Cruisair TWLC User manual

TWLC - Tempered Water Logic Controller
The Intelligent Control

Chiller Controls
TWLC
Tempered Water
Logic Control
Features:
•Up to six (6) stages: individual board
for each stage maximizes redundancy.
•Menu driven access and programming.
•Fault history.
•Up to 14 inputs.
•Connect to on-board computer.
•Fully automatic temperature staging
and chiller rotation.
•New for 2009!
Latest firmware revision V40 has new
features and improved chiller
protection.

•Microprocessor controlled
•Same reliability as the SMX logic boards
•Chiller boards can be networked together
•Only one keypad needed to control up to six chiller units.
•Additional keypads can be added up to the number of units in
the system.
•Up to six heat and cool temperature set point stages
•Easy to use display keypad with menu-driven screens
Features

•Capable of operating immersion heaters with high limit protection
•Automatic compressor stage rotation to achieve even run-time
•Automatic start up time delay on compressors
•Ability to monitor the control system locally or remotely via a
computer, a modem, and a dedicated phone line
•Complete system fault logs with run time reference
•If network is lost, each chiller operates independently
•When replacing a board, an initializing routine automatically
integrates the new board into the system
Features (cont’d.)

•Removable terminal strips - ease of board replacement
•Removable EPROM –software upgrade
•Two LED’s - indicate network cable integrity
•One display keypad hook up
•One serial port connection for computer or modem hook up for
local or remote monitoring
•Six outputs:
•Compressor
•Reversing Valve
•Circulating pump
•Seawater pump
•Immersion Heat
•Fault warning (for external alarm, i.e. light or buzzer)
The Board (features and outputs)

TWLC Power Logic Board
Removable Terminal Strip Removable E-Prom Display cable
Jack Computer or
Modem Jack Network cable
Jacks

CNP Cable
CXP Cable
Cables Used To Connect TWLC Control And
Circuit Boards
Use to connect keypad in same enclosure and network connections between boards
Use to connect remote mounted keypad to circuit board

The Board (inputs)
The board contains 16 inputs
•Common loop water return temperature sensor
•Loop water out temperature sensor
•Sea water out temperature sensor
•Flow switch
•Discharge pressure switch/transducer - Automatically recognizable
•Suction pressure switch/transducer - Automatically recognizable
•Compressor current transducer
•Common loop water supply temperature sensor

Inputs (Cont’d.)
•Immersion heater loop water temperature sensor
•Common sea water in temperature sensor
•Sea water pump current transducer
•Loop water pump current transducer
•Loop water pressure transducer
•Sea water pressure transducer
•Two additional auxiliary inputs –future enhancements
The Board (inputs) cont’d.

Menu-driven display screen
•4 lines of text, 20 characters per line
•Cool light - Indicates Cool mode
•Heat light - Indicates Heat, Reverse Cycle/Heaters, or Heaters Only modes
•Fault light - Indicates system faults
•Alarm buzzer - Indicates system faults
•Up and Down buttons - Changing parameter values and navigating through
menu screens and items within a menu
•Enter button - clearing a fault, advancing to another menu screen, and
selecting an item
•Back button - jump back to previous screen or condition
Display Keypad

•Off
•Cool
•Heat
•RevCyc/Heaters
Activates compressors first when sea water is 38 F (3.33 C),
compressors turn off, and immersion heaters turn on
•Heaters Only –activates immersion heaters only
Modes of Operation

•Displays which compressor or heater is on, disabled, or in
sustained shutdown
•Displays which mode the system is operating
•Displays the common loop water supply temperature
•Displays the loop water return temperature
System Screen

Main Menu
Chiller Status
•Displays the value of all input sensors that is connected to the board
Board output status, Software version number, Unit stage on each chiller
•Aids in troubleshooting the chiller system
Parameter Setting
•Displays heat and cool stage temperature set points and differentials (adjustable)
•Displays loop water temperature limits (non-adjustable)
•Displays high and low refrigerant pressure limits (non-adjustable)
•Displays sea water temperature limit (adjustable)
•Disable / enable alarm buzzer
•Select heavy or light load temperature set points
•Restore all settings to factory default
•Clear information that are logged by the board (password protected)
Initial Setup
•Displays how many chillers the control system recognizes
•What stage a chiller is in, and if the chiller is set to automatically rotate
•Initialize the boards for networking

Degrees Fahrenheit / Celsius (selectable)
Fault Log –Displays how many and what type of faults a chiller has encountered
Fault History –Displays up to the latest 300 system faults on each chiller
Input/Output Log
•Displays compressor, water pump, heater, and reversing valve run-times
•Minimum and maximum loop water temperatures
•Minimum and maximum sea water temperatures
•Minimum and maximum high and low refrigerant pressures
•Minimum and maximum AC voltage
Chiller On/Off –manually enable or disable a chiller
Output Status –displays board outputs (on or off)
Main Menu (cont’d.)

•Low AC Voltage condition
•Defective Temperature Sensors
•Loop Water Temperatures
•Extremely Low Loop Water Temperature Condition
•Extremely High Loop Water Temperature Condition
•Extremely High Immersion Heater Loop Water Temperature Condition
•Loop Water Flow Switch
•Improper In And Out Loop Water Temperature Differences On Each Chiller
•Loss Of System Network
•EPROM Errors
•Loop Water Pressure (w/ optional upgrade)
•Sea Water Temperatures (w/ optional upgrade)
•Sea Water Pressure (w/ optional upgrade)
•Suction Refrigerant Pressure (w/ optional upgrade)
•Discharge Refrigerant Pressure (w/ optional upgrade)
•Improper In And Out Sea Water Temperature Differences On Each Chiller (w/ optional)
What the System Monitors

•Requires 230VAC 1-PH power for control circuits
•Field-configured to run 230VAC 1-PH or 3-PH, or 380/460VAC 3-PH chiller
units
•Does not include compressor, loop and sea water pump breakers
•Includes loop and sea water pump 230VAC signal outputs to activate water
pump triggers
•Does not include loop or sea water pump contactor
•Does not include a display keypad (purchase separately)
•Includes a 2 FT display keypad cable
•Compressor current transducer can be added inside the box
•Includes a 10 FT length 12 conductor control cable to hook up to a chiller unit
Single Chiller Unit Control Panel Standard Features

•Flow switch (opens for more than 5 seconds)
Sustain shutdown after 5 faults
•Loop water low temperature limit (36 F (2.22 C))
Sustained shutdown after 3 faults
•Loop water high temperature limit (130 F (54.4 C))
Sustained shutdown after 3 faults
•Immersion heater loop water high temperature limit (150 F (65.5 C))
Sustained shutdown after 3 faults
•High discharge refrigerant pressure (exceeded 426 PSI)
Sustained shutdown after 5 faults
System Faults For Version 33 and Earlier Eproms

•Low suction refrigerant pressure (at 30 PSI)
No sustained shutdown
•Loss of network
Defective network cable and/or chiller board; each chiller still operates
independently
•In and Out Loop water temperature difference limit
In cool mode, if temperature difference is 14 F (7.8 C) or greater for 2
minutes, the chiller goes into sustained shutdown
•In and Out Sea water temperature difference limit
In cool mode, if temperature difference greater than 16 F (8.9 C) and less than
20 F (11 C) for 5 minutes, or greater than 20 F (11 C) for 2 minutes, the
chiller will go into sustained shutdown
System Faults For Version 33 and Earlier Eproms (cont’d.)

•Loop water out sensor
Sustained shut down on first fault
•Common loop water return sensor
With multiple chillers if the #1 sensor fails the system will use the next available water return
sensor and the unit will continue to run.
If all the return sensors fail, the system will use the common loop water supply sensor to monitor
stage set points.
•Common loop water supply sensor
The system will continue to operate
•Sea water out sensor
The system will continue to operate
•Sea water in sensor
The system will continue to operate and will use the next available sea water in senor, if
available.
•Immersion heater loop water sensor
Will use next available immersion heater loop water sensor and system continue to run.
If extra sensor is not available, then all heaters will be sustained shutdown.
System Faults for Sensors (cont’d.)

Temperature Sensors Locations For The
MTC Model Units
Loop water out sensor
•Located on the water outlet pipe on the top
of the plate coil
•This sensor is used to sense the Loop water
low temperature limit (Freeze sensor)
•Sensor is marked (Supply)
Common loop water return sensor
•Located on the water inlet pipe on the
bottom of the plate coil
•The chiller cycles on it’s set points by this
sensor
•All chillers read off of the #1 chiller.