Daikin EWAD TZ-B User manual

Air and Water cooled inverter chillers and heat pump
EWAD TZ - EWAD TZ B - EWWD VZ
Air and Water cooled inverter chillers
and heat pump
D-EOMZC00105-17EN
Operation Manual
1/84
Air cooled:
EWAD TZ
EWAD TZ-B
Water cooled:
EWWD VZ
Air and Water cooled inverter chillers and heat pump
D-EOMZC00105-17EN
OPERATION MANUAL

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Operation Manual
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Air and Water cooled inverter chillers and
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TABLE OF CONTENTS
1SAFETY CONSIDERATIONS...................................................................................................................... 7
1.1 General ................................................................................................................................................. 7
1.2 Avoid electrocution................................................................................................................................ 7
1.3 Safety Devices...................................................................................................................................... 7
1.3.1 General safety devices .................................................................................................................................7
1.3.2 Circuit safety devices....................................................................................................................................8
1.3.3 Component safety devices ...........................................................................................................................8
1.4 Available sensors.................................................................................................................................. 9
1.4.1 Pressure transducers....................................................................................................................................9
1.4.2 Temperature sensors....................................................................................................................................9
1.4.3 Thermistors...................................................................................................................................................9
1.4.4 Leak detectors..............................................................................................................................................9
1.5 Available Controls............................................................................................................................... 10
1.5.1 Evaporator pumps ......................................................................................................................................10
1.5.2 Condenser pumps (W/C units only)............................................................................................................10
1.5.3 Compressors ..............................................................................................................................................10
1.5.4 Expansion Valve.........................................................................................................................................10
1.5.5 Switchbox Pressurization fan for HFO units (W/C only)..............................................................................10
1.6 Customer Terminal Block Connections .............................................................................................. 10
1.6.1 Evaporator Flow Switch..............................................................................................................................11
1.6.2 Condenser Flow Switch (W/C units only)....................................................................................................11
1.6.3 Double setpoint...........................................................................................................................................11
1.6.4 Current limit (optional) ................................................................................................................................11
1.6.5 External Fault..............................................................................................................................................11
1.6.6 Rapid Restart (optional)..............................................................................................................................11
1.6.7 Remote On-Off ...........................................................................................................................................11
1.6.8 General Alarm.............................................................................................................................................11
1.6.9 Compressor Status.....................................................................................................................................11
1.6.10 Circuit Alarm (optional) ...............................................................................................................................11
1.6.11 Evaporator Pump Start ...............................................................................................................................12
1.6.12 Condenser Pump Start (W/C units only).....................................................................................................12
1.6.13 Demand limit...............................................................................................................................................12
1.6.14 Setpoint override.........................................................................................................................................12
1.6.15 Pump VFD Signal (A/C units only)..............................................................................................................12
2GENERAL DESCRIPTION ........................................................................................................................ 13
2.1 Basic Information................................................................................................................................ 13
2.2 Abbreviations used ............................................................................................................................. 13
2.3 Controller Operating Limits................................................................................................................. 13
2.4 Controller Architecture ........................................................................................................................ 14
2.5 Communication Modules .................................................................................................................... 14
3USING THE CONTROLLER...................................................................................................................... 15
3.1 General Recommendation.................................................................................................................. 15
3.2Navigating........................................................................................................................................... 15
3.3 Passwords .......................................................................................................................................... 16
3.4 Editing................................................................................................................................................. 16

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3.5 Basic Control System Diagnostic........................................................................................................ 17
3.6 Controller maintenance....................................................................................................................... 18
3.7Optional Remote User Interface......................................................................................................... 18
3.8 Embedded Web Interface................................................................................................................... 19
4MENU STRUCTURE.................................................................................................................................. 21
4.1 Main Menu .......................................................................................................................................... 21
4.2 View/Set Unit ...................................................................................................................................... 21
4.2.1 Thermostat Ctrl...........................................................................................................................................21
4.2.2 Network Ctrl................................................................................................................................................22
4.2.3 Compressor Vfd Setup (A/C Units only) .....................................................................................................22
4.2.4 Pumps ........................................................................................................................................................22
4.2.5 Condenser (W/C units only)........................................................................................................................23
4.2.6 Press Fan (W/C units only).........................................................................................................................23
4.2.7 Master/Slave...............................................................................................................................................23
4.2.7.1 Data....................................................................................................................................................24
4.2.7.2 Options...............................................................................................................................................24
4.2.7.3 Thermostat Ctrl ..................................................................................................................................25
4.2.7.4 Timers................................................................................................................................................25
4.2.7.5 Standby Chiller...................................................................................................................................25
4.2.8 Rapid Restart..............................................................................................................................................25
4.2.9 Date/Time...................................................................................................................................................25
4.2.10 Scheduler ...................................................................................................................................................26
4.2.11 Power Conservation ...................................................................................................................................26
4.2.12 Controller IP setup......................................................................................................................................27
4.2.13 Daikin on Site..............................................................................................................................................27
4.2.14 Menu Password..........................................................................................................................................27
4.3 View/Set Circuit................................................................................................................................... 28
4.3.1 Data............................................................................................................................................................28
4.3.2 Compressor................................................................................................................................................29
4.3.3 Condenser (A/C only).................................................................................................................................29
4.3.4 EXV ............................................................................................................................................................30
4.3.5 Economizer (A/C only)................................................................................................................................30
4.3.6 Settings (A/C units only).............................................................................................................................30
4.3.7 Variable VR.................................................................................................................................................30
4.4 Active Setpoint.................................................................................................................................... 30
4.5 Evaporator LWT.................................................................................................................................. 31
4.6 Condenser LWT (W/C Units only) ...................................................................................................... 31
4.7 Unit Capacity....................................................................................................................................... 31
4.8 Unit Mode............................................................................................................................................ 31
4.9 Unit Enable (A/C Units only)............................................................................................................... 32
4.10 Timers................................................................................................................................................. 32
4.11 Alarms................................................................................................................................................. 32
4.12 Commission Unit................................................................................................................................. 32
4.12.1 Alarm Limits................................................................................................................................................32
4.12.2 Calibrate Sensors.......................................................................................................................................33
4.12.2.1 Unit Calibrate Sensors .......................................................................................................................33
4.12.2.2 Circuit Calibrate Sensors....................................................................................................................33
4.12.3 Manual Control ...........................................................................................................................................34
4.12.3.1 Unit.....................................................................................................................................................34

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4.12.3.2 Circuit #1 (Circuit #2 if present)..........................................................................................................35
4.12.4 Scheduled Maintenance.............................................................................................................................36
4.13 About this Chiller................................................................................................................................. 36
5WORKING WITH THIS UNIT..................................................................................................................... 37
5.1 Unit Setup ........................................................................................................................................... 37
5.1.1 Control Source............................................................................................................................................37
5.1.2 Available Mode Setting...............................................................................................................................37
5.1.3 Temperature Settings.................................................................................................................................38
5.1.3.1 LWT Setpoint Setting .........................................................................................................................38
5.1.3.2 Thermostat Control Settings...............................................................................................................39
5.1.4 Alarm Settings ............................................................................................................................................40
5.1.4.1 Pumps................................................................................................................................................40
5.1.5 Power Conservation ...................................................................................................................................40
5.1.5.1 Demand Limit.....................................................................................................................................40
5.1.5.2 Current Limit (Optional)......................................................................................................................41
5.1.5.3 Setpoint Reset....................................................................................................................................41
5.1.5.4 Setpoint Reset by OAT Reset (A/C units only)...................................................................................41
5.1.5.5 Setpoint Reset by External 4-20 mA Signal .......................................................................................42
5.1.5.6 Setpoint Reset by Evaporator Return Temperature...........................................................................42
5.1.5.7 Soft Load............................................................................................................................................42
5.1.6 Date/Time...................................................................................................................................................43
5.1.6.1 Date,Time and UTC Settings .............................................................................................................43
5.1.6.2 Quiet Mode Scheduling (A/C units only).............................................................................................43
5.1.7 Scheduler ...................................................................................................................................................43
5.2 Unit/Circuit Start-up............................................................................................................................. 43
5.2.1 Unit Status..................................................................................................................................................43
5.2.2 Prepare the unit to start..............................................................................................................................44
5.2.2.1 Unit Switch Enable (A/C units only)....................................................................................................44
5.2.2.2 Unit Switch Enable (W/C units only)...................................................................................................44
5.2.2.3 Keypad Enable...................................................................................................................................45
5.2.2.1 BMS Enable.......................................................................................................................................45
5.2.3 Unit Start sequence....................................................................................................................................45
5.2.4 Circuit Status ..............................................................................................................................................45
5.2.5 Circuits start sequence...............................................................................................................................46
5.2.6 High Water Temperature Limit (A/C units only)..........................................................................................47
5.2.7 Low Evaporating Pressure..........................................................................................................................47
5.2.8 High Condensing Pressure.........................................................................................................................48
5.2.9 High Vfd Current.........................................................................................................................................48
5.2.10 High Discharge Temperature......................................................................................................................48
5.3 Condensation Control (A/C units only) ............................................................................................... 49
5.3.1 Fan Settings (A/C units only)......................................................................................................................49
5.3.1.1 Fan VFD Settings...............................................................................................................................49
5.4 Condensation Control (W/C units only) .............................................................................................. 50
5.5 EXV Control ........................................................................................................................................ 51
5.6 Economizer Control (A/C units only)................................................................................................... 51
5.7 Liquid Injection Control ....................................................................................................................... 52
5.8 Variable Volume Ratio Control ........................................................................................................... 52
6ALARMS AND TROUBLESHOOTING...................................................................................................... 53
6.1 Unit Alerts ........................................................................................................................................... 54
6.1.1 Bad Current Limit Input...............................................................................................................................54
6.1.2 Bad Demand Limit Input.............................................................................................................................54

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6.1.3 Bad Leaving Water Temperature Reset Input.............................................................................................54
6.1.4 Condenser Pump #1 Failure (W/C units only).............................................................................................55
6.1.5 Condenser Pump #2 Failure (W/C units only).............................................................................................55
6.1.6 Energy Meter Communication Fail..............................................................................................................55
6.1.7 Evaporator Pump #1 Failure.......................................................................................................................56
6.1.8 Evaporator Pump #2 Failure.......................................................................................................................56
6.1.9 External Event ............................................................................................................................................56
6.1.10 Fan Alarm Module Communication Fail (A/C units only) ............................................................................57
6.1.11 Heat Recovery Entering Water Temperature sensor fault (A/C units only).................................................57
6.1.12 Heat Recovery Leaving Water Temperature sensor fault (A/C units only)..................................................57
6.1.13 Heat Recovery Water Temperatures inverted (A/C units only)...................................................................58
6.1.14 Rapid Recovery Module Communication Fail.............................................................................................58
6.1.15 Switch Box Temperature sensor fault (A/C units only)................................................................................58
6.2 Unit Pumpdown Stop Alarms.............................................................................................................. 59
6.2.1 Condenser Entering Water Temperature (EWT) sensor fault.....................................................................59
6.2.2 Condenser Leaving Water Temperature (LWT) sensor fault ......................................................................59
6.2.3 Evaporator Entering Water Temperature (EWT) sensor fault.....................................................................59
6.2.4 Evaporator Water Temperatures inverted...................................................................................................60
6.2.5 Outside Air Temperature (OAT) Lockout (A/C units only)...........................................................................60
6.2.6 Outside Air Temperature sensor fault alarm (A/C units only)......................................................................60
6.3 Unit Rapid Stop Alarms....................................................................................................................... 61
6.3.1 Condenser Water Freeze alarm (W/C units only).......................................................................................61
6.3.2 Condenser Water Flow Loss alarm (W/C units only)..................................................................................61
6.3.3 Emergency Stop.........................................................................................................................................61
6.3.4 Evaporator Flow Loss alarm......................................................................................................................62
6.3.5 Evaporator Leaving Water Temperature (LWT) sensor fault ......................................................................62
6.3.6 Evaporator Water Freeze alarm..................................................................................................................62
6.3.7 External alarm.............................................................................................................................................63
6.3.8 Gas Leakage Alarm (W/C units only)..........................................................................................................63
6.3.9 Heat Recovery Water Freeze Protect alarm (A/C units only)......................................................................63
6.3.10 OptionCtrlrCommFail (A/C units only).........................................................................................................64
6.3.11 Power Fault (only for A/C units with the UPS option)..................................................................................64
6.3.12 PVM alarm (A/C units only).........................................................................................................................64
6.4 Circuit Alerts........................................................................................................................................ 65
6.4.1 Economizer Pressure Sensor fault (A/C units only)....................................................................................65
6.4.2 Economizer Temperature Sensor fault (A/C units only)..............................................................................65
6.4.3 Failed Pumpdown.......................................................................................................................................66
6.4.4 Fan Fault (A/C units only)...........................................................................................................................66
6.4.5 Gas Leakage Sensor fault (A/C units only).................................................................................................66
6.4.6 CxCmp1 MaintCode01 (A/C units only)......................................................................................................67
6.4.7 CxCmp1 MaintCode02 (A/C units only)......................................................................................................67
6.4.8 Power Loss (A/C units only)........................................................................................................................67
6.5 Circuit Pumpdown Stop Alarms.......................................................................................................... 68
6.5.1 Discharge Temperature Sensor fault..........................................................................................................68
6.5.2 Gas Leakage fault (A/C units only).............................................................................................................68
6.5.3 High Compressor Vfd Temperature fault (A/C units only)...........................................................................69
6.5.4 Liquid Temperature Sensor fault (W/C units only)......................................................................................69
6.5.5 Low Compressor Vfd Temperature fault (A/C units only)............................................................................69
6.5.6 Low Oil Level fault (W/C units only)............................................................................................................70

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heat pump
6.5.7 Low Discharge Superheat fault...................................................................................................................70
6.5.8 Oil Pressure Sensor fault............................................................................................................................70
6.5.9 Suction Temperature Sensor fault..............................................................................................................71
6.6 Circuit Rapid Stop Alarms................................................................................................................... 71
6.6.1 Compressor Extension Communication Error (W/C units only) ..................................................................71
6.6.2 EXV Driver Extension Communication Error (W/C units only)....................................................................71
6.6.3 Compressor VFD Fault...............................................................................................................................72
6.6.4 Compressor VFD OverTemp (A/C units only).............................................................................................72
6.6.5 Condensing Pressure sensor fault..............................................................................................................72
6.6.6 Economizer EXV Driver Error (A/C unit only)..............................................................................................73
6.6.7 Economizer EXV Motor Not Connected (A/C unit only)..............................................................................73
6.6.8 Evaporating Pressure sensor fault..............................................................................................................73
6.6.9 EXV Driver Error (A/C units only)................................................................................................................74
6.6.10 EXV Motor Not Connected (TZ B units only) ..............................................................................................74
6.6.11 Fail Start Low Pressure ..............................................................................................................................74
6.6.12 Fan VFD Over Current (A/C units only) ......................................................................................................75
6.6.13 High Discharge Temperature Alarm ...........................................................................................................75
6.6.14 High Motor Current Alarm...........................................................................................................................75
6.6.15 High Motor Temperature Alarm ..................................................................................................................76
6.6.16 High Oil Pressure Differential Alarm...........................................................................................................76
6.6.17 High Pressure alarm...................................................................................................................................76
6.6.18 Low Pressure alarm....................................................................................................................................77
6.6.19 Low Pressure Ratio Alarm..........................................................................................................................78
6.6.20 Maximum Number of Restart Alarm (A/C units only) ..................................................................................78
6.6.21 Mechanical High Pressure Alarm................................................................................................................79
6.6.22 Mechanical Low Pressure Alarm (W/C units only)......................................................................................79
6.6.23 No Pressure At Start Alarm ........................................................................................................................80
6.6.24 No Pressure Change At Start Alarm...........................................................................................................80
6.6.25 Overvoltage Alarm......................................................................................................................................80
6.6.26 Undervoltage Alarm....................................................................................................................................81
6.6.27 VFD Communication Failure.......................................................................................................................81
7OPTIONS.................................................................................................................................................... 82
7.1 Total Heat Recovery (Optional –A/C units only)................................................................................ 82
7.2 Energy Meter including Current Limit (Optional) ................................................................................ 82
7.3 Rapid Restart (Optional)..................................................................................................................... 83
7.4 Inverter Pump Kit (Optional) ............................................................................................................... 83

Air and Water cooled inverter chillers and heat pump
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1 SAFETY CONSIDERATIONS
1.1 General
Installation, start-up and servicing of equipment can be hazardous if certain factors particular to the installation
are not considered: operating pressures, presence of electrical components and voltages and the installation
site (elevated plinths and built-up up structures). Only properly qualified installation engineers and highly
qualified installers and technicians, fully trained for the product, are authorized to install and start-up the
equipment safely.
During all servicing operations, all instructions and recommendations, which appear in the installation and
service instructions for the product, as well as on tags and labels fixed to the equipment and components and
accompanying parts supplied separately, must be read, understood and followed.
Apply all standard safety codes and practices.
Wear safety glasses and gloves.
Use the proper tools to move heavy objects. Move units carefully and set them down gently.
1.2 Avoid electrocution
Only personnel qualified in accordance with IEC (International Electrotechnical Commission)
recommendations may be permitted access to electrical components. It is particularly recommended that all
sources of electricity to the unit be shut off before any work is begun. Shut off main power supply at the main
circuit breaker or isolator.
IMPORTANT: This equipment uses and emits electromagnetic signals. Tests have shown that the
equipment conforms to all applicable codes with respect to electromagnetic compatibility.
RISK OF ELECTROCUTION: Even when the main circuit breaker or isolator is switched off, certain circuits may
still be energized, since they may be connected to a separate power source.
RISK OF BURNS: Electrical currents cause components to get hot either temporarily or permanently. Handle
power cable, electrical cables and conduits, terminal box covers and motor frames with great care.
ATTENTION: In accordance with the operating conditions the fans can be cleaned periodically. A fan can start at
any time, even if the unit has been shut down.
1.3 Safety Devices
Each unit is equipped with safety devices of three different kinds:
1.3.1 General safety devices
Safeties of this level of severity will shut down all the circuits and stop the entire unit. When a general safety
device will occur a manual intervention on the unit will be required in order to re-establish the normal operability
of the machine. There are exceptions to this general rule in case of alarms linked to temporary abnormal
conditions.
Emergency Stop
A push button is placed on a door of the unit electrical panel. The button is highlighted by a red color in yellow
background. A manual pressure of the emergency stop button stops all loads from rotating, thus preventing
any accident which may occur. An alarm is also generated by the Unit Controller. Releasing the emergency
stop button enables the unit, which may be restarted only after the alarm has been cleared on the controller.

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The emergency stop causes all motors to stop, but does not switch off power to the unit. Do not service or
operate on the unit without having switched off the main switch.
1.3.2 Circuit safety devices
Safety of this level of severity will shut down the circuit they protect. The remaining circuits will keep running.
1.3.3 Component safety devices
Safety of this level of severity will shut down a component against abnormal running condition that could create
permanent damages to it. An overview of the protecting devices is listed below:
Overcurrent/Overload Protections
Overcurrent/overload devices protect electrical motors used on compressors, fans and pumps in case of
overload or short circuit. In case of inverter-driven motors, overload and overcurrent protection is integrated in
the electronic drives. A further protection from short circuit is accomplished by fuses or circuit breakers installed
upstream each load or group of loads.
Overtemperature Protections
Compressor and fan electrical motors are also protected from overheating by thermistors immersed into motor
windings. Should the winding temperature exceed a fixed threshold, the thermistors will trip and cause the
motor to stop. High Temperature Alarm is recorded in the Unit Controller only in case of compressors. Alarm
must be reset from the controller.
Do not operate on a faulty fan before the main switch has been shut off. Overtemperature protection is auto-
reset, therefore a fan may restart automatically if temperature conditions allow it.
Phase reversal, under/over voltage, ground fault protections
When one of those alarms occurs the unit is immediately stopped or even inhibited to start. The alarms clear
automatically once the problem is fixed. This auto clear logic allows the unit to automatically recover in case
of temporary conditions where the supply voltage reaches the upper or lower limit set on the protection device.
In the other two cases a manual intervention on the unit will be required in order to solve the problem. In case
of a phase reversal alarm two phases requires to be inverted.
In the event of a power supply outage, the unit will restart automatically without the need for an external
command. However, any faults active when the supply is interrupted are saved and may in certain cases
prevent a circuit or unit from restarting.
Direct intervention on the power supply can cause electrocution, burns or even death. This action must be
performed only by trained persons.
Flowswitch
The unit must be protected by a flowswitch. The flowswitch will stop the unit when the water flow becomes
lower than the minimum allowed flow. When the water flow is restored the flow protection resets automatically.
Exception is when the flowswitch opens with at least one compressor running, in this case the alarm shall be
cleared manually.
Freezing protection
Antifreeze protection prevents the water to freeze in the evaporator. It is automatically activated when the
water temperature (entering or leaving) at the evaporator drops below the antifreeze limit. In freeze condition
if the unit is in standby the evaporator pump will be activated to prevent freezing of the evaporator. If the freeze
condition will activate when the unit is running all the unit will shut down in alarm while the pump will keep
running. Alarm will automatically clear when the freeze condition will clear.
Low pressure protection

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If the circuit operates with a suction pressure lower than an adjustable limit for a certain time the circuit safety
logic will shut down the circuit and generate an alarm. The alarm requires a manual action on the Unit Controller
to be reset. Reset will take effect only if the suction pressure is no longer lower that the safety limit.
High Pressure Protection
If the discharge pressure becomes too high and exceeds a limit which is linked with the operational envelop
of the compressor the circuit safety logic will try to prevent the alarm or, if the corrective actions have no effect,
it will shut down the circuit before the Mechanical High Pressure switch will open. This alarm required a manual
action on the Unit Controller to be reset.
Mechanical High Pressure Switch
Each circuit is equipped with at least one high pressure switch which tries to prevent the relief safety valve to
open. When the discharge pressure becomes too high the Mechanical High Pressure switch will open and
immediately stop the compressor cutting the power supply to the auxiliary relay. The alarm can be cleared as
soon as the discharge pressure becomes normal again. The alarm must be reset on the switch itself and on
the Unit Controller. The triggering pressure value cannot be changed.
Relief Safety Valve
If the pressure becomes too high in the refrigerant circuit, the relief valve will open to limit the maximum
pressure. If this happens switch off immediately the machine and contact your local service organization.
Inverter fault
Each compressor can be equipped with its own inverter (integrated or external). The inverter can automatically
monitor its status and inform the Unit Controller in case of faults or pre-alarm conditions. If this happen the
Unit Controller will limit the compressor operation or eventually switch off the circuit in alarm. A manual action
on the controller will be needed in order to clear the alarm.
1.4 Available sensors
1.4.1 Pressure transducers
Two types of electronic sensors are used to measure suction, discharge and oil pressure on each circuit. The
range of each sensor is clearly indicated on the sensor casing. Discharge and oil pressures are monitored
using a sensor of the same range.
1.4.2 Temperature sensors
The evaporator water sensors are installed in the entering and leaving side. An outdoor temperature sensor is
mounted inside the chiller. Additionally each circuit installs a suction and discharge temperature sensors to
monitor and control the superheated refrigerant temperatures.
On refrigerant-cooled inverters additional sensors immersed into the cooling plate measure the temperature
of the drives.
1.4.3 Thermistors
Each compressor is equipped with PTC thermistors which are immersed into motor windings for motor
protection. Thermistors trip to a high value in case the motor temperature reaches a hazardous temperature.
1.4.4 Leak detectors
As an option the unit can be equipped with leak detectors to sense the air in the compressor cabin and being
able to identify a refrigerant leakage in that volume.

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1.5 Available Controls
1.5.1 Evaporator pumps
The controller can regulate one or two evaporator pumps and takes care of automatic change-over between
pumps. It’s also possible to prioritize the pumps and temporarily disable one of the two. The controller is also
able to control the pump speeds if the pumps are equipped with inverters.
1.5.2 Condenser pumps (W/C units only)
The controller can regulate one or two condenser pumps and takes care of automatic change-over between
pumps. It’s also possible to prioritize the pumps and temporarily disable one of the two.
1.5.3 Compressors
The controller can regulate one or two compressors installed on one or two independent refrigerant circuit (one
compressor per circuit). All the safeties of each compressor will be managed by the controller. Embedded
inverter safeties are handled by the inverter onboard electronic and only notified to the UC.
1.5.4 Expansion Valve
The controller can regulate an electronic expansion valve per each refrigerant circuit. Microtech® III embedded
logic will always guarantee the best operation for the refrigerant circuit.
1.5.5 Switchbox Pressurization fan for HFO units (W/C only)
In case of water cooled units which are installed in plant rooms it’s required to pressurize the switchbox to
avoid refrigerant accumulation that could lead to dangerous operations of the unit. To avoid this a
pressurization fan will maintain a constant air circulation inside the switchbox. This fan will be always running
when the internal temperature will exceed 23°C. Any drop in the delta pressure between the inside and the
ambient will generate a stop of the unit to re-establish a safe condition for the users.
1.6 Customer Terminal Block Connections
The contacts below are available at the user’s terminal block referred as MC24 or MC230 in the wiring diagram.
The following table summarizes the connections at the user’s terminal block.
Description
Terminals
EWAD
TZ
Terminals
EWAD
TZ B
Terminals
EWWD
VZ
Notes
Evaporator Flow Switch (mandatory)
708, 724
708, 724
708, 724
24 Vdc digital input
Condenser Flow Switch
-
-
888, 890
24 Vdc digital input
Double setpoint
703, 728
703,728
703, 728
24 Vdc digital input
Current limit enable
884, 885
885, 891
-
24 Vdc digital input
External Fault
881,884
881, 884
542, 501
24 Vdc digital input
Rapid Restart Enable (optional)
764, 765
-
764, 765
24 Vdc digital input
Back-up chiller (optional)
764, 763
-
-
24 Vdc digital input
LOC/BMS selection (optional)
894, 895
881-1, 834
894, 895
24 Vdc digital input
On-Off Remote
540, 541
540, 541
703, 749
230 Vac digital input
Heat/Cool Remote
-
-
892, 893
Leak Detector Output
-
-
552, 553
General Alarm
525, 526
525, 526
525, 526
NO digital output (24…230 Vac ext supply)
Compressor #1 status
512, 513
512, 513
-
NO digital output (24…230 Vac ext supply)
Compressor #2 status
514, 515
514, 515
-
NO digital output (24…230 Vac ext supply)
Alarm Circuit #1 (optional)
560, 561
892, 896
564, 565
NO digital output (24…230 Vac ext supply)
Alarm Circuit #2 (optional)
560, 562
894, 899
565, 566
NO digital output (24…230 Vac ext supply)
Evaporator Pump #1 start
806, 805
501, 530
527, 528
NO digital output (24 Vdc internal supply)
Evaporator Pump #2 start
806, 807
501, 531
559, 560
NO digital output (24 Vdc internal supply)
Condenser Pump #1 start
-
-
550, 551
NO digital output (24 Vdc internal supply)
Condenser Pump #2 start
-
-
559, 562
NO digital output (24 Vdc internal supply)
Demand Limit
888, 889
888, 889
887, 889
4-20 mA analog input
Current Limit (optional)
886, 890
887, 886
-
4-20 mA analog input
Setpoint Override
886, 887
890, 886
886, 887
4-20 mA analog input
Pump VFD Signal (optional)
882, 883
-
-

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1.6.1 Evaporator Flow Switch
Although the flow switch is offered as an optional, it is mandatory to install one and connect it to the digital
input terminals in order to enable chiller operation only when a minimum flow is sensed.
Operating the unit by-passing the flow switch input or without an appropriate flow switch may damage the
evaporator due to freezing. Operation of the flow switch must be checked prior to start up the unit.
1.6.2 Condenser Flow Switch (W/C units only)
Condenser flow switch is offered as an option but it’s not mandatory to connect it to the digital input terminals.
This input can be eventually closed by a jumper even if for a more reliable use it’s suggested to mount it. If not
installed, other protection will activate in order to protect the unit.
1.6.3 Double setpoint
This contact can be used to switch between two different LWT setpoints and, depending on the application,
between different modes of operation.
Ice operation must be selected in case of ice storage application. In this case the UC will run the chiller in
on/off mode, switching all the chiller off as soon as the setpoint is reached. In this case the unit will run to full
capacity and then will switch off applying an ice delay different chiller starts.
1.6.4 Current limit (optional)
This optional feature enables a capacity control of the unit in order to limit the input current. The current limit
feature is included in the Energy Meter option. The limiting signal will be compared with a limiting value set on
the HMI. By default the current limit setpoint is selected through the HMI; an external 4-20 mA signal can be
enabled to allow a remotely changeable setpoint.
1.6.5 External Fault
This contact is available to report to the UC a fault or a warning from an external device. It could be an alarm
coming from an external pump to inform the UC of the fault. This input can be configured as a fault (unit stop)
or a warning (displayed on the HMI without any action on the chiller).
1.6.6 Rapid Restart (optional)
Purpose of the rapid restart feature is to let the unit restart in the shortest possible time after a power failure,
and then recover in the shortest possible time (maintaining the reliability level of the normal operations) the
capacity it had before the power failure. The rapid restart is enabled by the enable switch.
1.6.7 Remote On-Off
This unit can be started through a remote enable contact. The Q0 switch must be selected to “Remote”.
1.6.8 General Alarm
In case of a unit alarm, this output is closed thus indicating a fault condition to an externally connected BMS.
1.6.9 Compressor Status
The digital output is closed when the related circuit is in run state.
1.6.10 Circuit Alarm (optional)
This option is included with the “Rapid Restart” option. The related digital contact is closed in case of alarm on
a circuit.

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1.6.11 Evaporator Pump Start
A 24 Vdc digital output (with internal supply) is enabled when a pump (#1 or #2) is required to start. The output
can be used to start an external pump (either at fixed or variable speed). The output requires an external input
or relay with less than 20 mA excitation current.
1.6.12 Condenser Pump Start (W/C units only)
A digital output is enabled when a pump (#1 or #2) is required to start. A pump will be required to start when a
compressor will be called to start.
1.6.13 Demand limit
This optional function can be used to limit the unit capacity percentage to a changeable limit value. This
limitation cannot be directly linked to a corresponding limitation of the unit current (50% demand limit can differ
from 50% of the unit FLA).
The demand limit signal can be changed continuously between 4 and 20 mA. The Microtech III will convert
this signal into a unit capacity limitation changing between minimum capacity and full capacity with a linear
relationship. A signal between 0 and 4mA will correspond to a full unit capacity, in this way if nothing is
connected to this input no limitation will be applied. The maximum limitation will never force a unit shutdown.
1.6.14 Setpoint override
This input allows to apply an offset on the Active Setpoint to adjust the operating point of the ELWT. This input
can be used to maximize the comfort.
1.6.15 Pump VFD Signal (A/C units only)
The “Pump VFD Signal” terminals are available for pump inverter kit option when factory wired speed reference
is required. These terminals are placed inside the main electrical panel. For more information about this option
see 7.4.

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2 GENERAL DESCRIPTION
2.1 Basic Information
Microtech® III is a system for controlling single or dual-circuit air/water-cooled liquid chillers. Microtech® III
controls compressor start-up necessary to maintain the desired heat exchanger leaving water temperature. In
each unit mode it controls the operation of the condensing devices to maintain the proper condensation
process in each circuit.
Safety devices are constantly monitored by Microtech® III to ensure their safe operation. Microtech® III also
gives access to a Test routine covering all inputs and outputs. All Microtech® III controls can work in
accordance with three independent modes:
Local mode: the machine is controlled by commands from the user interface.
Remote mode: the machine is controlled by remote contacts (volt-free contacts).
Network mode: the machine is controlled by commands from a BAS system. In this case, a data communication
cable is used to connect the unit to the BAS.
When the Microtech® III system operates autonomously (Local or Remote mode) it retains all of its own control
capabilities but does not offer any of the features of the Network mode. In this case monitoring of the unit
operational data is still allowed.
2.2 Abbreviations used
In this manual, the refrigeration circuits are called circuit #1 and circuit #2. The compressor in circuit #1 is
labelled Cmp1. The other in circuit #2 is labelled Cmp2. The following abbreviations are used:
A/C
Air Cooled
CEWT
Condenser Entering Water Temperature
CLWT
Condenser Leaving Water Temperature
CP
Condensing Pressure
CSRT
Condensing Saturated Refrigerant Temperature
DSH
Discharge Superheat
DT
Discharge Temperature
E/M
Energy Meter Module
EEWT
Evaporator Entering Water Temperature
ELWT
Evaporator Leaving Water Temperature
EP
Evaporating Pressure
ESRT
Evaporating Saturated Refrigerant Temperature
EXV
Electronic Expansion Valve
HMI
Human Machine Interface
MOP
Maximum operating pressure
SSH
Suction SuperHeat
ST
Suction Temperature
UC
Unit controller (Microtech III)
W/C
Water Cooled
2.3 Controller Operating Limits
Operation (IEC 721-3-3):
Temperature -40...+70 °C
Restriction LCD -20… +60 °C
Restriction Process-Bus -25….+70 °C
Humidity < 90 % r.h (no condensation)
Air pressure min. 700 hPa, corresponding to max. 3,000 m above sea level
Transport (IEC 721-3-2):
Temperature -40...+70 °C
Humidity < 95 % r.h (no condensation)

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Air pressure min. 260 hPa, corresponding to max. 10,000 m above sea level.
2.4 Controller Architecture
The overall controller architecture is the following:
One MicroTech III main controller
I/O extensions as needed depending on the configuration of the unit
Communications interface(s) as selected
Peripheral Bus is used to connect I/O extensions to the main controller.
Controller/
Extension Module
Siemens Part Number
Address
Usage
EWAD TZ
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Main Controller
POL687.70/MCQ
POL687.70/MCQ
POL687.00/MCQ
n/a
Used on all configurations
Extension Module
-
-
POL965.00/MCQ
2
Used on all configurations
EEXV Module 1
POL94U.00/MCQ
POL98U.00/MCQ
POL94U.00/MCQ
3
Used on all configurations
EEXV Module 2
POL94U.00/MCQ
POL98U.00/MCQ
-
4
Used when configured for 2 circuits
Extension Module
-
-
POL965.00/MCQ
4
Used when configured for 2 circuits
EEXV Module 2
-
-
POL94U.00/MCQ
5
Used when configured for 2 circuits
Extension Module
POL965.00/MCQ
-
-
5
Used on all configurations
Rapid Restart Module
POL945.00/MCQ
-
POL945.00/MCQ
22
Used with Rapid Restart option
HFO Module
-
-
POL945.00/MCQ
27
Used with HFO onW/C units
All boards are supplied from a common 24 Vac source. Extension boards can be directly powered by the Unit
Controller. All boards can be also supplied by a 24Vdc source.
CAUTION: Maintain the correct polarity when connecting the power supply to the boards, otherwise the peripheral
bus communication will not operate and the boards may be damaged.
2.5 Communication Modules
Any of the following modules can be connected directly to the left side of the main controller to allow a BAS or
other remote interface to function. Up to three can be connected to the controller at a time. The controller
should automatically detect and configure itself for new modules after booting up. Removing modules from
the unit will require manually changing the configuration.
Module
Siemens Part Number
Usage
BacNet/IP
POL908.00/MCQ
Optional
Lon
POL906.00/MCQ
Optional
Modbus
POL902.00/MCQ
Optional
BACnet/MSTP
POL904.00/MCQ
Optional

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3 USING THE CONTROLLER
The control system consists of a unit controller (UC) equipped with a set of extension modules that implement
additional features. All boards communicate via an internal peripheral bus with the UC. The Microtech III
continuously manages the information received from the various pressure and temperature probes installed
on the compressors and communicated to the unit .The UC incorporates a program that controls the unit.
The standard HMI consists of an inbuilt display (A) with 3 buttons (B) and a push’n’roll control (C).
The keypad/display (A) consists of a 5-line by 22 character display. The function of the three buttons (B) is
described below:

Alarm status (from any page it links with the page with alarm list, alarm log and alarm snapshot if available)

Back to Main Page

Back to the previous level (it can be the Main Page)
The push’n’roll command (C) is used to scroll between the different menu pages, settings and data available
on the HMI for the active password level. Rotating the wheel allows to navigate between lines on a screen
(page) and to increase and decrease changeable values when editing. Pushing the wheel acts as an Enter
Button and will jump from a link to the next set of parameters.
3.1 General Recommendation
Before switching on the unit read the following recommendations:
When all the operations and all the settings have been carried out, close all the switchbox panels
The switchbox panels can only be opened by trained personnel
When the UC requires to be accessed frequently the installation of a remote interface is strongly
recommended
Evaporator, compressors and related inverters are protected from freezing by electrical heaters. These
heaters are supplied through unit main supply and temperature controlled by thermostat or by the unit
controller. Also the LCD display of the unit controller may be damaged by extremely low temperatures.
For this reason, it is strongly recommended to never power off the unit during winter, especially in cold
climates.
3.2 Navigating
When power is applied to the control circuit, the controller screen will be active and display the Home screen,
which can also be accessed by pressing the Menu Button. The navigating wheel is the only navigating device
necessary, although the MENU, ALARM, and BACK buttons can provide shortcuts as explained previously.
An example of the HMI screens is shown in the following picture.
M
a
i
n
M
e
n
u
1
/
11
E
n
t
e
r
P
a
s
s
w
o
r
d

U
n
i
t
S
t
a
t
u
s
=
O
f
f
:
U
n
i
t
S
W
A
c
t
i
v
e
S
e
t
p
t
=
7
.
0
°
C
A bell ringing in the top right corner will indicate an active alarm. If the bell doesn’t move it means that the
alarm has been acknowledged but not cleared because the alarm condition hasn’t been removed. A LED will
also indicate where the alarm is located between the unit or circuits.
A
B
C
UC
A

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M
a
i
n
M
e
n
u
1
/

E
n
t
e
r
P
a
s
s
w
o
r
d

U
n
i
t
S
t
a
t
u
s
=
O
f
f
:
U
n
i
t
S
W
A
c
t
i
v
e
S
e
t
p
t
=
7
.
0
°
C
The active item is highlighted in contrast, in this example the item highlighted in Main Menu is a link to another
page. By pressing the push’n’roll, the HMI will jump to a different page. In this case the HMI will jump to the
Enter Password page.
E
n
t
e
r
P
a
s
s
w
o
r
d
2
/
2
E
n
t
e
r
P
W
*
*
*
*
3.3 Passwords
The HMI structure is based on access levels that means that each password will disclose all the settings and
parameters allowed to that password level. Basic informations about the status including the active alarm list,
active setpoint and controlled water temperature can be accessed without the need to enter the password.
The user UC handles two level of passwords:
USER
5321
MAINTENANCE
2526
The following information will cover all data and settings accessible with the maintenance password. User
password will disclose a subset of the settings explained in chapter 4.
In the Enter Password screen, the line with the password field will be highlighted to indicate that the field on
the right can be changed. This represents a setpoint for the controller. Pressing the push’n’roll the individual
field will be highlighted to allow an easy introduction of the numeric password. By changing all fields, the 4
digits password will be entered and, if correct, the additional settings available with that password level will be
disclosed.
E
n
t
e
r
P
a
s
s
w
o
r
d
2
/
2
E
n
t
e
r
P
W
5
*
*
*
The password will time out after 10 minutes and is cancelled if a new password is entered or the control powers
down. Entering an invalid password has the same effect as continuing without a password.
Once a valid password has been entered, the controller allows further changes and access without requiring
the user to enter a password until either the password timer expires or a different password is entered. The
default value for this password timer is 10 minutes. It is changeable from 3 to 30 minutes via the Timer Settings
menu in the Extended Menus.
3.4 Editing
The Editing Mode is entered by pressing the navigation wheel while the cursor is pointing to a line containing
an editable field. Once in the edit mode pressing the wheel again causes the editable field to be highlighted.
Turning the wheel clockwise while the editable field is highlighted causes the value to be increased. Turning
the wheel counter-clockwise while the editable field is highlighted causes the value to be decreased. The faster
the wheel is turned, the faster the value is increased or decreased. Pressing the wheel again cause the new
value to be saved and the keypad/display to leave the edit mode and return to the navigation mode.
A parameter with an “R” is read only; it is giving a value or description of a condition. An “R/W indicates a read
and/or write opportunity; a value can be read or changed (providing the proper password has been entered).
Example 1: Check Status, for example -is the unit being controlled locally or by an external network? We are
looking for the Unit Control Source Since this a unit status parameter, start at Main Menu and select View/Set
Unit and press the wheel to jump to the next set of menus. There will be an arrow at the right side of the box,

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indicating that a jump to the next level is required. Press the wheel to execute the jump. You will arrive at the
Status/ Settings link. There is an arrow indicating that this line is a link to a further menu. Press the wheel
again to jump to the next menu, Unit Status/Settings. Rotate the wheel to scroll down to Control Source and
read the result.
Example 2: Change a Set point, the chilled water set point for example. This parameter is designated as Cool
LWT Set point 1 and is a unit set parameter. From the Main Menu select View/Set Unit. The arrow indicated
that this is link to a further menu. Press the wheel and jump to the next menu View/Set Unit and use the wheel
to scroll down to Temperatures. This again has an arrow and is a link to a further menu. Press the wheel and
jump to the Temperatures menu, which contains six lines of temperatures set points. Scroll down to Cool LWT
1 and press the wheel to jump to the item change page. Rotate the wheel to adjust the set point to the desired
value. When this is done press the wheel again to confirm the new value. With the Back button it will be
possible to jump back to the Temperatures menu where the new value will be displayed.
Example 3: Clear an Alarm. The presence of a new alarm is indicated with a Bell ringing on the top right of
the display. If the Bell is frozen one or more alarm had been acknowledged but are still active. To view the
Alarm menu from the Main Menu scroll down to the Alarms line or simply press the Alarm button on the display.
Note the arrow indicating this line is a link. Press the wheel to jump to the next menu Alarms; there are two
lines here: Alarm Active and Alarm Log. Alarms are cleared from the Active Alarm link. Press the wheel to
jump to the next screen. When the Active Alarm list is entered scroll to the item AlmClr which is set to off by
default. Change this value to on to acknowledge the alarms. If the alarms can be cleared then the alarm counter
will display 0 otherwise it will display the number of alarm still active. When the alarms are acknowledged the
Bell on the top right of the display will stop to ring if some of the alarms are still active or will disappear if all
the alarms are cleared.
3.5 Basic Control System Diagnostic
MicroTech III controller, extension modules and communication modules are equipped with two status LED
(BSP and BUS) to indicate the operational status of the devices. The BUS LED indicates the status of the
communication with the controller. The meaning of the two status LED is indicated below.
Main Controller (UC)
BSP LED
Mode
Solid Green
Application running
Solid Yellow
Application loaded but not running (*) or BSP Upgrade mode active
Solid Red
Hardware Error (*)
Flashing Green
BSP startup phase. The controller needs time for starting.
Flashing Yellow
Application not loaded (*)
Flashing Yellow/Red
Fail safe mode (in case that the BSP upgrade was interrupted)
Flashing Red
BSP Error (software error*)
Flashing Red/Green
Application/BSP update or inizialization
(*) Contact Service.
Extension modules
BSP LED
Mode
BUS LED
Mode
Solid Green
BSP running
Solid Green
Communication running, I/O working
Solid Red
Hardware Error (*)
Solid Red
Communication down (*)
Flashing Red
BSP Error (*)
Solid Yellow
Communication running but parameter from the application
wrong or missing, or uncorrect factory calibration
Flashing Red/Green
BSP upgrade mode
Communication modules
BSP LED (same for all modules)
BSP LED
Mode
Solid Green
BPS running, communication with controller
Solid Yellow
BSP running, no communication with controller (*)
Solid Red
Hardware Error (*)
Flashing Red
BSP Error (*)
Flashing Red/Green
Application/BSP update
(*) Contact Service.

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BUS LED
BUS LED
LON
Bacnet MSTP
Bacnet IP
Modbus
Solid Green
Ready for
Communication. (All
Parameter loaded,
Neuron configured).
Doesn't indicate a
communication with other
devices.
Ready for
Communication. The
BACnet Server is started.
It doesn't indicate an
active communication
Ready for
Communication. The
BACnet Server is started.
It doesn't indicate an
active communication
All Communication
running
Solid
Yellow
Startup
Startup
Startup. The LED stays
yellow until the module
receives a IP Address,
therefore a link must be
established.
Startup, or one configured
channel not
communicating to the
Master
Solid Red
No Communication to
Neuron (internal error,
could be solved by
downloading a new LON
application)
BACnet Server down.
Automatically a restart
after 3 seconds are
initiated.
BACnet Server down.
Automatic restart after 3
seconds is initiated.
All configured
Communications down.
Means no communication
to the Master. The timeout
can be configured. In case
that the timeout is zero the
timeout is disabled.
Flashing
Yellow
Communication not
possible to the Neuron.
The Neuron must be
configured and set online
over the LON Tool.
3.6 Controller maintenance
The controller requires to maintain the installed battery. Every two years it’s required to replace the battery.
Battery model is: BR2032 and it is produced by many different vendors.
To replace the battery remove the plastic cover of the controller display using a screw driver as shown in the
following pictures:
Be careful to avoid damages to the plastic cover. The new battery shall be placed in the proper battery holder
which is highlighted in the following picture, respecting the polarities indicated into the holder itself.
3.7 Optional Remote User Interface
As an option an external Remote HMI can be connected on the UC. The Remote HMI offers the same features
as the inbuilt display plus the alarm indication done with a light emitting diode located below the bell button.
The Remote can be ordered with the unit and shipped loose as a field installed option. It can also be ordered
any time after chiller shipment and mounted and wired on the job as explained on the following page. The
remote panel is powered from the unit and no additional power supply is required.
All viewing and setpoint adjustments available on the unit controller are available on the remote panel.
Navigation is identical to the unit controller as described in this manual.

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The initial screen when the remote is turned on shows the units connected to it. Highlight the desired unit and
press the wheel to access it. The remote will automatically show the units attached to it, no initial entry is
required.
The Remote HMI can be extended up to 700m using the process bus connection available on the UC. With a
daisy-chain connection as below, a single HMI can be connected to up to 8 units. Refer to the specific HMI
manual for details.
3.8 Embedded Web Interface
The MicroTech III controller has an embedded web interface that can be used to monitor the unit when
connected to a local network. It is possible to configure the IP addressing of the MicroTech III as a fixed IP of
DHCP depending on the network configuration.
With a common web browser a PC can connect with the unit controller entering the IP address of the controller
or the host name, both visible in the “About Chiller” page accessible without entering a password.
When connected, it will be required to enter a user name and a password. Enter the following credential to get
access to the web interface:
User Name: ADMIN
Password: SBTAdmin!
The Main Menu page will be displayed. The page is a copy of the onboard HMI and follows the same rules in
terms of access levels and structure.


MicroTech® III

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In addition it allows to trend log a maximum of 5 different quantities. It’s required to click on the value of the
quantity to monitor and the following additional screen will become visible:
Depending on the web browser and its version the trend log feature may not be visible. It’s required a web
browser supporting HTML 5 like for example:
Microsoft Internet Explorer v.11,
Google Chrome v.37,
Mozilla Firefox v.32.
These software are only an example of the browser supported and the versions indicated have to be intended
as minimum versions.