Download Smardt Air Cooled Chiller O&M - Coward Environmental Systems

Oil-Free
Centrifugal Chiller
Air-Cooled Chiller Manual
Installation, Operation &
Maintenance Manual
IOM-AC February 2008
TABLE OF CONTENTS
PRODUCT DESCRIPTION .......................................................................................................................4
PURPOSE OF THIS DOCUMENT ..............................................................................................................4
DEFINITION OF ACRONYMS ...................................................................................................................4
REFRIGERANT SAFETY GUIDELINES ...................................................................................................5
STORAGE AND HANDLING .....................................................................................................................7
RELIEF VALVES....................................................................................................................................7
ELECTRICAL SAFETY ................................................................................................................................7
RIGGING.........................................................................................................................................................8
HANDLING ...........................................................................................................................................8
FOUNDATION .......................................................................................................................................8
LIFTING METHOD .................................................................................................................................8
CLEARANCE.......................................................................................................................................10
INSTALLATION OVERVIEW ....................................................................................................................11
STORAGE ....................................................................................................................................................12
CHILLED WATER SYSTEM......................................................................................................................13
PRESSURE DROP TABLE ....................................................................................................................13
CHILLED W ATER PUMPS.....................................................................................................................14
W ATER VOLUME ................................................................................................................................14
VARIABLE W ATER FLOW .....................................................................................................................14
OPERATING LIMITS .............................................................................................................................15
FLOW SWITCH ...................................................................................................................................15
CONTROL WIRING REFERENCE...........................................................................................................16
GENERAL ..........................................................................................................................................16
ELECTRICAL W IRING ..........................................................................................................................16
FIELD W IRING ....................................................................................................................................16
COMPONENTS – CONTROLS.................................................................................................................16
COMMISSIONING.......................................................................................................................................21
CONTROLS I/O POINT FUNCTIONALITY ................................................................................................21
SERVICE AND MAINTENANCE ..............................................................................................................23
SEQUENCE OF OPERATION ..................................................................................................................23
GENERAL ..........................................................................................................................................23
POWER UP TO RUNNING ....................................................................................................................25
RUNNING WITH AN ALARM LIMIT (FAULT AVOIDANCE)...........................................................................27
NORMAL SHUT DOWN .........................................................................................................................28
ABNORMAL SHUT DOWN (FAULT PRESENT).........................................................................................29
MAINTENANCE ..........................................................................................................................................30
COMPRESSOR ...................................................................................................................................30
HEAT EXCHANGER – CONDENSER COILS ............................................................................................30
HEAT EXCHANGER – EVAPORATOR BARREL ........................................................................................30
EVAPORATOR BARREL FREEZE PROTECTION W HILE OFFLINE DURING W INTER MONTHS .......................31
MAINTENANCE INSPECTIONS...............................................................................................................31
TROUBLESHOOTING ...............................................................................................................................33
FAULT DIAGNOSIS CHART...................................................................................................................33
SERVICE PROCEDURES .........................................................................................................................35
Smardt Air-Cooled Chiller IOM Manual
2
CONNECTING REFRIGERANT GAUGES .................................................................................................35
REMOVING REFRIGERANT...................................................................................................................35
REFRIGERANT LEAK TESTING .............................................................................................................36
MACHINE NOT OPERATING - NO CHARGE ..............................................................................................36
DEHYDRATION PROCEDURE - CHILLER DEHYDRATION ..........................................................................36
CHARGING THE REFRIGERATION SYSTEM ............................................................................................38
CHECK SUB-COOLING - SUB-COOLING MEASUREMENT PROCEDURE .....................................................38
SUPERHEAT MEASUREMENT PROCEDURE ...........................................................................................38
SOLDERING PROCEDURE....................................................................................................................39
CHECKING IGV OPERATION................................................................................................................39
CHECKING ELECTRONIC EXPANSION VALVE OPERATION ......................................................................39
INCIDENT REPORT PROCEDURE .........................................................................................................40
WARRANTY.................................................................................................................................................40
APPENDICES ..............................................................................................................................................42
For product support issues, corrections, or enquiries, contact:
Product Support
[email protected]
Smardt Inc.
1800 Trans Canada Hwy
Dorval, QC, Canada H9P 1H7
Tel : +1 514 426 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 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 doublecoated 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 aircooled 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 electrical 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 Smardt 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 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.
 Stop 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/m³:
 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
come into contact with the
eyes
Eye irritation
Rinse with plenty of clean water
immediately. Consult a doctor
immediately.
Liquid refrigerant has come
into contact with the eyes
Extreme eye irritation, watery
eyes, redness and swollen
eyelids.
Rinse with plenty of clean water
immediately. Consult a doctor
immediately.
Gaseous refrigerant
has come into contact
with the skin
No risk
Liquid refrigerant has come
into contact with the skin
Frostbite with burn-like skin
problems (redness, blistering)
Inhalation
refrigerant
of
gaseous
Inability to move,
unconsciousness Risk of
suffocation!
Smardt Air-Cooled Chiller IOM Manual
Rinse with plenty of clean water
immediately. Consult a doctor
immediately.
Take person out into the fresh air
immediately. Consult a doctor
immediately.
If patient stops breathing: artificial
resuscitation. Inform the poison
control center.
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
Substances to be avoided
Refrigerant reacts strongly with alkali metals and
alkaline earth metals Pulverized aluminum and
pulverized zinc catalyzes the decomposition of the
refrigerant.
Other information
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.
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 service 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.
Wait at least 10 minutes after isolating power
before opening compressor access covers.
Smardt Air-Cooled Chiller IOM Manual
7
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 chiller’s high center
of gravity must be considered when rigging to ensure that the chiller is secure and
balanced when suspended. A spreader bar / I-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.
Chiller Series
Number of
compressors
Number of fans
Total length "L" - m
(ft-in)
Weight - kg (lbs)
Center of gravity
"CG" -m (ft-in)
Number of lifting
lugs
Min and max chiller
MCA - A*
Chiller MOP -A*
Minimum field
wiring**
Flow range -l/s
(gpm)
Number of passes
Water conn size
("Vict.)
Service clearance
"S" - m (ft-in)
A280
A310
A540
A560
A580
A610
A770
A840
1
4
3,74 (12'
3")
3000
(6600)
2,10 (6'
11")
1
6
4,89 (16'
0")
3500
(7700)
2
8
6,04 (19'
10")
4500
(9900)
3,45 (11'
4")
2
8
7,20 (23'
7")
4500
(9900)
4,30 (14'
1")
2
10
7,60 (24'
11")
5351
(11770)
4,40 (14'
5")
3
10
7,60 (24'
11")
5450
(11990)
2,85 (9' 4")
2
8
4,89 (16'
0")
4500
(9900)
3,45 (11'
4")
5,25 (17' 3')
3
12
8,75 (28'
9")
6350
(13970)
5,25 (17'
3')
4
4
4
4
6
6
6
6
140-180
225-300
190-220
300
280-330
350
280-330
300-350
280-330
400
330-380
450
390-430
450-500
450-470
450-500
2/0
8-18
(127-285)
2
2/0
10-20
(159-317)
2
2 x 2/0
12-30
(190-476)
2
2 x 2/0
17-37
(270-587)
2
2 x 2/0
19-45
(301-713)
3
2 x 3/0
21-48
(333-713)
3
2 x 3/0
26-54 (412856)
2
2 x 3/0
26-54
(412-856)
2
4
4
5
6
6
2,0 (6' 7")
3,4 (11' 2")
6
3,4 (11'
2")
6
2,0 (6' 7")
5
3,4 (11'
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
Figure 1. Rigging Diagram, chiller dimensions and clearances
* Values shown are typical. Refer to Smardt 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 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.
UNIT PLACEMENT
Single unit, floor level
Single unit, pit installation
no deeper than height of
unit
Units side by side, floor
level
Units side by side, pit
installation no deeper than
height of unit
SIDE CLEARANCE
6 feet
8 feet
12 feet between units, 6
feet on other sides
16 feet between units, 8
feet on other sides
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 Installed
Smardt-supplied, Fieldinstalled
Field supplied, Field Installed
Delivery Inspection
Rigging
Shall be performed by the purchaser of the chiller.
Safety chains,
Clevis connectors,
Lifting beam equipment, skates, rollers, cranes…….ETC
Isolation
Isolation pads,
Spring isolators
Electrical
(optional) Differential pressure
transmitters.
Water piping
Entering and leaving chilled water
sensors
Flow switches,
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
mounted on changeover manifold
Vent lines,
Flexible connections
Refrigerant
Graphical touch panel interface.
3ph power to chiller,
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.
(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 and the chiller.
Fully inspect the chiller before accepting delivery from shipping company. Detail
any damage that may have occurred during shipping. Advise Smardt 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 chiller, supply temperature wells for visual thermometers,
supply and install chiller isolation valves, drain and vent lines, install differential
pressure gage.
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
[email protected], 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 technician 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
W031.1B.44N
8.0
DP - PSI
W502.2B.22N
W058.2B.44F
W062.2B.33N
W074.3B.22N
6.0
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 throughout 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 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 gpm 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
successfully 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 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
Figure 2. Field Wiring for Aircooled Chiller
COMPONENTS – CONTROLS
Smardt Chiller Control solutions are ready to use Touch Screen Displays and I/O
devices, developed specifically for turbocor chiller applications.
DESCRIPTION
Full color touch panel graphical chiller control system
Smardt Air-Cooled Chiller IOM Manual
Manufacturer
Kiltech Inc
MODEL#
KCT 1000
16
Features/ Benefits
 Enhanced energy efficiency capabilities, utilizing the latest compressor optimization
technologies
 Remote monitoring - via web to obtain real time energy/ performance data and system
interrogation
 Panel mount 10.4” TFT Color Touch Screen Displays available
 Modular Input/ Output devices – allowing for simple expansion
User friendly navigation and trending capabilities
Engineered solution – allows for quick and simple installation and commissioning.
 Live updates/ system configuration functionality.
 Variable speed condenser controls.
 In built stepper motor controls for EXV’s.
 Continuous data logging – 1 year of data stored on device in easy to use .csv format.
 Logging of 32,000 chiller and compressor faults and events.
Specifications
Operating System
 Custom, real time O/S
 Memory - Up to 256 Mb (application specific)
Graphic Terminal
 Colour, SVGA TFT LCD, with resistive type touch screen
 Resolution – 800 x 600
 Luminance – 400 nits (suitable for exterior use)
Power Supply
 24VAC – 50/60Hz
 25vA max
Inputs and Outputs
 Thermistor Inputs (10K NTC) – Qty. 8
 Digital Inputs (Voltage Free) - Qty. 8
 Analogue Inputs (4-20mA or 0-10V) – Qty. 8
Physical Dimensions
 Digital Outputs (Relay) – Qty. 8
 Enclosure – 16” x 24”
 Analogue Outputs (0-10VDC) – Qty. 6
EXV
Output
–
Bipolar
Stepper
Motor
 Colour – White, enamel (gloss)

Drive
 Category - Nema 1
BAS Protocols
 Weight – 45 Lbs
TM
Environment
 Modbus , TCP/IP module
TM
 Modbus , RTU RS485 module
 Operating range: 0° – 50°C (32° –
®
122°F)
 LonTalk , FT-10 module
TM
BacNet
,
MSTP
module
 Storage range: -10° – 70°C (14° –

TM
158°F)
 BacNet , IP module
 Relative humidity: 5 - 95% RH – non
condensing
Smardt Air-Cooled Chiller IOM Manual
17
Figure 3. Controls Wiring Diagram – With Dp Transmitters
Smardt Air-Cooled Chiller IOM Manual
18
Figure 4. Controls Wiring Diagram – No Dp Transmitters
Smardt Air-Cooled Chiller IOM Manual
19
Figure 5. Field Wiring Terminations
Smardt Air-Cooled Chiller IOM Manual
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 Turbocor 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
Chilled Water In Temp
Chilled Water Out Temp
Not used
Not Used
Liquid Refrigerant Temp
(Condenser liquid)
Outdoor Air Temp
Spare
Spare
Digital Inputs
BAS Enable
Chilled Water Flow Proof
Smardt Air-Cooled Chiller IOM Manual
Function
Used for leaving chilled water control and
monitoring of the chiller.
Low leaving chilled water fault and High
Evaporator ΔT faults may be generated from this
sensors reading.
Used to monitor inlet chilled water. High
Evaporator ΔT 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.
Used for monitoring only.
Used for monitoring only.
Used for monitoring and control.
Condenser loop uses this value to as a reference
of minimum condensing temperature.
No function
No function
Function
Enables and disables the chiller via a set of volt
free contacts provided via a BAS system.
Monitors chilled water flow status through chiller
21
Condenser status
Not Used
Hp/LP safety
Chilled Water pump status
Not Used
Not Used
Relay Outputs
Compressor Enable
Condenser VFD Enable / Stage 1
fans
Stage 2 Fans
Stage 3 Fans
Stage 4 Fans
Stage 5 Fans
Chiller faulted
Chiller Running
Analogue Outputs
Condenser VFD (4-20mA)
Not Used
Chiller % Design kW (4-20mA)
Refrigerant SH / level control
output (4-20mA)
Smardt Air-Cooled Chiller IOM Manual
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 fan or VFD fault contact. If not required
– Bridge connection.
No function.
Monitors digital input for a closure of an external
HP or LP switch. A chiller fault is stopped on a
“pressure safety cutout fault” if input circuit is
closed.
Monitors chilled water pump status. May be
connected to auxiliary contact of chilled water
pump contactor or VFD status.
None
None
Function
Pilot relay used to enable an external 2, 4 or 6
pole relay connected to each of the Turbocor
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,
output is enabled when chiller starts to run and
condensing temperature is above the minimum
temperature limit setting in controller.
Condenser fan pilot relay.
Condenser fan pilot relay.
Condenser fan pilot relay.
Condenser fan pilot relay.
Relay is enabled whenever the chiller has a
compressor or chiller fault active.
Relay is enabled whenever the chiller is in a
running state.
Function
Variable speed control signal for condenser fan.
Signal is generated from condenser control loop.
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.
Output to control an electronic expansion valve
from a refrigerant level sensor or suction super
heat measurement. Control output is generated
from chiller controllers EXV control loop.
22
Hot gas valve (0-10VDC)
Selectable Loop Output (0-10VDC)
Analogue Inputs
Condenser VFD feed back
Spare
Spare
BAS load limit
Set point reset
Refrigerant level sensor
Outside air temp
Outside air RH%
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.
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.
Function
Monitors cooling tower variable speed drive actual
speed.
No Function.
No Function.
Input to limit the demand output control to the
compressors. 4mA input = no demand limiting,
20mA = full demand limiting to 25%.
Input 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.
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.
Input for remote outside air temperature sensor
with 4-20mA or 0-10V output.
Input for outside air relative humidity. Scaling for
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
Compressor reset
Waiting for start
command
ed
m
fir
n
Co
St
ar
tc
om
m
an
d
n
ow
td
u
Sh
STOPPED
STARTING
Auto reset timer
expired
Auto
Waiting on flow and
compressor start
Stop command or Diagnostic
Shutdown timer
active – preparing full
shutdown
St
op
co
m
m
an
d
St
ed
irm
f
on
tC
ar
Running
ete
lt D
Fa u
d
cte
Running
Running – on Limit
Alarm cleared
Auto fault reset timer
active
Fa
ult
De
tec
ted
Alarm condition reached
FAULTED
Alarm Avoid
Reducing capacity
Figure 6. Sequence of Operation
Smardt Air-Cooled Chiller IOM Manual
24
Figure 7. Power Up to Running
Power Up to Running
Smardt Air-Cooled Chiller IOM Manual
25
Figure 8. Temperature Pull Down and Normal Running
Temperature Pull Down and Normal Running
Smardt Air-Cooled Chiller IOM Manual
26
Figure 9. Running with an Alarm Limit (Fault Avoidance)
Running with an Alarm Limit (Fault Avoidance)
Smardt Air-Cooled Chiller IOM Manual
27
Figure 10. Normal Shut Down
Normal shut down
Smardt Air-Cooled Chiller IOM Manual
28
Figure 11. Abnormal Shut Down (Fault Present)
Abnormal Shut Down (Fault Present)
Smardt Air-Cooled Chiller IOM Manual
29
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 installed. 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
evaporator 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.
Frequency of Maintenance for Smardt Chillers
ITEM
TASK
Frequency
3mths
Electrical
checks
Check Main power supply voltages
Check Electrical terminals are tight
Check Hot spots / discoloration on power cables Check
Amperages are as per design
Electronic
inspections
Check communication cables are secure
Check pressure and temperature sensor connections
are secure.
Check there are no signs of physical damage /
discoloration on printed circuit boards.
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
6mths
12mths








31
Compressor
refrigeration
circuit
inspections
Air
cooled
condenser
inspection (if
fitted)
Check all mounting bolts are secure
Check for refrigerant leaks
Check for mechanical damage
Check operating temperatures and pressures
Check airflow is not obstructed.
Check fin surfaces are clean
Check fans rotation (direction).
Check fan motor overload devices








Clean condenser coils

Check fan blades for tightness on shaft



Check fans for loose rivets and cracks
Check coil fins for damage
Table 6. Frequency of maintenance for Smardt chillers
Frequency of Maintenance – Turbocor Compressor
ITEM
TASK
General
inspections
Check for visible mechanical damage to compressor
Check for excessive vibration from other rotating
equipment
Electrical
Check main power supply voltages (refer to p 47
inspections
Turbocor service manual)
Check electrical terminals are tight
Check for signs of hotspots / discoloration on power
cables
Check amperages as per design
Check DC Bus voltage
Check capacitor mid bus voltage
Replace capacitor set
Check operation of all system safety devices and
interlocks
Check all communications cables are secure and tight
Check all electronic modules are secure
Check physical condition of all exposed Printed Circuit
Boards (PCB’s)
Check all exposed PCB’s for dust build-up and clean if
necessary
Check calibration pressure / temperature sensors
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)
Table 7. Frequency of Maintenance – Turbocor compressor
Smardt Air-Cooled Chiller IOM Manual
Frequency
3mths

6mths
12mths



















As Required
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 condenser, 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
Insufficient refrigerant charge
Check set points
Check transducer
Check evaporator liquid level
Check sub-cooling
Check discharge temperature
High
discharge
pressure
(water-cooled machines)
Restricted refrigerant flow
Check EXV operation
Check filter driers
Suction valve closed
Compressor IGV stuck open
Check valve position
Check indicated position and
carry out standard IGV
checks.
Check tower set point
Condenser water temp. too
high
Check flow as per design
Low condenser water flow
Clean tubes
High discharge pressure (aircooled machines)
Fouled water tubes
Blocked water strainer
Faulty pressure transducer
Non-condensable in
system.
Clean strainer
Replace transducer
System overcharged
Adjust charge
Discharge valve closed
Check valve position
Restriction in pipe work
Correct pipe work
Blocked / restricted airflow
Remove obstructions
Dehydrate system
Electrical
Motor failure
Remove
cause
of
recirculation
Correct
power
supply
connection Reset / investigate
cause
Repair / replace
Faulty pressure transducer
Non-condensable in system
Replace transducer Dehydrate
system
Air re-circulation
Fans
reversed
overload(s) tripped
Smardt Air-Cooled Chiller IOM Manual
33
System overcharged
Adjust charge
Discharge valve closed
Check valve position
Restriction in pipe work
Correct pipe work
SYMPTOMS
POSSIBLE CAUSE
ACTION
High-evaporator pressure
Chilled water temperature too
high
Check temperature sensor.
Pressure sensor faulty
Check for excessive water
flow.
IGV failure
Replace transducer
Check operation (refer
procedure)
Low refrigerant temperature
cutout
Insufficient refrigerant charge.
Check refrigerant charge.
Replace sensor.
Faulty sensor. Water
temperature too low. Water
flow blocked
Check set points.
Find / repair blockage
Drive temperature too high
No motor cooling.
Check pipe work / valves.
Insufficient sub-cooling. Faulty
sensor
Check compressor solenoids
(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 requires 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 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 in 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 isolation 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.
7. 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.
Install 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 total 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 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 soldering 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 guide
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
liquid 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 customers. 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. 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
(i) 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 Smardt 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
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 for commissioning will be chargable for normal labor and expenses.
Job Name
Job Location
Contractor
Contact Name
Phone Number
P.O. Number
Date of Pre-Commissioning
Requested Date of Start-Up
General
Electrical and Controls
Other checks
Installation Location
Power wiring matches nameplate
Remote condenser valves installed
Chiller mounted on a level surface
Interlock wiring completed
Drain and purge valves operational
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
System pressure checked & no leaks
System pressure checked & no leaks
Chilled water system is vented
Water system is vented
Flow switch installed and functional
Flow switch installed and functional
Strainers cleaned after flush
Strainers cleaned after flush
Service clearances per requirements
Service clearances per requirements
Glycol concentration checked
Glycol concentration checked
Pump rotation checked
Pump rotation checked
Bypass valves installed & functional
Bypass Valves installed & functional
Design condenser flow rate
Certifications Required?
Other site or commissioning notes
Site Notes
Signature
Design chilled water flow rate
Signature Date
Commissioning and Warranty Initiation Form
Smardt, Inc. 1800 Trans Canada Highway Dorval, Quebec Canada H9P 1H7 www.smardt.com
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
Project Name
Site Address
Site Contact
Contact Phone
Commissioning Date
Commissioned By
Chiller Nameplate Details
Chiller Model Number
Serial Number
Compressor Model
Date of Manufacture
Nominal Capacity
Refrigerant Type
Refrigerant Charge
Nom. Tons / Comp.
FLA / Compressor
Voltage
LRA / Compressor
MCA
MOCP Min.
MOCP Max.
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
Compressor 1
Compressor 2
Compressor 3
Compressor 4
Compressor 5
Compressor 6
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 leak 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
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.
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 switches 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
Interlock connections for flow are present at DI-2 and DI-3
Run signal wiring is present at terminal DI-1
Refrigerant pressure relief piping is installed
Start the chiller. Complete system checks and run checks.
Complete and record all controller settings.
With system loaded, capture all Monitor detail screenshots
Record any final controller settings
Measured Performance Details
Evaporator Flow Rate, GPM
Condenser Flow Rate, GPM
Evaporator Pressure, PSI
Condenser Pressure, PSI
Evaporator Pressure Drop, PSI
Condenser Pressure Drop, PSI
Software Versions
Controller Software Revision
I/O PCB Serial Number
Interface Software Revision
Touch Panel Serial Number
Setup Chiller Model and Communications
I/O Option - Default=1
Evap Type - Default=Water Chiller
Number Compressors - Default=4
Cond Type - Default=Water Cooled
Compressor Type - Default=TT300 134A
Design Max kW - Default=270 kW
Language - Default=English
I/O Comm Port - Default=3
Units - Default=°F, psi, °R
I/O Baud Rate - Default=19200
I/O Stop Bits - Default=2
BAS Stop Bits - Default=2
Comp. Comm Port - Default=2
ModBus Address - Default=1
Comp. Baud Rate - Default=38400
BAS Min Send Time - Default=3 sec.
Comp Stop Bits - Default=2
BAS Max Send Time - Default=15 sec.
BAS Comm Port - Default=4
Start Mode - Default=BAS Input DI-1
BAS Baud Rate - Default=19200
Data Capture Time - Default=900
Compressor Circuits
Compressor 1 Circuit - Default=1
Compressor 4 Circuit - Default=1
Compressor 2 Circuit - Default=1
Compressor 5 Circuit - Default=1
Compressor 3 Circuit - Default=1
Compressor 6 Circuit - Default=1
Alarms and Trip Limits
Suction Pressure Alarm - Default=34 psi
Entering Cw Alarm - Default=95°F
Suction Pressure Trip - Default=24 psi
Entering Cw Trip - Default=104°F
Discharge Pressure Alarm - Default=154 psi
Chw Flow Delay - Default=30 sec
Discharge Pressure Trip - Default=176 psi
Trigger Delay - Default=5 sec
Over Current Alarm - Default=300 A
Cw Flow Delay - Default=30 sec
Over Current Trip - Default=350 A
Trigger Delay - Default=5 sec
Leaving Chw Alarm - Default=39°F
Max Faults per 12 Hr - Default=12
Leaving Chw Trip - Default=35.6°F
Auto Fault Reset Delay - Default=180 sec
Delta-T Alarm - Default=14°R
Max Compressor Hrs - Default=5000 hrs
Delta-T Trip - Default=18°R
Max Compressor Faults / Hr - Default=4
Temperature Controls
HVAC Mode - Default=HVAC Cool
Lookward Time - Default=120 sec
Cooling Setpoint - Default=44.6°F
Startup Timer - Default=100 sec
Heating Setpoint - Default=95°F
Startup Output - Default=15%
Start Temp + Setpoint - Default=5.4°R
Ramp Per Minute - Default=3%
Start Temp - Setpoint - Default=5.4°R
Min Output - Default=10%
Deadband - Default=0.2°R
Max Output - Default=100%
Proportional Band - Default=18°R
Setpoint Reset Mode - Default=AI-5
Integral Gain - Default=2500
Reset Temp Low - Default=6.0°R
Derivative Gain - Default=5000
Reset Temp High - Default=0.0°R
Max Slew Rate - Default=2%
Condenser Loop Controls
Control Mode - Default=Cw in Temp
Min Output - Default=0%
Dead Band - Default=0.5°R
Max Output - Default=100%
Proportional Band - Default=27°R
Min Setpoint - Default=65°F
Integral Gain - Default=3500
Start Setpoint - Default=78.8°F
Derivative Gain - Default=5000
Max Slew Rate - Default=5%
Condenser Variables
Startup Timer - Default=100 sec
Min Temp Limit - Default=65°F
Startup Output - Default=25%
Max Temp Limit - Default=85°F
Ramp Per Minute - Default=5%
Max Output - Default=100%
Expansion Valve Control
Control Mode - Default=Cond Level
Startup Output - Default=25%
Dead Band - Default=0.10°R
Ramp Per Minute - Default=5%
Proportional Band - Default=50°R
Min Output - Default=0%
Integral Gain - Default=1500
Max Output - Default=100%
Derivative Gain - Default=3000
Setpoint - Default=50°F
Max Slew Rate - Default=25%
Setpoint Reset - Default=0°F
Startup Timer - Default=180 sec
Hot Gas Valve Control
Control Mode - Default=Temp Diff
Ramp Per Minute - Default=5%
Dead Band - Default=0.5°R
Min Output - Default=0%
Proportional Band - Default=18°R
Max Output - Default=100%
Integral Gain - Default=2000
Setpoint - Default=10.8°F
Derivative Gain - Default=5000
Setpoint Reset - Default=0°F
Max Slew Rate - Default=25%
Stage Unloader Startup Timer - Default=0 sec
Startup Timer - Default=180 sec
Stage Unloader Startup Output - Default=350%
Startup Output - Default=100%
Auxiliary Control
Control Mode - Default=SST
Startup Timer - Default=0 sec
Dead Band - Default=0.30°R
Startup Output - Default=0%
Proportional Band - Default=10°R
Ramp Per Minute - Default=5%
Integral Gain - Default=1500
Min Output - Default=0%
Derivative Gain - Default=5000
Max Output - Default=100%
Max Slew Rate - Default=5%
Setpoint - Default=44.6°F
Compressor Setup
Demand Override - Default=80%
Max Starts per Day - Default=12
RPM Stage Up - Default=50%
Max Compressor Starts / Hr - Default=6
RPM Stage Down - Default=5%
Compressor #1 Mode - Default=Modbus
Stage Up Delay - Default=300 sec
Compressor #2 Mode - Default=Modbus
Stage Down Delay - Default=300 sec
Compressor #3 Mode - Default=Modbus
Pressure Ratio Limit - Default=2.4
Compressor #4 Mode - Default=Modbus
Number Comps. Start - Default=1
Compressor #5 Mode - Default=Modbus
IGV Percent Limit - Default=25%
Compressor #6 Mode - Default=Modbus
Mode - Default=Equal
Input / Output Scaling Setup
Entering Chw Offset - Default=0.0°R
Tempeature 7 Offset - Default=0.0°R
Leaving Chw Offset - Default=0.0°R
Tower VFD AI - Default=0.0Hz
Entering Cw Offset - Default=0.0°R
Chw Pump AI - Default=0.0Hz
Leaving Cw Offset - Default=0.0°R
Cw Pump AI - Default=0.0Hz
Outside Air Temp Offset - Default=0.0°R
BAS Limit AI - Default=0.0%
Liquid Temp Offset - Default=0.0°R
Setpoint Reset - Default=0.0°R
Refrigerant Level - Default=0.0%
AOA RH% AI - Default=0.0%
Outside Air Temp AI - Default=0.0°R
Stepper Drive Setup
Output Mode - Default=EXV
Step Rate per Sec - Default=100
Max Steps - Default=6000
Additional Site or Commissioning Notes
Site Notes
NOTICE: This form must be completed, signed and received by Smardt to initiate product warranty.
Signature
Signature Date
Completion Date
INCIDENT REPORT
INCIDENT REPORT PROCEDURE
INCIDENT REPORT
Incident Report No.
Incident Date
Sales Order No.
Customer Name
RMA No.
Site Name
PO No.
Technician
Chiller Model No.
Commission Date
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:
INCIDENT REPORT
Chiller Type
A.
□ Water-cooled
Chiller Application
B.
□
B.
□ Plant room
Process-cooling
Chiller Location
Number of compressors on the
chiller
Total hours of chiller operation before failure
Total Kilowatt hours of operation before failure
Replaced Components
For every replaced and / or failed component, please fill in a record.
Component One:
Chiller/Compressor
Serial No.
Part Description
If replaced, new part
serial No.
Component Two:
Chiller/Compressor
Serial No.
Part Description
If replaced, new part
serial No.
Component Serial
No.
Part No.
Component Serial
No.
Part No.
INCIDENT REPORT
Smardt Inc. 1800 Trans Canada Hwy, Dorval, QC, Canada H9P 1H7
Phone :
+1 514 426 8989
Fax: +1 514 426 5757
Email: [email protected]
www.smardt.com
TABLE OF CONTENTS
Introduction_________________________________________________________________ 2
Connection Diagram ___________________________________________________________________________ 3
Communication related parameters________________________________________________________________ 4
Modbus Messages & the Modbus Protocol__________________________________________________________ 4
Modbus Message Format _______________________________________________________________________ 5
Modbus RTU Mode Transmission ________________________________________________________________ 7
MODBUS Message Timing (RTU Mode) __________________________________________________________ 7
Modbus Error Checking Methods _________________________________________________________________ 8
Parity Checking_______________________________________________________________________________ 8
CRC Checking _______________________________________________________________________________ 9
Function Codes _______________________________________________________________________________ 9
Modbus Commands Supported __________________________________________________________________ 10
Read Holding Registers ___________________________________________________________________ 10
Write Holding Registers ___________________________________________________________________ 11
Exception Codes _____________________________________________________________________________ 12
Product Specific Information __________________________________________________ 13
Modbus Register List _________________________________________________________________________ 13
Modbus Data Description _____________________________________________________ 16
Modbus Data Scaling In PLC/ BAS_____________________________________________ 17
Temperature Conversion _______________________________________________________________________ 17
Power Input Conversion _______________________________________________________________________ 17
Pressure Conversion __________________________________________________________________________ 17
Chiller Alarm Codes __________________________________________________________________________ 18
Chiller Fault Codes ___________________________________________________________________________ 19
Chiller Operating Mode or State _________________________________________________________________ 20
Compressor Operating State ____________________________________________________________________ 20
Compressor Alarms___________________________________________________________________________ 21
Compressor Faults____________________________________________________________________________ 21
Compressor Magnetic Bearing Faults _____________________________________________________________ 22
Compressor Motor Faults ______________________________________________________________________ 22
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____________________________________________________
23
23
24
24
24
24
25
Sample Software Routines ____________________________________________________ 25
Bit Detection in Basic __________________________________________________________________ 25
Modbus Defintion Rev09
-1-
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
Modbus Defintion Rev09
-2-
Slave Chiller#2
Connection Diagram
Interconnection Diagram during RS-485 Transfer
Slave Chiller Control#1
RS485 Comms to
PLC
RX+
RX+
RX-
RXComm
Comm
Slave Chiller Control#2
RX+
RXComm
Termination resistor of
150ohm applied to last
slave on RS485
network
Above: Sample connection diagram between multiple
controllers and master plc.
Left: Connection points found on rear of touch panel.
Connection
points to BAS
System
Modbus Defintion Rev09
-3-
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 =
Stop Bits - possible settings =
Modbus Slave Address =
9600, 19200 & 38400
1 or 2
1 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 & the Modbus Protocol
Communication on a MODBUS Network is initiated (started) by a “Master” (BAS) 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.
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
-4-
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 errorchecking 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 Address: 8-bit value representing the slave being addressed (1 to 247), 0 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
-5-
Response
The example illustrates the normal response to a request for a single 16-bit Register.
Slave Address: 8-bit value representing the address of slave, 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 is identified by the function code being a copy of the query function code but with the mostsignificant bit set to logic ‘1’.
Slave Address: 8-bit value representing the address of slave, which has just responded.
Function Code: 8 bit value which is the function code 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-
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 is 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 ending 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-
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 frame, 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 is 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.
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 “1’s”.
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-
CRC Checking
The error check bytes of the MODBUS messages contain a Cyclical Redundancy Check (CRC) value
that is 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 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 is 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, if one is used, are not included in the error check bytes.
During generation of the error check bytes, each 8-bit character is exclusive OR'ed with the register
contents. The result is 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 is 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 8bit 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 = ErrorWord 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:
Function 16:
Function 8:
Read Holding Registers.
Pre-Set Multiple Registers
Diagnostics
Modbus Defintion Rev09
-9-
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:
The slave unit may respond as follows with two data points:
Modbus Defintion Rev09
- 10 -
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
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 High
Error Check Low
Example (Hex)
01
10
00
00
00
01
02
00
00
3D
45
The following response from the slave would indicate a successful write
Field Name
Slave Address
Function
Starting Address High
Starting Address Low
Number of Registers High
Number of Registers Low
Error Check High
Error Check Low
Modbus Defintion Rev09
- 11 -
Example (Hex)
01
10
00
00
00
01
41
C6
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 (84) 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 Defintion Rev09
- 12 -
Product Specific Information
Modbus Register List
Variable Name
Data Type
nviChillerEnable
nviCoolSetpt
nvoOnOff
nvoActiveSetpt
nviCapacityLim
nviEntChWTemp
nviMode
nviHeatSetpt
nvoActualCapacity
nvoCapacityLim
nvoLvgCHWTemp
nvoEntCHWTemp
nvoEntCndWTemp
nvoLvgCndWTemp
nvoLiqRefTemp
nvoAlarmDescr
nvoChillerStat
nviOutdoorTemp
nvoOutdoorTemp
nviOutdoorRH
nvoOutdoorRH
nvoChlrPwr
nviChlrPwrLim
nvoChlrPwrLim
nvoEntCndWSetpt
nvoActiveEntCndWSetpt
nvoChlrState
nvoRpm_1
nvoRpm_2
nvoRpm_3
nvoRpm_4
nvoRpm_5
nvoRpm_6
nvoDrvPwr_1
nvoDrvPwr_2
nvoDrvPwr_3
nvoDrvPwr_4
nvoDrvPwr_5
nvoDrvPwr_6
nvoDrvRunHours_1
nvoDrvRunHours_2
nvoDrvRunHours_3
nvoDrvRunHours_4
// snvt_switch - 0/1
// snvt_temp_p // snvt_switch - 0/1
// snvt_temp_p
// snvt_lev_percent
// snvt_temp_p
// snvt_hvac_mode
// snvt_temp_p
// snvt_lev_percent
// snvt_lev_percent
// snvt_temp_p
// snvt_temp_p
// snvt_temp_p
// snvt_temp_p
// snvt_temp_p
// snvt_chlr_type
// snvt_chlr_status
// snvt_temp_p
// snvt_temp_p
// snvt_lev_percent
// snvt_lev_percent
// snvt_power_kilo - total power
// snvt_power_kilo - total power limit
// snvt_power_kilo
// snvt_temp_p
// snvt_temp_p
// snvt_state_16
// snvt_rpm
// snvt_rpm
// snvt_rpm
// snvt_rpm
// snvt_rpm
// snvt_rpm
// snvt_power_kilo
// snvt_power_kilo
// snvt_power_kilo
// snvt_power_kilo
// snvt_power_kilo
// snvt_power_kilo
// snvt_time_hour
// snvt_time_hour
// snvt_time_hour
// snvt_time_hour
Modbus Register
Modbus Defintion Rev09
- 13 -
40001
40002
40003
40004
40005
40006
40007
40008
40009
40010
40011
40012
40013
40014
40015
40016
40017
40018
40019
40020
40021
40022
40023
40024
40025
40026
40027
40028
40029
40030
40031
40032
40033
40034
40035
40036
40037
40038
40039
40040
40041
40042
40043
nvoDrvRunHours_5
nvoDrvRunHours_6
nvoIgvPosition_1
nvoIgvPosition_2
nvoIgvPosition_3
nvoIgvPosition_4
nvoIgvPosition_5
nvoIgvPosition_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
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 -
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
nvoMTR_State_6
nvoCoolingTowerSpd
nvoCondPumpSpd
nvoChillerModel
nvoDigitalInputs
nvoDigitalOutputs
nvoNextComprStarting
Modbus Defintion Rev09
// snvt_state_16
// snvt_lev_percent
// snvt_lev_percent
// snvt_count
// Binary representation of di status
// Binary representation of relay status
// Binary representation of relay status
- 15 -
40093
40094
40095
40096
40097
40098
40099
Modbus Data Description
Modbus data in the Kiltech controller consists of the following types of data:
•
Switch points. Switch data have only to possible values 0 or 1 and are used to represent things
like enable/ disable function status.
•
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.
•
Percentage points. Percentage points represent data such as percent chiller loading or
percentage motor speed, these points may be read and write.
•
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).
•
State points, these points are integer values that represent a product defined state such as
“Chiller Running” or “Chiller Faulted”.
•
RPM points, these points represent actual motor shaft speeds in revolutions per minute scaled
1:1.
•
Pressure points, these points represent system pressures scaled psia x10 or kPa x10.
•
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 -
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 -
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 is not a condition that shuts down the chiller but
it will cause the capacity to be limited.
Bit Value
1
2
3
4
5
6
7
Fault Description
Low Chilled Water Temp
Low suction pressure alarm
High discharge pressure alarm
Over current alarm.
High evaporator delta temp alarm
Over network set capacity limit alarm
Over network set power limit
Modbus Defintion Rev09
- 18 -
Integer Value
1
2
4
8
16
32
64
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
0x0040
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:
Bit Value
Fault Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Low Chilled Water Temp
Low suction pressure fault
High discharge pressure fault
Over current fault.
High evaporator delta temp fault
No chilled water flow fault
No condenser water flow fault
Chiller failed to start fault
External HP/LP pressure cutout safety fault
Emergency stop button activated fault
Gas leakage input fault
Maximum starts per day exceeded fault
Loss of I/O module communications fault
No Compressors Available to Run
Spare
Spare
Integer Value
1
2
4
8
16
32
64
128
256
512
1024
2048
4096
16348
32768
65536
*For more details on bit description please see section - Program Examples.
Modbus Defintion Rev09
- 19 -
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
0x0040
0x0080
0x0100
0x0200
0x0400
0x0800
0x1000
0x2000
0x4000
0x8000
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
Pull down State
Run State
Compressor Stage Up State
Compressor Stage Down State
Alarm Avoidance State
Fault State
Shutting Down State
0
1
2
3
4
5
6
7
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
Offline State, No power.
Resetting IGV & Drive
Ready to run state
Ramping to min operating speed
Running normally
Running in alarm avoidance mode “capacity limited”
Resetting with a fault present
Idle with a fault present
Clearing fault
Compressor Locked out, discharge pressure fault or over current fault
generated inside compressor. Compressor requires power down to
reset fault
Compressor 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)
Compressor interlock open
Integer Value
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Modbus registers 40064 to 40069 hold the compressor state for compressors 1 to 6.
Modbus Defintion Rev09
- 20 -
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:
Bit Value
1
2
3
4
5
6
7
8
9
Fault Description
High Inverter Temperature Alarm
High Discharge Temperature Alarm
Low Suction Pressure Alarm
High Discharge Pressure Alarm
High 3ph Current Alarm
High Rotor Temperature Alarm
Low Leaving Temperature Alarm
High Pressure ratio Alarm
High SCR Temperature Alarm
Integer Value
1
2
4
8
16
32
64
128
256
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
0x0040
0x0080
0x0100
*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 is represented as a different bit
in a 16bit register.
Bit Value
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fault Description
High Inverter Temperature Fault
High Discharge Temperature Fault
Low Suction Pressure Fault
High Discharge Pressure Fault
High 3ph Current Fault
High Rotor Temperature Fault
Low Leaving Temperature Fault
High Pressure Ratio Fault
Generic Motor or Bearing Fault
Faulty Compressor Sensor Fault
High SCR Temperature Fault
Compressor Locked Out
Motor Winding Over Temperature Fault
Not Used
Not Used
Not Used
Integer Value
1
2
4
8
16
32
64
128
256
512
1024
2048
4096
16348
32768
65536
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
0x0040
0x0080
0x0100
0x0200
0x0400
0x0800
0x1000
0x2000
0x4000
0x8000
*Compressor fault registers are located in registers 40076 to 40081. If the fault register is equal to zero
then the compressor has no faults.
Modbus Defintion Rev09
- 21 -
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.
Bit Value
1
2
3
4
5
6
7
8
Fault Description
Bearing Calibration Failed
Startup Check Failed
Thrust Bearing Displacement Over Limit
Thrust Bearing Over Current Fault
Front Bearing Displacement Over Limit
Front Bearing Over Current Fault
Rear Bearing Displacement Over Limit
Rear Bearing Over Current Fault
Integer Value
1
2
4
8
16
32
64
128
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
0x0040
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.
Bit Value
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fault Description
Motor Single phase over current
DC Bus Over Voltage
Motor High Current Warning
Motor High Current Fault
Inverter Error Signal Active
Over Current during Startup – Rotor May
Be Locked
Bearing Error Active
Bearing Warning Active
Output voltage on motor generates no
current
Soft start error detected
24VDC Out of bounds error
Motor back emf low
Eeprom Checksum error
Generator mode active
SCR Phase loss
System in startup mode
Integer Value
Hex Value
1
2
4
8
16
32
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
64
128
256
0x0040
0x0080
0x0100
512
1024
2048
4096
16348
32768
65536
0x0200
0x0400
0x0800
0x1000
0x2000
0x4000
0x8000
*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
- 22 -
Example Program Usage
Starting and Stopping the Chiller
To start the chiller via the modbus communication protocol the following sequence is applicable:
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
- 23 -
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:
•
•
•
HVAC Heat Mode = 0
HVAC Cool Mode = 1
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 network 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 is 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
- 24 -
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.
Bit Value
1
2
3
4
5
6
Description
Integer Value
Compressor #1 START REQUEST
Compressor #2 START REQUEST
Compressor #3 START REQUEST
Compressor #4 START REQUEST
Compressor #5 START REQUEST
Compressor #6 START REQUEST
1
2
4
8
16
32
Hex Value
0x0001
0x0002
0x0004
0x0008
0x0010
0x0020
Sample Software Routines
Bit 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) > 0)
End Function
Modbus Defintion Rev09
- 25 -
Chiller Not Running – General Checks
KTS 000001 Rev: 1_Troubleshooting Guide
Page 1 of 12
General Cont.
More checks
Chiller Not Operating Cont..
Timers Active?
Yes
Wait For Applicable Timers to
Complete
Timers Too Long?
Go To Commissioning Settings
to Re-configure
No
Is Process
Temperature above
specified Delta T
above Set Point?
No
Press Setup and check
Temperature Control Settings
Yes
Has Chiller/
Compressors
Exceeded Number of
Faults For a Given
Period of Time?
Yes
Check Fault Type on Chiller or
Compressor
Repair and Cycle Power to
Chiller Controller
KTS 000001 Rev: 1_Troubleshooting Guide
Page 2 of 12
Controller Software
Go To
Controller
Software
Section
Controller Software
Does Controller
“Boot Up”
Yes
Incorrect
Images?
No
Yes
Incorrect Text
Fields?
Yes
No
Check Image Files (Within HD2)
Invalid Disc Error
Appears?
Yes
No
Default Windows
Image Pops Up
USB Stick Left Installed During
Power Up
Re-format Panel PC and Upload
Application Software
Yes
No Software installed to
Panel PC
Re-format Panel PC and Upload
Application Software
No
Error Message Cannot Find Files
Check Commissioning Settings/
Chiller Model - To Match I/O definition
Yes
Power Fluctuation Has
Occurred and Requires
Reset
No
Check USB Stick and
Upload Application
Software Again
No Display or image
problems
Yes
Panel PC / Hard Drive
Failed
Replace Panel PC
KTS 000001 Rev: 1_Troubleshooting Guide
Page 3 of 12
Faults
Go To Fault
Section
1
Fault Present
Low_LVGCHW_
Fault Active?
Yes
No
Check Leaving Chiller Water
Temperature Sensor
CW_Flow_Fualt
Active?
Yes
Check Condenser Water Flow
Switch and Circuit
Check Ramp Up Settings Ramping Up Too Quick For
Load?
Low_SUCP_Fault
Active?
Yes
Check Pressure Sensors
Check Condenser Water
Flows Per Design
Fail_Start_Fault
Active?
Yes
HP_Switch_Fault
Active?
Yes
Check Compressor(s) - Failed
To Start When Requested
Check Expansion Valve Control
No
Check Pressure rations vs Demand Compressor(s) driving Out Of Surge?
High_DISP_Fault
Active?
Yes
No
High_Amps_Fault
Active?
Yes
No
Check Pressure Sensors
Check Expansion Valve Control
Check Expansion Valve Control
Check Pressure rations vs Demand Compressor(s) driving Out Of Surge?
Check Pressure rations vs Demand Compressor(s) driving Out Of Surge?
Check Expansion Valve Control Pumping Liquid
Emergency_Switch
_Fault Active?
Yes
Yes
Check Leaving and Return Chiller
Water Temperature Calibration
Operator Intervention
Check Circuit
Check Pressure rations vs Demand Compressor(s) driving Out Of Surge?
High_Evap_Delta_
Fault?
Check Pressure Sensors
Gas_Switch_Fault
Active?
Yes
Check Refrigerant Monitor
Operation
Check For Refrigerant Leaks
No
Check Flows Per Design
Check Circuit
CHW_Flow_Fault
Active?
Yes
Check Chilled Water Flows
Per Design
Max_Starts_Exceeded
Active?
1
KTS 000001 Rev: 1_Troubleshooting Guide
Too Many Start Per Set Time
Frame
Chiller Ramping up too Quick ,
causign excessive cycling
Check Chilled Water Flow Switch
and Circuit
No
Yes
Process Load Too Low for
Given Chiller Capacity
More
Faults
Process Loop Extremely Small
- Install inertia Tank
Page 4 of 12
Faults Cont.
KTS 000001 Rev: 1_Troubleshooting Guide
Page 5 of 12
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
Still No Communications
“After Reboot”?
No
Check Cables Connections
Replace RS232/485 Converter
Is The Correct
Number of
Compressors Being
Displayed?
No
Ensure Correct Commissioning
Settings In The Controller
Yes
Check Cables/ Communication Wiring
Termination
Yes
Does the Controller
only Communicate with
Some Compressors?
No
Is Compressor
Interlock Open?
Possible Faulty Compressor Card (BMCC)
Recheck Via Modpoll/ Compressor Monitoring Program
No
Check Interlock Circuit To
Compressor
Yes
No Demand From Controller - Being Held “Off” by
other means. Continue Investigation
KTS 000001 Rev: 1_Troubleshooting Guide
Page 6 of 12
Input/ Output Module – General Checks
KTS 000001 Rev: 1_Troubleshooting Guide
Page 7 of 12
I/O Module - Detailed Checks
KTS 000001 Rev: 1_Troubleshooting Guide
Page 8 of 12
Chiller Running – Not Making Set Point
Chiller Running - Not
Making Set Point
Demand
Increasing From
Chiller Control?
No
Are Any Alarms
Active?
Yes
Yes
Determine Alarm Type and
Investigate Cause
No
Check External BAS Load Limiting
or Set Point Reset
Is The Actual KW
Equal To the
Desired KW?
No
Is Actual Speed
Close To, Or At
“Surge Speed”?
No
Yes
Are There Any
Compressor Alarms
Active?
Are Any
Compressors
“Offline” Or In
Fault?
Pressure Ratio Too Low To Allow
Compressors To Load Up To Desired KW
(Motor Power)
Yes
Yes
Yes
Investigate/ Correct Compressor Issue or
Operational Condition
Correct Compressor Issue and Reset
No
Compressors Meeting
Requested Capacity
Check Compressor Staging If Taking too long to Load up
Load Too Great For Chiller?
KTS 000001 Rev: 1_Troubleshooting Guide
Page 9 of 12