operating Mode or State At any one time the chiller is operating in one of eight defined states each state is represented by an integer value they are State Description Integer Value Idle State Compressor Stage Down State Fault State 6 Shutting Down State Modbus register 40027 holds the chiller operating state the state Compressor Operating State At any one time each compressor is operating in one of thirteen kiltech defined states each state is represented by an integer value and they are Compressor State Description Integer Value Offline State No power 0 Resetting IGV amp Drive Il Ready to run state 2 Running normally Running in alarm avoidance mode capacity limited Resetting with a fault present Idle with a fault present 7 Clearing fault Compressor Locked out discharge pressure fault or over current fault generated inside compressor Compressor requires power down to reset fault C
55. k check per applicable code 3 Using a vacuum pump pull down to 500 microns Compressor checks and setting controller safeties DANGER DO NOT REMOVE COMPRESSOR COVERS WHILE POWER IS ON USE FIELD SERVICE WIRING KIT Confirm and record the line voltage is per rated input 5 Measure Line 1 2 line 2 3 and 1 3 on each compressor Confirm and record each phase E voltage to ground Remove the power input cover Confirm that the line voltage at each compressor s terminals match the display readings Verify that the suction pressure and discharge pressure match the controller readings H Verify suction and discharge pressure alarm limits for each compressor Set suction for 3 psi below controller value Set discharge 5 psi higher than controller value Commissioning Checklist Unit is level and vibration isolation installed Water flow switches are installed and connected to correct terminals External piping is supported and aligned to header stubs Discharge suction liquid line and motor valves are open Adequate service clearance exists around the unit Compressor circuit breakers are OFF Power ON the chiller Water strainers are installed on both heat exchanger inlets Power ON the controls System selected to OFF See manual Water treatment is commissioned Establish flows and assure flow interlocks are closed Chilled and Condenser water systems filled and purged of air Check and record vessel pressure drops Flow switche
56. l the evacuation hoses between the chiller and the vacuum pump Start the vacuum pump Open all isolation valves on the chiller to ensure that there is a vacuum achieved throughout the system Once a vacuum has been achieved connect an approved vacuum testing device and check the results If the vacuum reading is less than 500 microns isolate the vacuum hoses in the event that the reading is affected by the running vacuum pump Let the chiller remain under vacuum for approximately 1 hour Recheck the vacuum reading If the reading does not increase by 50 microns within this time the chiller is ready to be recharged with refrigerant If the system was severely contaminated by an internal electrical failure or by the presence of moisture a triple dehydration procedure should be carried out breaking the vacuum each time with refrigerant or nitrogen to remove all contamination During operation carry out refrigerant analysis on a regular basis and change filter driers as required Smardt Air Cooled Chiller IOM Manual 37 Charging the Refrigeration System Use pure refrigerant from non contaminated cylinders Turn on the chilled water and condenser water pumps Connect up charging lines to the bottom of the evaporator vessel and the charging cylinder Purge lines removing non condensables Add the correct amount of refrigerant charge to the evaporator vessel as indicated by the name plate In the event that a minimum of 75 of the tot
57. lave which has just responded Function Code 8 bit value which when a copy of the function code in the query indicates that the slave recognized the query and has responded See also Exception Response Byte Count 8 bit value indicating the number of data bytes contained within this response Data Hi The top most significant eight bits of a 16 bit number representing the register s requested in the query Data Lo The bottom least significant eight bits of a 16 bit number representing the register s requested in the query Error Check Lo The bottom least significant eight bits of a 16 bit number representing the error check value Error Check Hi The top most significant eight bits of a 16 bit number representing the error check value Exception Response If an error is detected in the content of the query excluding parity errors and Error Check mismatch the function code will be modified to indicate that the response is an error response called an exception response and the data bytes will contain a code that describes the error The exception response 1s identified by the function code being a copy of the query function code but with the most significant bit set to logic 1 Slave Function Error Code Error Error Address Code Check Lo Check Hij Slave Address 8 bit value representing the address of slave which has just responded Function Code 8 bit value which is the function cod
58. lectrical Y ihecke Check Main power supply voltages Check Electrical terminals are tight Check Hot spots discoloration on power cables Check Amperages are as per design Frequency of Maintenance for Smardt Chillers Y Electronic Check communication cables are secure v inspections Check pressure and temperature sensor connections y are secure Check there are no signs of physical damage Y discoloration on printed circuit boards Y Check the printed circuit boards are free of dust Check EXV winding resistance do NOT disturb connections unless repair is required Smardt Air Cooled Chiller IOM Manual 31 Compressor Check all mounting bolts are secure refrigeration Check for refrigerant leaks circuit Check for mechanical damage inspections Check operating temperatures and pressures Check airflow is not obstructed Check fin surfaces are clean Check fans rotation direction Check fan motor overload devices Gemcmemerchs Check fan blades for tightness on shaft mE Check fans for loose rivets and cracks Check coil fins for damage Table 6 Frequency of maintenance for Smardt chillers Air cooled condenser inspection if fitted Frequency of Maintenance Turbocor Compressor ITEM TASK 3mths 12mths General Check for visible mechanical damage to compressor Y inspections Check for excessive vibration from other rotating equipment Electrical Check main power supply voltages refer to p 47 insp
59. ller supply temperature wells for visual thermometers supply and install chiller isolation valves drain and vent lines install differential pressure gage K Supply and install water flow switches and wiring back to chiller control panel interlock pump starters auxiliary contact with flow switch for extra protection if possible Note Piping made to and from the chillers water connections and pressure relief valves must be made in such a way that weight and strain is removed from the chillers connections All chilled water piping up to chillers connections should be adequately insulated Strainers with 20mesh filters should be installed upstream of the evaporator and condenser Adequate valving should be supplied to permit draining of water from the evaporator and condenser as well as cleaning of the strainers Smardt Inc also recommends the installing piping contractor leave at least 3ft between the pre installed water piping and the chillers grooved connections This is to allow for proper fitting of piping to the chillers water box upon placement of the chiller Supply and install vent cocks on each water box Introduce water into the chiller and check for any possible leaks Fill out the Smardt Inc commissioning form Appendix A and send back to productsupport smardt com once this is satisfactorily received by the product support group a chiller activation code is sent With the supervision of a Smardt Inc qualified startup te
60. lly if the minimum and maximum flow rates are not exceeded Check individual rating sheets for minimum and maximum flow rates Operating Limits Maximum standby ambient temperature 130 F 54 C Maximum operating ambient temperature 105 F 41 C Minimum operating ambient temperature standard 38 F 3 C Minimum operating ambient temperature operational low ambient control 0 F 18 C Leaving chilled water temperature 38 60 F 3 16 C Operating Delta T range 6 16 F 14 9 C Maximum operating inlet fluid temperature 76 F 24 C Maximum startup inlet fluid temperature 90 F 32 C Maximum non operating inlet fluid temperature 100 F 38 C Note High ambient option can be installed at the factory to allow operating temperatures 105 125 F 41 52 C Flow Switch A flow switch for the chilled water system is necessary to assure adequate water flow to the evaporator before starting the unit A flow switch will also shut down the unit if the water flow is interrupted to guard against evaporator freezing The flow switch is to be field installed in chilled water piping and wired to the control panel by installing contractor Smardt Air Cooled Chiller IOM Manual 15 CONTROL WIRING REFERENCE General All applicable codes should be adhered to The Limited Product Warranty does not cover damaged equipment caused by wiring noncompliance An open fuse results from an overload a short or a ground Correct
61. m equipment skates rollers cranes ETC Isolation Isolation pads Spring isolators Electrical optional Differential pressure Graphical touch panel interface 3ph power to chiller transmitters Circuit breakers fused disconnect Ground wiring BAS call for cooling wiring External BAS temperature reset input BAS communications wiring Chilled water pump contactor control voltage and motor controls BAS demand limit wiring High speed internet connection for remote monitoring Water piping Entering and leaving chilled water Flow switches sensors Chiller isolation valves Differential pressure gage with shutoffs Vent and drain lines Pressure relief valves water side if required Pipe thermometers and wells Pipe insulation Balancing valves Strainers Pressure relief valves Pressure relief valves x2 Vent lines mounted on changeover manifold Flexible connections Refrigerant optional Refrigerant Table 3 Installation Requirements and Responsibility Chart For extra information please refer to the electrical and mechanical sections of this document Locate and group all parts shipped loose and reconcile with packing slip provided with chiller Parts shipped loose may be touch screen control panel temperature sensors refrigerant and spare parts that may have been specified at order time Loose parts are generally shipped inside the power entry electrical panel or strapped between the line reactor panels
62. m the poison control center Inability to move Smardt Air Cooled Chiller IOM Manual 6 Storage and Handling Only use refrigerant in ventilated areas Ensure that the container is sealed appropriately cap chain Only use containers which are suitable for Refrigerant R 134a and for the intended pressure and temperature Store containers at a temperature of less than 50 C in a ventilated area Avoid long periods of exposure to heat Stability and Reactivity Stability Stable under normal conditions Refrigerant reacts strongly with alkali metals and alkaline earth metals Pulverized aluminum and pulverized zinc catalyzes the decomposition of the refrigerant Substances to be avoided If escaping vapors come into contact with fire or very hot objects they form decomposition products which produce a high degree of irritation and have strong thermal effects It is possible that an explosive mixture could be formed under high pressure and with a high proportion of air Other information Relief Valves Ensure relief valves vent outside a building in accordance with national safety regulations and Jurisdictional requirements Concentrations of refrigerant in enclosed spaces can displace oxygen and lead to asphyxiation Do not disable any safety devices ELECTRICAL SAFETY WARNING Low voltage in electrical equipment is potentially lethal Isolate incoming electrical power before attempting installation or serv
63. mardt as stated in Smardt s specifications Any software or any other change to Smardt s supplied Articles made by Buyer or Buyer s customers will automatically nullify the warranty and may cause legal action by Buyer against Buyer and Buyer s customers iv the Articles have not been repaired by any un authorized third party other than those as approved by Smardt v the Buyer or Buyer s customer using the Article has followed and is capable of demonstrating all required inspection and maintenance requirements as specified by Smardt s specifications Smardt Air Cooled Chiller IOM Manual 41 APPENDICES Smardt Air Cooled Chiller IOM Manual 42 DN 2 S p RDI Pre Commissioning Form Request for Start Up Smardt Inc 1800 Trans Canada Highway Dorval Quebec Canada H9P 1H7 www smardt com Instructions This form provides a checklist of requirements to be completed prior to a factory supervised start up Please complete this form and return to Smardt This Adobe Acrobat Form allows you to complete it electronically and print it for manual handling Either email or fax the completed form to Smardt Reach Smardt by Fax at 514 426 5757 The services of an authorized Smardt technician is required on site on the Requested Start Up Date Please allow a minimum of TWO WEEKS NOTICE Smardt will make every attempt to accomodate the requested date but may not based on prior committments NOTE Costs incurred due to system not being ready
64. me the receiving device flushes the incomplete message and assumes that the next byte will be the address field of a new message Similarly if a new message begins earlier than 3 5 character times following a previous message the receiving device will consider it a continuation of the previous message This will result in an error as the value in the final CRC field will not be valid for the combined messages Modbus Error Checking Methods Standard MODBUS serial networks use two error checking processes the error check bytes mentioned above check message integrity whilst Parity checking even or odd can be applied to each character in the message The master 1s configured by the user to wait for a predetermined timeout interval The master will wait for this period of time before deciding that the slave is not going to respond and that the transaction should be aborted Care must be taken when determining the timeout period from both the master and the slaves specifications The slave may define the response time as being the period from the receipt of the last bit of the query to the transmission of the first bit of the response The master may define the response time as period between transmitting the first bit of the query to the receipt of the last bit of the response It can be seen that message transmission time which is a function of the baud rate must be included in the timeout calculation Query Transmission Time Respons
65. n the system is maintained the nitrogen can be removed and the dehydration can be performed on the chiller Dehydration procedure Chiller Dehydration Dehydration is recommended if the chiller has been open for a considerable period of time if the chiller is known to contain moisture or if there has been a complete loss of chiller holding charge or refrigerant pressure Dehydration can be done at room temperatures Using a cold trap may substantially reduce the time required to complete the dehydration The higher the room temperature the faster dehydration takes place At low room temperatures a very deep vacuum is required to boil off any moisture If low ambient temperatures are involved contact a qualified service representative for the dehydration techniques required Perform dehydration as follows 1 Connect a high capacity vacuum pump 5 cfm 002 m3 s or larger is recommended to the refrigerant charging valve Fig 2 Tubing from the pump to the chiller should be as short in length and as large in diameter as possible to provide least resistance to gas flow 2 Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum Open the shutoff valve to the vacuum indicator only when taking a reading Smardt Air Cooled Chiller IOM Manual 36 Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum 3 If the entire chiller is to be dehydrated open all isolatio
66. n valves if present 4 With the chiller ambient temperature at 60 F 15 6 C or higher operate the vacuum pump until the manometer reads 29 8 in Hg vac ref 30 in bar 0 1 psia 100 61 kPa or a vacuum indicator reads 35 F 1 7 C Operate the pump an additional 2 hours Do not apply a greater vacuum than 29 82 in Hg vac 757 4 mm Hg or go below 33 F 56 C on the wet bulb vacuum indicator At this temperature and pressure isolated pockets of moisture can turn into ice The slow rate of evaporation sublimation of ice at these low temperatures and pressures greatly increases dehydration time 5 Valve off the vacuum pump stop the pump and record the instrument reading 6 After a 2 hour wait take another instrument reading If the reading has not changed dehydration is complete If the reading indicates vacuum loss repeat Steps 4 and 5 T If the reading continues to change after several attempts perform a leak test up to the maximum 160 psig 1103 kPa pressure Locate and repair the leak and repeat dehydration When the system has been open for a lengthy period and contamination has occurred it is important to dehydrate the system to remove any moisture ATTENTION Never apply power to the unit while under a vacuum NOTE Use the same hoses as in the leak testing procedure making sure the lines are free of leaks If possible use copper lines to minimize potential leaks between the chiller and the vacuum pump Instal
67. nding points The receiving devices recognize the start of the message read the Slave Address to determine if they are being addressed and know when the message is completed so that they can use the Error Check bytes to confirm the integrity of the query Partial messages can be detected and discarded In RTU mode messages start with a silent interval of at least 3 5 character times The first field then transmitted is the device address The allowable characters transmitted for all fields are hexadecimal 0 9 A F Devices monitor the network bus continuously including during the silent intervals When the first field the address field is received each device decodes it to find out if it is the addressed device If the device determines that it is the one being addressed it decodes the whole message and acts accordingly if it is not being addressed it continues monitoring for the next message Following the last transmitted character a silent interval of at least 3 5 character times marks the end of the message A new message can begin after this interval Modbus Defintion Rev09 7 K KILTECH Modbus Communications Definition In the Integra 1000 and 2000 a silent interval of 60msec minimum is required in order to guarantee successful reception of the next request The entire message frame must be transmitted as a continuous stream If a silent interval of more than 1 5 character times occurs before completion of the fra
68. nput receives signal from BAS system to reset the chilled water temperature set point Scaling for the set point reset is configured on controller touch panel Refrigerant level sensor Input to receive a signal from a refrigerant level sensor connected to either the evaporator or condenser of chiller This sensor is used to control the electronic expansion output with 4 20mA or 0 10V output this sensor user configurable on touch panel Table 5 Controls I O Point Functionality SERVICE AND MAINTENANCE SEQUENCE OF OPERATION General The graphical chiller control system is responisible for providing demand to compressors staging on and off compressors control of electronic expansion valves control of load balance valves alarm condition avoidance and fault detection shutdown In order to run the chiller the following field installed inputs must be made DI 1 BAS enable Start command DI 2 Chilled water flow proof DI 3 Condenser water flow proof Bridge DI 3 if air cooled chiller For physical wiring locations of inputs see Control wiring diagram Field connections section of submittal Smardt Air Cooled Chiller IOM Manual 23 POWER UP SYSTEM INITIALIZE STOPPED Shutdown timer Stop command or Diagnostic active preparing full shutdown Alarm cleared peyoees uonipuoo Wely Figure 6 Sequence of Operation Smardt Air Cooled Chiller IOM Manual 24
69. nvoBRG State 3 nvoBRG State 4 nvoBRG State 5 nvoBRG State 6 nvoMTR State 1 nvoMTR State 2 nvoMTR State 3 nvoMTR State 4 nvoMTR State 5 Modbus Defintion Rev09 snvt time hour snvt time hour snvt lev percent snvt lev percent snvt lev percent snvt lev percent snvt lev percent snvt lev percent snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt press snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 snvt state 16 14 Modbus Communications Definition 40044 40045 40046 40047 40048 40049 40050 40051 40052 40053 40054 40055 40056 40057 40058 40059 40060 40061 40062 40063 40064 40065 40066 40067 40068 40069 40070 40071 40072 40073 40074 40075 40076 40077 40078 40079 40080 40081 40082 40083 40084 40085 40086 40087 40088 40089 40090 40091 40092 lt KILTECH Modbus Comm
70. o Still No Communications After Reboot s The Correct Number of Compressors Being Displayed No Ensure Correct Commissioning Settings In The Controller Yes Does the Controller only Communicate with Some Compressors Yes Check Cables Communication Wiring Termination No Possible Faulty Compressor Card BMCC Recheck Via Modpoll Compressor Monitoring Program No Check Interlock Circuit To Compressor Is Compressor Interlock Open Yes No Demand From Controller Being Held Off by other means Continue Investigation KTS 000001 Rev 1 Troubleshooting Guide Check Cables Connections Replace RS232 485 Converter Page 6 of 12 K KILTECH Troubleshooting Guide Input Output Module General Checks Go To I O Module Section Input Output Module Section Are The Temperature Input Within Typical Rage And Responding Temperature Variation Are RX TX LED s Flashing on I O Module No No Does the I O Module have 24AC present No Investigate Control Power Circuit Y es Yes Yes Check Temperature Check RS232 485 Module Sensor and Circuit s Input Open at terminals Check with Multimeter Is Digital Input 1 Yes BAS Enable Open Is BAS requesting Cooling Yes Check Circuit No N s Input Open at terminals Check with Yes Check Circuit Multimeter O No Digital Inputs Faulty Ch
71. ol concentration checked Pump rotation checked Pump rotation checked Bypass valves installed amp functional Bypass Valves installed amp functional ALLE HHE Ab ui Other site or commissioning notes Site Notes S Smardt Inc 1800 Trans Canada Highway Dorval Quebec Canada H9P 1H7 www smardt com RDT Commissioning and Warranty Initiation Form Instructions This form provides a checklist of requirements for commissioning a Smardt chiller Please complete this form and return to Smardt You may complete it electronically print it sign it and return it to Smardt within 72 hours of the commissioning Reach Smardt by Fax at 514 426 5757 NOTE Smart will not initiate the warranty unless this form is completed signed and returned to Smardt Project Details Chiller Nameplate Details Evaporator flow rate GPM Condenser flow rate GPM Evaporator pressure drop Condenser pressure drop Max pressure high side Max pressure low side BMCC Software Revision Model Number Serial Number Pre Commissioning Leak Check The Smardt chiller arrives without a refrigerant charge but contains a nitrogen holding charge Upon receipt of the chiller visually check for any aparent damage and perform an evacualtion and initial charge and leak check 1 Verify there is no visible damage to the chiller 4 Place an initial charge of R134a refrigerant into the chiller 2 Remove the nitrogen holding charge 5 Perform a lea
72. oldering process be sure that any component that may be affected by the addition of heat to the area be cooled by means of a wet rag wrapped around the component Once the soldering process is complete cool down the pipe work and shut off the nitrogen supply Once cool the system can be reassembled and tested for leaks Checking IGV Operation During compressor ramp up the inlet quide vanes open depending on load conditions as indicated by the ball bearing on the outside of the IGV housing If the ball does not move further testing will be required refer to the Compressor Service Manual When the Turbocor compressor is not in operation the Inlet Guide Vanes will move to the closed position Checking Electronic Expansion Valve Operation During operation the EXV modulates maintaining the pre set liquid level in the condenser The EXV responds to the liquid level sensor via the chiller controller If the liguid level sensor is operating correctly use the chiller controller interface to manually drive the EXV Verify that the liquid level fluctuates according to the drive signal as observed through the sight glass on the cooler If the EXV fails to respond to the manual input the EXV is defective and requires replacement Smardt Air Cooled Chiller IOM Manual 39 INCIDENT REPORT PROCEDURE Smardt strives for product excellence and maintains a competent staff of professionals in application design and service to serve our custome
73. ompressor Locked out by chiller Requires manual reset via chiller controller Compressor Exceeded Maximum number of starts per hour Compressor Exceeded Maximum number failed starts per hour Manual reset power cycle required 13 Compressor interlock open 14 Modbus registers 40064 to 40069 hold the compressor state for compressors 1 to 6 Modbus Defintion Rev09 20 lt KILT ECH Modbus Communications Definition Compressor Alarms The Turbocor compressor has 9 alarms defined An alarm in the compressor is NOT a condition that stops the compressor it is a condition where the compressor operates at reduced capacity in order to avoid a fault Compressor alarms are resented in bit format see table below Fault Description Integer Value 4 High Discharge Pressure Alarm 8 0x0008 6 HighRotor Temperature Alarm 8 High Pressure ratio Alam 18 9 High SCR Temperature Alam For more details on bit description please see section Program Examples Compressor alarm registers may be found in locations 40070 to 40075 If the register is equal to zero then compressor has no active alarms Compressor Faults The Turbocor compressor has thirteen general faults defined each fault 1s represented as a different bit in a 16bit register Fault Description Integer Value High Inverter Temperature Fault 0x0001 AN High Discharge Temperature Fault 27 0x0002 2 2 3 Low Suct
74. or 3 Circuit Default 1 Alarms and Trip Limits Suction Pressure Alarm Default 34 psi Suction Pressure Trip Default 24 psi Discharge Pressure Alarm Default 1 54 psi Discharge Pressure Trip Default 176 psi Over Current Alarm Default 300 A Over Current Trip Default 350 A Leaving Chw Alarm Default 39 F Leaving Chw Trip Default 35 6 F Delta T Alarm Default 14 R Delta T Trip Default 18 R OOOH ULL EON Evap Type Default Water Chiller Cond Type Default Water Cooled Design Max kW Default 270 kW I O Comm Port Default 3 I O Baud Rate Default 19200 BAS Stop Bits Default 2 ModBus Address Default 1 BAS Min Send Time Default 3 sec BAS Max Send Time Default 15 sec Start Mode Default BAS Input DI 1 Data Capture Time Default 900 Compressor 4 Circuit Default 1 Compressor 5 Circuit Default 1 Compressor 6 Circuit Default 1 Entering Cw Alarm Default 95 F Entering Cw Trip Default 104 F Chw Flow Delay Default 30 sec Trigger Delay Default 5 sec Cw Flow Delay Default 30 sec Trigger Delay Default 5 sec Max Faults per 12 Hr Default 12 Auto Fault Reset Delay Default 180 sec Max Compressor Hrs Default 5000 hrs Max Compressor Faults Hr Default 4 EENDEN UL bu Temperature Controls HVAC Mode Default HVAC Cool Cooling Setpoint Default 44 6 F Heating Setpoint Default 95 F Start Temp Setpoint Default 5 4 R Start Temp S
75. or trained and certified technician In order to activate the warranty the commissioning form must be completed and submitted to Smardt A copy of the Smardt Commissioning form can be found in Appendix A of this document Controls I O Point Functionality The air cooled chiller control program in the Kiltech control system is applicable to flooded air chillers with one or two refrigerant circuits and a common condenser and chilled water circuit The software is configurable for up to six Turbocor compressors on a Smardt chiller Temperature Inputs Used for leaving chilled water control and monitoring of the chiller Chilled Water In Temp Low leaving chilled water fault and High Evaporator AT faults may be generated from this sensors reading Used to monitor inlet chilled water High Chilled Water Out Temp Evaporator AT faults may be generated from this sensors reading Used for condenser water control and monitoring Condenser control algorithm for variable speed cooling tower fan and variable speed condenser water pump use this temperature as feedback Not used Not Used Used for monitoring only Liquid Refrigerant Temp Condenser liquid Used for monitoring only Used for monitoring and control Outdoor Air Temp Condenser loop uses this value to as a reference of minimum condensing temperature BAS Enable Enables and disables the chiller via a set of volt free contacts provided via a BAS system Chilled Water Flow Proo
76. ord XOR byte in message FOR Each bit in byte LSB ErrorWord AND Hex 0001 IF LSB 1 THEN ErrorWord ErrorWord 1 ErrorWord ErrorWord 2 IF LSB 1 THEN ErrorWord ErrorWord XOR Hex A001 NEXT bit in byte NEXT Byte in message END Function Codes The function code part of a MODBUS message defines the action to be taken by the slave The Kiltech Chiller Control products support the following function codes Function 3 Read Holding Registers Function 16 Pre Set Multiple Registers Function 8 Diagnostics Modbus Defintion Rev09 9 lt IC ILT Ten m Modbus Communications Definition Modbus Commands Supported Read Holding Registers MODBUS code 03 reads the contents of the 4X registers 40 000 Range Example The following query will request the prevailing Enable Status and the Cooling set point from slave one Starting Address High 00 1 1 Number of Points High O00 The slave unit may respond as follows with two data points Modbus Defintion Rev09 10 lt IC ILT C en Modbus Communications Definition Write Holding Registers MODBUS code 16 decimal 10 Hex writes the contents of the 4X registers Example The following query will set the Enable to off Field Name Example Hex Slave Address Function starting Address High Starting Address Low Number of Registers High Number of Registers Low Byte Count Data High Data Low Error Check H
77. quires the addition of refrigerant do not use reclaimed refrigerant unless it is of guaranteed quality and oil free Connect the low pressure hose blue hose to the access valve provided at the suction ball valve Connect the high pressure hose red hose to the access valve provided at the discharge ball valve Purge both gauge lines to ensure that non condensables which can lead to false pressure readings are removed from the line Once this is complete the service technician can evaluate the refrigeration system Removing Refrigerant Whenever removing refrigerant from the evaporator and condenser vessels water flow must be established prior to carrying out this procedure Water flow prevents a freeze up condition that will cause leaks between the water and refrigerant circuits leading to major component failure This procedure may vary depending on the type of service required Install the gauge manifold set or refrigerant recovery lines to the chiller set in the appropriate area of service Connect the common refrigerant hose to the suction side of an approved refrigerant recovery system Connect a hose between the discharge side of the recovery system and the recovery container Purge all lines of non condensables Switch on the recovery system and transfer the refrigerant The time of transfer depends on the type of transfer system and the volume of refrigerant To assist the transfer it is important to maintain a cool
78. r tubes Working a round nylon or bristle brush attached to a rod in and out of the tubes loosens the sludge After cleaning flush the tubes with clean water Commercial tube cleaning equipment is readily available to aid this task Evaporator Barrel Freeze Protection While Offline during Winter Months When temperatures are expected to be below freezing and the unit is not in duty the appropriate storage freeze protection procedure must be followed To protect the heat exchanger during freezing conditions it is the owner s responsibility to ensure that either 1 All water is drained from the barrel or 2 The barrel is filled with a glycol solution appropriate to avoid freezing at whatever the worst case temperature is based on the city of installation Maintenance Inspections Smardt recommends that on site operational checks be carried Operational checks evaluate the system performance fault history and trends The following list of preventative maintenance items must be carried out by authorized and qualified personnel in the recommended timeframe See Table 5 and 6 Owner s responsibilities Report any damage to the chiller set Report any faults that occur with the chiller set Turn off the chiller if fault condition persists Maintain a safe working environment in the plant room free from obstructions and debris Provide adequate lighting Ensure plant room ventilation is adequate and as per government regulations E
79. ressor Motor Faults Example Program Usage 23 Starting and Stopping the Chiller Changing the Chiller Set point Setting a Chiller Demand Limit Changing the Chiller Operational Mode Setting the outside air Temperature and Relative Humidity Setting the chiller demand limit via nviCapacityLim register 40005 Detecting Next Compressor Starting Sample Software Routines 25 Bit Detection in Basic Modbus Defintion Rev09 a ds ND XO 0 olan dtu 17 17 17 18 19 20 20 21 21 22 22 23 23 24 24 24 25 29 lt IC ILT C en Modbus Communications Definition Introduction The Kiltech Controller Series uses the Modbus RTU protocol a protocol widely used in the HVAC and industrial automation industries This manual explains how the Modbus communication functionality works For information on how the chiller controller operates please refer to the complete Kiltech chiller control operating manual With Modbus communications data transfer is possible between a single master PLC and up to 64 Kiltech Chiller Controllers the slave As the master the BAS transfers data simultaneously between single slave chiller controllers the address for each slave must first be set The slave chiller controller receiving data from the master will execute the instructed function and then respond to the master BAS Master Control BAS Slave Chiller 1 Slave Chiller 2 Modbus Defintion Rev09 2 lt KILTECH Modbus Communi
80. revolutions per minute scaled 1 1 e Pressure points these points represent system pressures scaled psia x10 or kPa x10 e Binary or Bit points these points are 16bit integer data where each represents a different piece of information for example each bit may represent a different type of error on a compressor Modbus Defintion Rev09 16 lt KILTECH Modbus Communications Definition Modbus Data Scaling In PLC BAS Temperature Conversion Temperatures points exported from the Kiltech Chiller controller are represented as degrees multiplied by a factor of 10 Example 66 7 F is transported across the modbus protocol as 667 Power Input Conversion Power in kilowatts is represented on the modbus protocol as kW multiplied by a factor of 10 Example 133 7KW is transported across the modbus protocol as 1337 Pressure Conversion Pressure points in kPa and psi is represented on the modbus protocol as absolute pressure multiplied by a factor of 10 Example 45 5psi is transported across the modbus protocol as 455 To convert to gauge pressures subtract 14 7psi from scaled number when controller is set to imperial units and 100kPa from scaled number in metric Modbus Defintion Rev09 17 lt IC ILT E CH Modbus Communications Definition Chiller Alarm Codes Active chiller alarms are read from register 40016 Alarms are represented in bit format each bit representing a different chiller alarm A chiller alarm
81. rk write the outside air temperature multiplied by ten to register 40018 To set the outside air relative humidity writes a value with no scaling between 10 and 100 to register 40020 Setting the chiller demand limit via nviCapacityLim register 40005 The capacity limit register enables the BAS system to demand limit the chiller This register 1s useful in situations where the total power demand to non essential services in a building may need to be limited The nviCapacityLim register 40005 when set below 100 limits the chiller maximum capacity by limiting the demand value sent to each of the operating compressors Example Sending a value of 56 to register 40005 will cause the controller to limit the compressors capacity from 0 to 56 The The current value of the capacity limit can be read back from register 40010 Modbus Defintion Rev09 e s lt KILTECLCLH H Modbus Communications Definition Detecting Next Compressor Starting To detect which compressor is to be started before it is actually enabled a BAS system may read register 40099 Register 40099 sets a different bit for each compressor before it starts The bit remains set until the compressor is stopped Compressor 1 START REQUEST 0x0001 Compressor 2 START REQUEST 2 0x0002 Compressor 3 START REQUEST 0x0004 Compressor 4 START REQUEST 0x0008 Compressor 5 START REQUEST 0x0010 6 Compressor 6 START REQUEST 32 0x0020 Sample Software Routines Bi
82. rol Control Mode Default Temp Diff Dead Band Default 0 5 R Proportional Band Default 18 R Integral Gain Default 2000 Derivative Gain Default 5000 Max Slew Rate Default 25 Startup Timer Default 180 sec Startup Output Default 100 Auxiliary Control Control Mode Default SST Dead Band Default 0 30 R Proportional Band Default 10 R Integral Gain Default 1500 Derivative Gain Default 5000 Max Slew Rate Default 5 Compressor Setup Demand Override Default 80 RPM Stage Up Default 50 RPM Stage Down Default 5 Stage Up Delay Default 300 sec Stage Down Delay Default 300 sec Pressure Ratio Limit Default 2 4 Number Comps Start Default 1 IGV Percent Limit Default 25 Mode Default Equal ALL O dl Setpoint Reset Default 0 F Ramp Per Minute Default 5 Min Output Default 0 Max Output Default 100 Setpoint Default 10 8 F Setpoint Reset Default 0 F Stage Unloader Startup Timer Default 0 sec Stage Unloader Startup Output Default 350 Startup Timer Default 0 sec Startup Output Default 0 Ramp Per Minute Default 5 Min Output Default 0 Max Output Default 100 Setpoint Default 44 6 F Max Starts per Day Default 12 Max Compressor Starts Hr Default 6 Compressor 1 Mode Default Modbus Compressor 2 Mode Default Modbus Compressor 3 Mode Default Modbus Compressor 4 Mode Default Modbus Compressor 5 Mode Default
83. ror Error Address Code Address Address af Points of Points Check Check HI Hi Lo LO Hi Slave Address 8 bit value representing the slave being addressed 1 to 247 O is reserved for the broadcast address The SPR and Integra products do not support the broadcast address Function Code 8 bit value telling the addressed slave what action is to be performed 3 4 or 16 are valid for Integra Start Address Hi The top most significant eight bits of a 16 bit number specifying the start address of the data being requested Start Address Lo The bottom least significant eight bits of a 16 bit number specifying the start address of the data being requested Number of Points Hi The top most significant eight bits of a 16 bit number specifying the number of registers being requested Number of Points Lo The bottom least significant eight bits of a 16 bit number specifying the number of registers being requested Error Check Lo The bottom least significant eight bits of a 16 bit number representing the error check value Error Check Hi The top most significant eight bits of a 16 bit number representing the error check value Modbus Defintion Rev09 s lt ITECH Modbus Communications Definition Response The example illustrates the normal response to a request for a single 16 bit Register Slave Function Data Hi Address Code Slave Address 8 bit value representing the address of s
84. rs If you have a problem with a Smardt chiller we want to know about it To report an incident and request an RMA please submit a Chiller Incident Report For your convenience this form is found in the Appendix A WARRANTY STANDARD Smardt Inc hereinafter referred to as the Company warrants that it will provide free replacement parts in the event any product manufactured by the Company and used in the United States or Canada proves defective in material or workmanship for a period of twelve 12 months from initial start up or eighteen 18 months from date of shipment whichever expires sooner Goods not manufactured by the Company but also sold under this agreement are warranted only to the extent that the manufacturer warranted them to the Company or directly to the customer The Company s liability to the customer shall not exceed the lesser of the cost of correcting defects in the goods sold or the original purchase price of the goods and the Company shall not in any event be liable to buyer or third parties for any delays or special indirect or consequential damages The Company s warranty does not apply to any goods which have been opened disassembled repaired or altered by anyone other than the Company or its authorized service representative or which have been subjected to misuse misapplication or abuse The Company is not obligated to pay any labor or service costs for removing or replacing parts or any shipping charges
85. s installed and set for minimum flow per specs Verify HP switch is for 15 psi less than design pressure Electrical and control wiring installed and meets specifications Verify LP switch is for 3 psi less than controller pressure setting Separate ground conductor installed per code Close compressor breakers Complete monitor program checks Complete main power checks With main power OFF confirm tightness of power and all terminal block connections Capture Monitor Commissioning screenshot for each compressor Start the chiller Complete system checks and run checks Interlock connections for flow are present at DI 2 and DI 3 Complete and record all controller settings Run signal wiring is present at terminal DI 1 With system loaded capture all Monitor detail screenshots LI TE p Ej O O GEG FEE EF EPE Refrigerant pressure relief piping is installed LLLI ET EJ L1 01 EJ C1 EJ 3 01 P1 E LJ Record any final controller settings Measured Performance Details Software Versions Setup Chiller Model and Communications I O Option Default 1 Number Compressors Default 4 Compressor Type Default TT300 134A Language Default English Units Default F psi R I O Stop Bits Default 2 Comp Comm Port Default 2 Comp Baud Rate Default 38400 Comp Stop Bits Default 2 BAS Comm Port Default 4 BAS Baud Rate Default 19200 Compressor Circuits Compressor 1 Circuit Default 1 Compressor 2 Circuit Default 1 Compress
86. s on the chiller Total hours of chiller operation before failure s Total Kilowatt hours of operation before failure w sss S S P s Replaced Components For every replaced and or failed component please fill in a record Component One Chiller Compressor Serial No Part Description A EE UO If replaced new part serial No Component Two Chiller Compressor Serial No A O Part Description If replaced new part serial No SMARDT INCIDENT REPORT Smardt Inc 1800 Trans Canada Hwy Dorval QC Canada H9P 1H7 Phone 1 514 426 8989 Fax 1 514 426 5757 Email productsupport smardt com www smardt com lt KILTECHI Modbus Communications Definition TABLE OF CONTENTS Introduction 2 Connection Diagram Communication related parameters Modbus Messages amp the Modbus Protocol Modbus Message Format Modbus RTU Mode Transmission MODBUS Message Timing RTU Mode Modbus Error Checking Methods Parity Checking CRC Checking Function Codes Modbus Commands Supported Read Holding Registers Write Holding Registers Exception Codes Product Specific Information 13 Modbus Register List Modbus Data Description 16 Modbus Data Scaling In PLC BAS 17 Temperature Conversion Power Input Conversion Pressure Conversion Chiller Alarm Codes Chiller Fault Codes Chiller Operating Mode or State Compressor Operating State Compressor Alarms Compressor Faults Compressor Magnetic Bearing Faults Comp
87. ser as per specifications Fault Diagnosis Chart SYMPTOMS POSSIBLE CAUSE ACTION Low suction pressure Low chilled water flow Check flow as per design Chilled water temperature too low Faulty pressure transducer Check transducer Check set points Insufficient refrigerant charge Check evaporator liquid level Check sub cooling Check discharge temperature Restricted refrigerant flow Check EXV operation Check filter driers Suction valve closed Check valve position Compressor IGV stuck open Check indicated position and carry out standard IGV checks High discharge pressure Condenser water temp too Check tower set point water cooled machines high Check flow as per design Low condenser water flow Clean tubes Fouled water tubes Blocked water strainer Clean strainer Faulty pressure transducer Replace transducer Non condensable in system Dehydrate system System overcharged Adjust charge Discharge valve closed Check valve position Restriction in pipe work Correct pipe work High GEEA PI ate Al Blocked restricted airflow Remove obstructions cooled machines Remove cause of re circulation Correct power supply connection Reset investigate cause Motor failure Repair replace Air re circulation Fans reversed Electrical overload s tripped Faulty pressure transducer Replace transducer Dehydrate Non condensable in system system Smardt Air Cooled Chiller IOM Manual 33 TT Semovrhaged Adwstc
88. t Chiller Not Operating Cont Timers Active Yes No Is Process Temperature above specified Delta T above Set Point No Yes Has Chiller Compressors Exceeded Number of Faults For a Given Period of Time Yes Wait For Applicable Timers to Complete Press Setup and check Temperature Control Settings Check Fault Type on Chiller or Compressor Repair and Cycle Power to Chiller Controller KTS 000001 Rev 1 Troubleshooting Guide Troubleshooting Guide Timers Too Long Go To Commissioning Settings to Re configure Page 2 of 12 K KILTECH Controller Software Go To Controller Software Section Controller Software Does Controller Yes Incorrect No Boot Up Images Yes No Check Image Files Within HD2 Invalid Disc Error Yes USB Stick Left Installed During Appears Power Up No Re format Panel PC and Upload Application Software Default Windows Yes No Software installed to Image Pops Up Panel PC Re format Panel PC and Upload No Application Software Error Message Yes Power Fluctuation Has Occurred and Requires Cannot Find Files Reset No Check USB Stick and Upload Application Software Again No Display or image problems Replace Panel PC Yes Panel PC Hard Drive Failed KTS 000001 Rev 1_Troubleshooting Guide Troubleshooting Guide Incorrect Text Fields Yes Check Commissioning Settings
89. t Detection in Basic Public Function ExamineBit ByVal Byte As Long ByVal Bit As Long As Boolean The ExamineBit function will return True or False depending on the value of the nth bit Bit of an integer Byte Dim mask As Double Create a bitmask with the 2 to the nth power bit set mask 2 Bit Return the truth state of the 2 to the nth power bit ExamineBit Byte And mask gt 0 End Function Modbus Defintion Rev09 Tor K KILTECH Troubleshooting Guide Chiller Not Running General Checks Chiller Not Operating Power To Controller Active With Voltage Present No Turn On Power or Carry Out Fault Finding on Applicable Power Circuit Power Re instated Controller Turned On Turn On Controller At Switch Yes Go To Controller Controller Fully Booted No Up With Correct Active Software Application Images Section Yes any Faults Go To Faults Present With Yes Section Error Icon Flashing Yes Go To Compressor Unsure Compressor Communications Section OK Yes I O Module Unsure e Tol Communications Section OK Yes xternal Interlocks Closed Press I O Data Tab Check Interlock Circuits BAS Cooling Call Chilled Water Flow Condenser Water Flow Note circuits must be closed to initiate cooling KTS 000001 Rev 1 Troubleshooting Guide Page 1 of 12 amp KILTECH General Con
90. the cause of the open fuse before replacing the fuse and restarting the fan motor or compressor All eletrical wiring should be copper Use copper wiring for all wiring to the unit See Appendix B for Kiltech Modbus Communications Definition Electrical Wiring The main power input connection for the Smardt range of chillers is a single point termination via a main termination box supplied as standard on each chiller unit From the main termination box each compressor control box power and controls is pre wired to the individual compressors All power wiring from this point is the responsibility of the installing contractor All wiring must be installed in accordance with appropriate local and national electrical codes and will require a circuit breaker or fuses to protect the main wiring run from the final distribution sub board to the unit Compressor motors are designed to operate satisfactorily over a range of 10 percent of the standard design voltage Field Wiring WIRING DIAGRAM I 4 Lt mri I Ti EI v vit 4 __ L Er ae A L 1 eae s 1s 1 PN c F FAN 4N N 2 UP TO 12 a J A 1 Montreal Quebec Canada Figure 2 Field Wiring for Aircooled Chiller COMPONENTS CONTROLS Smardt Chiller Control solutions are ready to use Touch Screen Displays and l O devices developed specifically for turbocor chiller applications DESCRIPTION Manufacturer
91. unications Definition nvoMTR_State_6 snvt state 16 40093 nvoCoolingTowerSpd snvt lev percent 40094 nvoCondPumpSpd snvt lev percent 40095 nvoChillerModel snvt count 40096 nvoDigitallnputs Binary representation of di status 40097 nvoDigitalOutputs Binary representation of relay status 40098 nvoNextComprStarting Binary representation of relay status 40099 Modbus Defintion Rev09 15 lt KILTECH Modbus Communications Definition Modbus Data Description Modbus data in the Kiltech controller consists of the following types of data e Switch points Switch data have only to possible values O or 1 and are used to represent things like enable disable function status e Temperature points Temperature data is represented as Cx10 or Fx10 temperature data may be read only such as a leaving air water measurement or may be read write such as a temperature set point e Percentage points Percentage points represent data such as percent chiller loading or percentage motor speed these points may be read and write e Electrical consumption in kilowatts these points represent consumed electrical power from compressors or fans in kWx10 and may be read or write write applies total kW input limit setting e State points these points are integer values that represent a product defined state such as Chiller Running or Chiller Faulted e RPM points these points represent actual motor shaft speeds in

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