Carrier OPN-OPT-OL Installation manual

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Ch hi il ll le ed d W Wa at te er r S Sy ys st te em m
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Op pt ti im mi iz ze er r v v2 2
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In ns st ta al ll la at ti io on n a an nd d S St ta ar rt t- -u up p G Gu ui id de e
CARRIER CORPORATION ©2019
A member of the United Technologies Corporation family · Stock symbol UTX · Catalog No. 11-808-574-01 · 6/25/2019

Verify that you have the most current version of this document from www.hvacpartners.com or your local Carrier
office.
Important changes are listed in Document revision history at the end of this document.
CARRIER CORPORATION ©2019. All rights reserved throughout the world. i-Vu is a registered trademark of Carrier
Corporation. All other trademarks are the property of their respective owners.

Contents
What is the Chilled Water System Optimizer? .......................................................................................................... 1
Specifications ........................................................................................................................................................2
Chiller system configurations .............................................................................................................................3
Installation overview ............................................................................................................................................5
Safety considerations...........................................................................................................................................6
Installing the Chilled Water System Optimizer ......................................................................................................... 7
To mount the controller .......................................................................................................................................7
Wiring the controller for power...........................................................................................................................7
To wire for power ................................................................................................................................... 8
Addressing the controller............................................................................................................................................ 9
To set the controller address on the Open network ........................................................................................9
To choose an IP addressing scheme .............................................................................................................. 10
To obtain an IP address using DHCP .............................................................................................................. 10
To assign a custom IP address ........................................................................................................................ 10
Wiring for communications ......................................................................................................................................13
Ethernet wiring specifications ......................................................................................................................... 13
To wire to the BACnet over IP network (DHCP) ............................................................................................. 14
To wire to a BACnet over IP network (assign a custom IP) ......................................................................... 14
Wiring for third party protocols.................................................................................................................................16
To wire Modbus devices on Port S2................................................................................................................ 16
To wire a third-party device .............................................................................................................................. 17
Communicating through the Local Access port with a USB Link ..........................................................................18
To communicate using PuTTY ......................................................................................................................... 19
Installing the controller into an i-Vu® Control System ...........................................................................................21
To configure third party protocols in the i-Vu® interface ............................................................................ 22
To set up the driver....................................................................................................................................................23
Driver ................................................................................................................................................................... 23
Notification Classes........................................................................................................................................... 24
Calendars ............................................................................................................................................................ 25
Common and Specific Alarms ......................................................................................................................... 26
Custom Translation Tables............................................................................................................................... 26
BACnet firewall................................................................................................................................................... 26
Protocols ............................................................................................................................................................. 27
Troubleshooting .........................................................................................................................................................28
Controller LED's.................................................................................................................................................. 28
To restore factory defaults ............................................................................................................................... 29
To get the serial number .................................................................................................................................. 30
To replace the controller's battery .................................................................................................................. 30
To take the controller out of service ............................................................................................................... 30
Start-up and Commissioning ....................................................................................................................................31
Network Points................................................................................................................................................... 31
General conditions and status......................................................................................................................... 32
Chilled water temperature optimizer reset ................................................................................................... 34
Chilled water optimizer reset - Start-up.......................................................................................................... 36
Chilled water optimizer reset - Tuning............................................................................................................ 37
Condenser water optimizer reset .................................................................................................................... 39
Condenser water optimizer reset - Start-up................................................................................................... 41
Condenser water optimizer reset - Tuning ..................................................................................................... 42
Device Address Binding ............................................................................................................................................45

Contents
Configuring the Chilled Water System Optimizer's Properties page .....................................................................47
Compliance ................................................................................................................................................................48
CE Compliance ................................................................................................................................................... 48
FCC Compliance................................................................................................................................................. 48
BACnet Compliance........................................................................................................................................... 48
Appendix A: The Chilled Water System Optimizer —Status only view of the Properties page ..........................49
General Conditions & Status............................................................................................................................ 50
Section 1 - Optimizer - Primary Enable Conditions....................................................................................... 50
Section 2 - Chiller System Power, Efficiency, and Thermal Load Input Status ........................................ 51
Section 3 - Stagger Reset - Enable Conditions.............................................................................................. 52
Chilled Water Temperature Optimizer Reset ................................................................................................ 53
Section 1 - Chilled Water System Optimizer - Enable conditions............................................................... 53
Section 2 - Automatic Overrides of Chilled Water Reset............................................................................. 53
Section 3 - Manual Overrides of Chilled Water Reset - and other Settings .............................................. 54
Condenser Water Temperature Optimizer Reset ......................................................................................... 54
Section 1 - Condenser Water System Optimizer - Enable Conditions ....................................................... 55
Section 2 - Manual Overrides of Condenser Water Reset - and other Settings ....................................... 55
Section 3 - Condenser Water Setpoint Reset - Output & Limit Settings ................................................... 55
Electric Metering - Combined kW of Monitored Equipment........................................................................ 56
Appendix B: The Chilled Water System Optimizer Commissioning view of the Properties page ......................58
General Conditions & Status............................................................................................................................ 59
Section 1 - Optimizer - Primary Enable Conditions....................................................................................... 60
Section 2 - Chiller System Power, Efficiency, and Thermal Load Input Status ........................................ 63
Section 3 - Stagger Reset - Enable Conditions.............................................................................................. 65
Section 4 - Optimizer Setpoint Change Mode ............................................................................................... 66
Chilled Water Temperature Optimizer Reset ................................................................................................ 68
Section 1 - Chilled Water System Optimizer - Enable conditions............................................................... 69
Section 2 - Automatic Overrides of Chilled Water Reset............................................................................. 70
Section 3 - Manual Overrides of Chilled Water Reset - and other Settings .............................................. 75
Condenser Water Temperature Optimizer Reset ......................................................................................... 80
Section 1 - Condenser Water System Optimizer - Enable Conditions ....................................................... 82
Section 2 - Manual Overrides of Condenser Water Reset - and other Settings ....................................... 83
Section 3 - Condenser Water Setpoint Reset - Output & Limit Settings ................................................... 87
Electric Metering - Combined kW of Monitored Equipment........................................................................ 89
Appendix C: Network Points List for Chilled Water System Optimizer.................................................................91
Document revision history ........................................................................................................................................93

Chilled Water System Optimizer v2 CARRIER CORPORATION ©2019
Installation and Start-up Guide 1 All rights reserved
The Chilled Water System Optimizer (Part# OPN-OPT-OL) provides precise chilled water and condenser water
setpoint optimization by carefully balancing the energy use of both the chilled water plant equipment and the
chilled water consumers. This results in an overall reduction in energy use and electrical demand.
You can select from the following protocols:
BACnet/IP
Modbus RTU or ASCII
Modbus/IP
CAUTION The Chilled Water System Optimizer does not support BACnet MS/TP or BACnet/ARC156
networks.
WARNING The Chilled Water System Optimizer must not be used as a router. This function is not supported.
What is the Chilled Water System Optimizer?

What is the Chilled Water System Optimizer?
Chilled Water System Optimizer v2 CARRIER CORPORATION ©2019
Installation and Start-up Guide 2 All rights reserved
Specifications
Driver
drv_opn_opt_std
Number of control programs
WARNING This controller only supports a single Chilled Water System
Optimizer program and no other control programs.
Power
24 Vac ±10%, 50–60 Hz
24 VA power consumption
26 Vdc (25 V min, 30 V max)
Single Class 2 source only, 100 VA or less
Port E1 (10/100 BaseT
Ethernet)
For Ethernet LAN, BACnet IP, and Modbus TCP/IP communication at 10 or 100
Mbps, half duplex
Both Assigned (default) and DHCP IP addressing are supported and DIP switch
selectable
Port S1 (BACnet MS/TP)
Not supported - do not use.
BACnet port (ARCNET)
Not supported - do not use.
Port S2
Configurable EIA-485/EIA-232 port for Modbus (RTU and ASCII modes) - 9600 bps,
19.2 kbps, 38. 4 kbps
Local Access
For system start-up and troubleshooting
Real time clock
Battery-backed real-time clock keeps track of time in event of power failure
Battery
10-year Lithium CR123A battery ensures the following data is retained for a
maximum of 720 hours during power outages:
Time
Graphics
Control programs
Editable properties
Schedules
Trends
To conserve battery life, you can set the driver to turn off battery backup after a
specified number of days and depend on the archive function to restore data when
the power returns.
A low battery is indicated by the Battery Low LED or a low battery alarm in the i-
Vu® application, a touchscreen device, and Field Assistant.
Protection
Built-in surge and transient protection for power and communications in
compliance with EN61000-6-1.
Incoming power and network connections are protected by non-replaceable
internal solid-state polyswitches that reset themselves when the condition that
causes a fault returns to normal.
The power and network connections are also protected against transient excess
voltage/surge events lasting no more than 10 msec.
CAUTION To protect against large electrical surges on serial EIA-485
networks, place a PROT485 at each place wire enters or exits the building.

What is the Chilled Water System Optimizer?
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Installation and Start-up Guide 3 All rights reserved
Status indicators
LED status indicators for Port S1 and S2 communication, Ethernet Port E1
communication, and low battery status. Seven segment status display for running,
error, power status, archive valid, and brownout.
Environmental operating
range
-20 to 140°F (-29 to 60°C), 10–90% relative humidity, non-condensing
Storage temperature range
-24 to 140°F (-30 to 60°C), 0 to 90% relative humidity, non-condensing
Physical
Rugged aluminum cover, removable screw-type terminal blocks
Overall dimensions
A:
B:
7-1/2 in. (19.1 cm)
11-5/16 in. (28.7 cm)
Mounting dimensions
C:
D:
E:
F:
5 in. (12.7 cm)
10-7/8 in. (27.6 cm)
1-1/4 in. (3.2 cm)
1/4 in. (.6 cm)
Mount with 6-32 by 1/2 in. mounting screws
Depth
1-1/4 in. (3.2 cm)
Weight
1.4 lbs (0.64 kg)
BACnet support
Conforms to the BACnet Building Controller (B-BC) Standard Device Profile as
defined in ANSI/ASHRAE Standard 135-2012 (BACnet) Annex L, Protocol Revision
9
Listed by
UL916 (Canadian Std C22.2 No. 205-M1983, CE, FCC Part 15 - Subpart B - Class A
Chiller system configurations
The program is scalable, so it can be applied from a minimal system including only the chiller and chilled water
pump components, to a larger system, including condenser water side components and air handling unit fans, as
illustrated below.

What is the Chilled Water System Optimizer?
Chilled Water System Optimizer v2 CARRIER CORPORATION ©2019
Installation and Start-up Guide 4 All rights reserved
Even though the controller works with a variety of chilled water system components, it must be used with parallel
chiller systems and operates best with variable speed pumps and variable speed fans.
The Chilled Water System Optimizer works with systems containing any of the following:
Single chiller or multiple chillers piped in parallel
Chilled water pumps
Cooling towers
Condenser water pumps
Variable speed air handling unit fans (w/ chilled water coils)
Chilled water side –when secondary pumps and tertiary pumps are part of the chilled water system,
including variable air handling unit fans.
Condenser water side –systems with multiple cooling towers and condenser water pumps dedicated to their
corresponding chiller, or piped in parallel.
CAUTIONS
The control program can be less effective if the setpoint response is not predictable. For example, when the
cooling towers are widely staged to come on above certain temperature thresholds, rather than using
modulating VFD fans or pumps for capacity control.
The Chilled Water System Optimizer is not designed for series arrangements or absorption chillers.
The Chilled Water System Optimizer can be applied to the following chiller system designs:
Chilled water supply side
○Up to 8 chillers piped in parallel arrangement
Centrifugal, scroll type, or screw type chillers

What is the Chilled Water System Optimizer?
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Installation and Start-up Guide 5 All rights reserved
Equal-sized or unequal-sized
○Up to 40 primary, secondary, and/or tertiary variable speed pumps
○Up to 40 variable speed air handling unit fans serviced by chilled water system
Condenser water supply side
○Up to 20 condenser water pumps
○Up to 20 cooling tower variable speed or staged fans
Installation overview
WARNING This controller only supports a single Chilled Water System Optimizer program and no other
control programs.
The Chilled Water System Optimizer collects remote power (kW) values and facility thermal load values residing in
other controllers through Network Input points.
The program functions most efficiently and provides increased energy savings if all pumps and fans have variable
frequency drives and as more power inputs are measured, though it is not necessary.
Control Inputs
Power Inputs —Sum of power inputs Σ kW
○Chiller power kW (required)
○Chilled Water Pump kW (required)
○Cooling Tower Fan kW (optional)
○Condenser Water Pump kW (optional)
○Air Handling Unit Fan kW (desirable but not absolutely necessary)
Load Input —Total Cooling Load
NOTE This is thermal cooling load in tons, whether calculated from the difference between chilled water
supply and return temperatures and the flow rate, or tonnage that is read directly.
Result —kW/Ton (Dividing total kW by the thermal load equals the efficiency benchmark of kW/ton)
Control Outputs –Network Outputs
The optimization program has only two control outputs. They are either Network Outputs or BACnet Analog Values.
Chilled water supply temperature reset
Condenser water supply temperature setpoint

What is the Chilled Water System Optimizer?
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Safety considerations
WARNING Disconnect electrical power to the controller before wiring it. Failure to follow this warning could
cause electrical shock, personal injury, or damage to the controller.

Installing the Chilled Water System Optimizer
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Follow these steps:
1 Mount the controller. (page 7)
2 Wire the controller for power. (page 7)
3 Set the controller's address. (page 18, page 9)
4 Communicate through the Local Access port. (page 18)
5 Wire for communications. (page 13)
6 Add the controller to the i-Vu® application. (page 21)
7 Set up driver. (page 23)
To mount the controller
WARNING
When you handle the Chilled Water System Optimizer:
•Do not contaminate the printed circuit board with fingerprints, moisture, or any foreign material.
•Do not touch components or leads.
•Handle the board by its edges.
•Isolate from high voltage or electrostatic discharge.
•Ensure that you are properly grounded.
Screw the controller into an enclosed panel using the mounting slots on the cover plate. Leave about 2 in. (5 cm) on each
side of the controller for wiring. See mounting dimensions in Specifications (page 2).
Wiring the controller for power
WARNING Do not apply line voltage (mains voltage) to the controller's ports and terminals.
CAUTIONS
The controller is powered by a Class 2 power source. Take appropriate isolation measures when mounting it
in a control panel where non-Class 2 circuits are present.
Carrier controllers can share a power supply as long as you:
Maintain the same polarity.
Use the power supply only for Carrier controllers.
Installing the Chilled Water System Optimizer

Installing the Chilled Water System Optimizer
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Installation and Start-up Guide 8 All rights reserved
To wire for power
1 Make sure the controller’s power switch is in the OFF position to prevent it from powering up before you can
verify the correct voltage.
2 Remove power from the power supply.
3 Pull the screw terminal connector from the router's power terminals labeled 24 Vac/Vdc and Ground.
4 Connect the transformer wires to the screw terminal connector.
5 Apply power to the power supply.
6 Measure the voltage at the controller’s power input terminals to verify that the voltage is within the operating
range of 21.6 –26.4 Vac or 23.4 - 28.6 Vdc.
7 Insert the screw terminal connector into the controller's power terminals.
8 Turn on the controller's power.
9 Verify that the Run LED (a dot in the lower right corner of the Module Status LED) begins blinking. The Module
Status LED will display 8 for about 5 seconds and then reverts to 0, until controllers have been found and
downloaded. There is a chase pattern when the router is running with no errors.

Addressing the controller
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Installation and Start-up Guide 9 All rights reserved
To address the controller for third-party integration, in the i-Vu® interface, go to Driver Properties > Protocols >
Properties tab. Refer to the appropriate protocol Integration Guide for further details.
The controller needs...
That is unique
on the...
Notes
An IP address
IP Network
Set the IP Addr DIP switch to choose one of the following:
DHCP —to obtain an IP address from a DHCP server
If there is no DHCP server, the following are the default
IP settings:
○192.168.168.xx, where xx = rotary address
○subnet mask = 255.255.255.0
○default gateway = 192.168.168.254
Assigned —a custom IP address
NOTE The controller address is also used to
autogenerate the BACnet device instance/name for the
router. See Configuring BACnet device instance and
network number.
To set the controller address on the Open network
CAUTION The controller address must be unique on the IP and Open network.
1 If wired for power, turn off the power.
NOTE The controller only reads the rotary switch positions during power up or upon reset.
2 Use the rotary switches to set the address. Set the Tens (10's) switch to the tens digit of the address, and set
the Ones (1's) switch to the ones digit. Valid addresses are 1 - 99.
EXAMPLE If the controller’s address is 25, point the arrow on the Tens (10's) switch to 2 and the arrow on
the Ones (1's) switch to 5.
10's 1's
1
3
4
5
2
7
8
9
6
0
1
3
4
5
2
7
8
9
6
0
3 Turn on the controller's power.
CAUTION The factory default setting is 00 and must be changed to successfully install your controller.
Addressing the controller

Addressing the controller
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To choose an IP addressing scheme
Carefully plan your addressing scheme to avoid duplicate IP addresses.
If there is a DHCP server on the network, and, if you have a single controller or multiple controllers that exist
on the SAME subnet, use DHCP addressing. Skip to the section To obtain an IP address using DHCP (page
10).
If you have multiple controllers that reside on different subnets, you cannot use DHCP addressing. Instead,
give each controller an assigned IP address. Skip to the section To assign a custom IP address (page 10).
NOTE This network configuration also requires that you configure IP Broadcast Management Devices
(BBMDs). See To set up BACnet Broadcast Management Devices.
To obtain an IP address using DHCP
1 Turn the controller's power off.
2 Set the IP Addr DIP switch DHCP to On.
3 Turn the controller's power on. The DHCP server assigns an IP address to the controller.
CAUTION If the DHCP server is not found, the following default IP address settings will be used:
IP address = 192.168.168.xx, where xx = controller address (rotary switch settings)
Subnet Mask = 255.255.255.0
Default Gateway = 192.168.168.254
To assign a custom IP address
1 Obtain the IP address, subnet mask, and default gateway address for the router from the facility network
administrator.
2 Turn the controller's power off.
3 Set the controller's IP Addr DIP switch Assigned to On.
4 Configure the controller by setting the Router Config Mode DIP switch Console to On using a terminal
program such as PuTTY or Hyperterminal.
5 Turn the controller's power on.

Addressing the controller
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PREREQUISITES
A computer with a USB port
A USB Link cable —See To communicate through the Local Access port with a USB Link (page 18)
CAUTION If multiple controllers share power but polarity was not maintained when they were wired, the
difference between the controller's ground and the computer's AC power ground could damage the USB Link and
the controller. If you are not sure of the wiring polarity, use a USB isolator between the computer and the USB
Link. Purchase a USB isolator online from a third-party manufacturer.
Using PuTTY
1 Download and install PuTTY from the PuTTY website
(http://www.chiark.greenend.org.uk/~sgtatham/putty/download.html).
2 Connect the laptop to the local access port of the router, ZS sensor, or an SPT sensor using the USB Link
cable(s).
USB Link
Connect to
Local Access port
12 ft
Connect to
USB port
7 3/4 in.
NOTE If using a USB isolator, plug the isolator into your computer's USB port, and then plug the USB Link
cable into the isolator.
3 To change a router's IP address, subnet mask, or default gateway, set its IP Address DIP switch to Assigned.
4 Start PuTTY.
5 Under Category > Connection, select Serial.
6 Under Options controlling local serial lines, enter the following settings:
Field
Value
Serial line to connect to
Replace X with the computer's port number that the USB Link cable
is connected to.
NOTE To find the port number, select Start > Control Panel >
System > Device Manager > Ports (Com & LPT). The COM port
number is beside Silicon Labs CP210x USB to UART Bridge.
Speed (baud)
115200
Data Bits
8
Stop Bits
1

Addressing the controller
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Parity
None
Flow Control
None
7 Click Open. A window similar to the one below appears.
8 Do one of the following:
○To change a property value:
a. Type the number of the property, then press Enter.
b. Type the new value, then press Enter.
○To take an action, type number of the action, then press Enter.
9 If you changed a value, type 1, then press Enter to restart the controller.
10 Close PuTTY.
11 Verify that you can communicate with the controller by issuing a PING command to the IP address specified in
step 12.
NOTE Your computer must be on the same subnet as the controller for the PING command to work.
12 When finished, set the controller's Router Config Mode DIP switch to OFF to restore normal functionality to
the Local Access port.
13 Cycle the controller's power to accept the Router Config Mode changes.

Wiring for communications
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The controller has multiple ports. See table below for port descriptions.
Port
Protocol
Port type(s)
Baud rate(s)
Use for
Ethernet
Port E1
BACnet/IP
Modbus/IP
NOTE Both
protocols can
run
simultaneously
Ethernet
10 Mbps
100 Mbps
LAN connection
S2*
Modbus
EIA-485
9600, 19.2k, or 38.4k bps
Third-party communication
Local
Access
Enhanced
Access
Rnet
115.2 kbps
Configuration
System start-up and
troubleshooting
* The Config Mode DIP switch Console must be Off (down position) to use Port S2. Port S2 supports only one
protocol and one wire type at a time.
CAUTION The Chilled Water System Optimizer does not support BACnet MS/TP or BACnet ARCNET networks.
Ethernet wiring specifications
For...
Use...
Maximum Length
Ethernet
CAT5e or higher Ethernet cable
328 feet (100 meters)
*For details see the Open Controller Network Wiring Guide.
WARNING Do not apply line voltage (mains voltage) to the controller's ports and terminals.
Wiring for communications

Wiring for communications
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To wire to the BACnet over IP network (DHCP)
1 Turn off the controller's power.
2 Check the communications wiring for shorts and grounds.
3 Set the Assigned/DHCP DIP switch to the DHCP position.
4 Verify DIP switch 1is set to Carrier Tools (Off).
5 Connect Port E1, which is the only port that speaks BACnet over IP.
6 Turn on the controller's power.
To wire to a BACnet over IP network (assign a custom IP)
1 Turn off the controller's power.
2 Using the rotary switches, set the controller's address. Set the Tens (10's) switch to the tens digit of the
address, and set the Ones (1's) switch to the ones digit.
EXAMPLE If the controller’s address is 25, point the arrow on the Tens (10's) switch to 2 and the arrow on
the Ones (1's) switch to 5.
10's
1's
1
3
4
5
2
7
8
9
6
0
1
3
4
5
2
7
8
9
6
0
3 Obtain the IP address, subnet mask, and default gateway address for the controller from the facility network
administrator.
4 Set the Assigned/DHCP DIP switch to the Assigned position.
5 Set the +100/0 DIP switch to On to add 100 to x in the IP address.
EXAMPLE If you turn on this DIP switch and the MAC address is 25, the IP address is 192.168.168.125.
NOTE The DHCP address is an intranet address. Data packets from this address are not routable to the
Internet.
6 Set the following using a touchscreen device or PuTTY.
○IP address
○A unique Device Instance number

Wiring for communications
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7 Connect Port E1, which is the only port that speaks BACnet over IP.
Wiring Specifications
○328 feet (100 meters)
○Use one of the following CAT5 or higher Ethernet cables:
A cross-over cable to connect the controller directly to the third-party device
A straight-through cable to connect the controller to a hub or switch, and a second straight-through
cable to connect the hub or switch to the third-party device
NOTE Use the same polarity throughout the network segment.
8 Turn on the controller's power.

Wiring for third party protocols
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You can connect third party protocols after you set up BACnet. The driver for the controller allows access to the
following third party protocols. Additional drivers are not required.
You can use this combination of protocols or a subset of them:
Port
Protocol(s)
Port S2
Modbus RTU or ASCII, master or slave
Port E1
All or any combination of the following:
BACnet/IP
Modbus/IP
To wire Modbus devices on Port S2
1 Turn off the controller's power.
2 Check the communications wiring for shorts and grounds.
3 Set the Router Config Mode DIP switch Console to Off (down position).
4 Wire the controller's Port S2 to the third-party device, then set the S2 jumper. See table and notes below.
5 Turn on the controller's power.
For...
Use controller port...
Wire Carrier
terminal...
...to third-party
device terminal
Set the port's jumper(s)
on controller
EIA-232
S2
TX
Rx
Signal Ground
Rx
Tx
Gnd
EIA-232
EIA-485,
2-wire
S2
Net+
Net-
+
-
EIA-485
2-wire
NOTES
If you cannot determine the media type or connections of the third-party device, contact your third-party
representative.
Use the same polarity throughout the network segment.
Repeaters are required for more than 31 devices. See your third-party device manufacturer's
recommendations.
Wiring for third party protocols