Thermal Care Accuchiller TCF Instruction Manual

Table of Contents
Foreword .................................................................................................................................................................................................................. 1
Safety Guidelines .................................................................................................................................................................................................. 1
Pre-Installation....................................................................................................................................................................................................... 2
Receiving Inspection ....................................................................................................................................................................................... 2
Unit Storage........................................................................................................................................................................................................ 3
Installation - Chiller.............................................................................................................................................................................................. 3
Foundation.......................................................................................................................................................................................................... 3
Unit Location ...................................................................................................................................................................................................... 3
Rigging.................................................................................................................................................................................................................. 3
Process Fluid Piping......................................................................................................................................................................................... 3
Condenser Water Piping................................................................................................................................................................................ 3
Water Pressure Gauges.................................................................................................................................................................................. 3
Master Temperature Sensor......................................................................................................................................................................... 4
Installation - Electrical......................................................................................................................................................................................... 4
Compressor Control Logic ................................................................................................................................................................................ 5
Master/Slave....................................................................................................................................................................................................... 5
General Control Operation ............................................................................................................................................................................... 5
System Initialization......................................................................................................................................................................................... 5
Figure 1 –Start-Up Splash Screen ......................................................................................................................................................... 5
Home - System Overview.................................................................................................................................................................................. 5
System Overview............................................................................................................................................................................................... 5
Figure 2 –Water-Cooled Chiller Home Screen ................................................................................................................................ 5
Table 1 –System Overview Functions.................................................................................................................................................. 6
Home - Full Screen............................................................................................................................................................................................... 6
Figure 3 –Full Screen Display Mode .................................................................................................................................................... 6
Menu 1 - Overview............................................................................................................................................................................................... 7
Figure 4 –Menu 1 Screen ......................................................................................................................................................................... 7
Table 2 –Menu 1 Functions..................................................................................................................................................................... 7
Figure 9............................................................................................................................................................................................................. 7
Menu 1 - Alarms.................................................................................................................................................................................................... 8
Alarms Active...................................................................................................................................................................................................... 8
Figure 5 –HMI Alarm Handler ................................................................................................................................................................ 8
Alarm Setup ........................................................................................................................................................................................................ 8
Figure 6 –Alarm Setup............................................................................................................................................................................... 8
Menu 1 –Circuit Details..................................................................................................................................................................................... 8
Circuit Details Screen ...................................................................................................................................................................................... 8
Figure 7 –Circuit Details Screen............................................................................................................................................................. 8
Circuit Details Screen –Turbocor............................................................................................................................................................... 8
Figure 8 –Turbocor Screen ...................................................................................................................................................................... 8
Circuit Details Screen –Interlocks.............................................................................................................................................................. 9

Figure 9 –Interlocks .................................................................................................................................................................................... 9
Figure 10 –Critical Interlocks .................................................................................................................................................................. 9
Menu 1 –Circuit Demand ................................................................................................................................................................................. 9
Circuit Demand Screen................................................................................................................................................................................... 9
Figure 11 –Demand Circuit...................................................................................................................................................................... 9
Menu 1 –Logging ................................................................................................................................................................................................ 9
Figure 12 –Logging Screen...................................................................................................................................................................... 9
Menu 1 –Trending............................................................................................................................................................................................... 9
Figure 13 –Trending Screen .................................................................................................................................................................... 9
Menu 1 –Inputs / Outputs .............................................................................................................................................................................10
Inputs / Outputs Screens.............................................................................................................................................................................10
Figure 14 –Digital Inputs Screen .........................................................................................................................................................10
Figure 15 –Digital Outputs Screen .....................................................................................................................................................10
Figure 16 –Analog Outputs Screen....................................................................................................................................................10
Figure 17 –Analog Inputs Screen........................................................................................................................................................10
Figure 18 –RTD Inputs Screen..............................................................................................................................................................10
Menu 1 –Hot Gas Bypass................................................................................................................................................................................11
Hot Gas Bypass Setup Screen....................................................................................................................................................................11
Figure 19 –Hot Gas Bypass Screen.....................................................................................................................................................11
Table 3 –HGBP Setup Parameters.......................................................................................................................................................11
Menu 1 –Expansion Valve Setup .................................................................................................................................................................11
EXV Control Setup Screen...........................................................................................................................................................................11
Figure 20 –EXV Control Screen............................................................................................................................................................11
Table 4 –EXV Setup Parameters ..........................................................................................................................................................11
Menu 1 –Discharge Control Setup .............................................................................................................................................................12
Discharge Control Setup Screen...............................................................................................................................................................12
Figure 21 –Discharge Control Screen................................................................................................................................................12
Table 5 –Discharge Setup Parameters ..............................................................................................................................................12
Menu 1 –Modbus Compressor(s)................................................................................................................................................................13
Compressor Modbus Screen......................................................................................................................................................................13
Figure 22 –Circuit 1 Additional Detail ...............................................................................................................................................13
Table 6 –Modbus Setup..........................................................................................................................................................................13
Menu 1 –Flow / Capacity................................................................................................................................................................................13
Flow/Capacity Screen....................................................................................................................................................................................13
Figure 23 –Flow / Capacity Screen .....................................................................................................................................................13
Menu 1 –Pump Control...................................................................................................................................................................................14
Pump Control Screen ....................................................................................................................................................................................14
Figure 24 –Pump Control Screen........................................................................................................................................................14
Table 7 –Pump Setup Parameters ......................................................................................................................................................14
Menu 1 –Staging................................................................................................................................................................................................14
Compressor Staging Setup Screen..........................................................................................................................................................14

Figure 25 –Compressor Staging Screen...........................................................................................................................................14
Table 8 –Compressor Staging Parameters......................................................................................................................................14
Menu 1 –Stage Order ......................................................................................................................................................................................15
Compressor Staging Setup Screen..........................................................................................................................................................15
Figure 26 –Compressor Stage Order Screen..................................................................................................................................15
Table 9 –Compressor Staging Local Parameters ..........................................................................................................................15
Menu 1 –PLC/HMI Settings ...........................................................................................................................................................................15
Figure 27 –PLC IP Address.....................................................................................................................................................................15
Menu 2 –Overview ............................................................................................................................................................................................15
Figure 28 –Menu 2 Screen.....................................................................................................................................................................15
Table 10 –Menu 2 Functions.................................................................................................................................................................15
Menu 2 –Defaults ..............................................................................................................................................................................................16
Figure 29 –Restore Factory Settings..................................................................................................................................................16
Figure 30 –Factory Settings Restored ...............................................................................................................................................16
Menu 2 –Remote Mode..................................................................................................................................................................................16
Menu 2 –Modbus/BAS ....................................................................................................................................................................................16
Figure 31 –Modbus Setup Screen ......................................................................................................................................................16
Start-Up ..................................................................................................................................................................................................................17
Step 1 –Connect Main Power ...................................................................................................................................................................17
Step 2 –Fill Coolant Circuit ........................................................................................................................................................................17
System Fill Water Chemistry Requirements.....................................................................................................................................17
Table 11 –Fill Water Chemistry Requirements...............................................................................................................................18
Table 12 - Recommended Glycol Solutions.....................................................................................................................................18
Step 3 - Check Condenser ..........................................................................................................................................................................19
Step 4 –Check Refrigerant Valves ...........................................................................................................................................................19
Step 5 –Check Low Temperature Alarm...............................................................................................................................................19
Step 6 –Turn On Control Power ..............................................................................................................................................................19
Step 7 –Establish Coolant Flow................................................................................................................................................................19
Step 8 –Initial Unit Operation...................................................................................................................................................................19
Preventive Maintenance...................................................................................................................................................................................20
Once a Week ....................................................................................................................................................................................................20
Once a Month ..................................................................................................................................................................................................20
Once Every 6 Months....................................................................................................................................................................................20
Once a Year.......................................................................................................................................................................................................20
Once Every 5 years.........................................................................................................................................................................................21
Maintenance .........................................................................................................................................................................................................21
Cleaning the Operator Interface...............................................................................................................................................................21
Troubleshooting..................................................................................................................................................................................................22
Drawings.................................................................................................................................................................................................................23

1
Foreword
The central chiller consists of a refrigeration circuit to
provide cooling of water or coolant.
This manual is to serve as a guide for installing,
operating, and maintaining the equipment. Improper
installation, operation, and maintenance can lead to
poor performance and/or equipment damage. Use
qualified installers and service technicians for all
installation and maintenance of this equipment.
This manual is for our standard product. The
information in this manual is general in nature. Unit-
specific drawings and supplemental documents are
included with the equipment as needed. Additional
copies of documents are available upon request.
Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment, we do not
reference them in this manual.
The equipment uses a hydrofluorocarbon (HFC),
trade named R-134a, as a chemical refrigerant for
heat transfer purposes. This chemical is sealed and
tested in a pressurized system containing ASME
coded vessels; however, a system failure will release
it. Refrigerant gas can cause toxic fumes if exposed
to fire. Place these units in a well-ventilated area,
especially if open flames are present. Failure to
follow these instructions could result in a hazardous
condition. We recommend the use of a refrigerant
management program to document the type and
quantity of refrigerant in the equipment. In addition,
we recommend only licensed and EPA certified
service technicians work on our refrigeration circuits.
Safety Guidelines
Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.
General Warning
Electricity Warning
Sharp Element Warning
Hot Surface Warning
Flammable Material Warning
Explosive Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Repair
Connect an Earth Terminal to Ground

2
Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in this manual as
well as tags, stickers, and labels on the equipment.
WARNING: Any use or misuse of this equipment
outside of the design intent may cause injury or harm.
WARNING: Vent all refrigerant relief valves in
accordance to ANSI/ASHRAE Standard 15, Safety Code
for Mechanical Refrigeration. Locate this equipment in
a well-ventilated area. Inhalation of refrigerant can be
hazardous to your health and the accumulation of
refrigerant within an enclosed space can displace
oxygen and cause suffocation.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains refrigerant under
pressure. Accidental release of refrigerant under
pressure can cause personal injury and or property
damage.
WARNING: This equipment may contain fan blades or
other sharp edges. Make sure all fan guards and other
protective shields are securely in place.
WARNING: The exposed surfaces of motors, refrigerant
piping, and other fluid circuit components can be very
hot and can cause burns if touched with unprotected
hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Shut off the electric power at the main disconnect
before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: The equipment will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
proximity to the chiller.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
Pre-Installation
Receiving Inspection
When the unit arrives, verify the information on the
unit nameplate agrees with the order
acknowledgement and shipping papers. Inspect the
equipment for any visible damage and verify all
items shown on the bill of lading are present. If
damage is evident, document it on the delivery
receipt by clearly marking any item with damage as
“unit damage” and notify the carrier. In addition,
notify our Customer Service Department and they
will provide assistance with preparing and filing
freight damage claims, including arranging for an
estimate on repair costs; however, filing the shipping
damage claim is the responsibility of the receiving
party. Do not install damaged equipment without
getting the equipment repaired.
Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.
Start unpacking the unit, inspect for concealed
damage, and take photos of any damage found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. Refrigerant
lines can be susceptible to damage in transit. Check
for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its
mounting point.
Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment. In addition, notify our Customer
Service Department and they will provide assistance
with preparing and filing freight damage claims,
including arranging for an estimate on repair costs;
however, filing the shipping damage claim is the
responsibility of the receiving party.

3
Unit Storage
When storing the unit it is important to protect it
from damage. Blow out any water from the unit;
cover it to keep dirt and debris from accumulating or
getting in, and store in an indoor sheltered area that
does not exceed 145°F.
Installation - Chiller
Foundation
Install the unit on a rigid, non-warping mounting
pad, concrete foundation, or level floor suitable to
support the full operating weight of the equipment.
When installed the equipment must be level within
¼ inch over its length and width.
Unit Location
To ensure proper airflow and clearance space for
proper operation and maintenance allow a minimum
of 36 inches of clearance between the sides of the
equipment and any walls or obstructions. Avoid
locating piping or conduit over the unit to ensure
easy access with an overhead crane or lift to lift out
heavier components during replacement or service.
In addition, ensure the condenser and evaporator
refrigerant pressure relief valves can vent in
accordance with all local and national codes.
Rigging
The chiller has a frame to facilitate easy movement
and positioning with a crane or forklift. Follow
proper rigging methods to prevent damage to
components. Avoid impact loading caused by
sudden jerking when lifting or lowering the chiller.
Use pads where abrasive surface contact may occur.
Process Fluid Piping
Proper insulation of chilled process fluid piping is
crucial to prevent condensation. The formation of
condensation adds a substantial heat load to the
chiller.
The importance of properly sized piping cannot be
overemphasized. See the ASHRAE Refrigeration
Handbook or other suitable design guide for proper
pipe sizing. In general, run full size piping out to the
process and reduce pipe size at connections as
needed. One of the most common causes of
unsatisfactory chiller performance is poor piping
system design. Avoid long lengths of hoses, quick
disconnect fittings, and manifolds wherever possible
as they offer high resistance to water flow. When
manifolds are required, install them as close to the
use point as possible. Provide flow-balancing valves
at each machine to assure adequate water
distribution in the entire system.
Condenser Water Piping
The performance of a water-cooled condenser is
dependent on the flow and temperature of the
cooling water used. Insufficient cooling of the
condenser will result in the reduction of cooling
capacity of the chiller and under extreme conditions
may result in the chiller shutting down due to high
refrigerant pressure. Allowing the condenser to plug
up from contaminants in the condenser water
stream adversely affects performance. In order to
reduce maintenance costs and chiller downtime, a
water treatment program is highly recommended for
the condenser cooling water. Contact our Customer
Service Department for assistance in the proper
procedure for cleaning out any plugged condenser.
The nominal water-cooled condenser is designed for
85°F condenser cooling water supply. Under normal
operation there will be about a 10°F rise through the
condenser resulting in 95°F exiting water. To ensure
proper water flow through the condenser, ensure the
condenser water pump provides at least 25 psi or
water at a flow rate of 3 gpm per ton of chiller
capacity.
The condenser has a two-way condenser water-
regulating valve. The condenser water-regulating
valve controls the amount of water allowed to pass
through the condenser in order to maintain proper
refrigeration pressures in the circuit.
To prevent damage to the condenser and/or water-
regulating valve, the water pressure should not
exceed 150 psig.
Water Pressure Gauges
Install pressure gauges in the inlet and outlet of both
the condenser and evaporator chilled water piping
to provide the ability to read the pressure drop
across the chiller and aid in preventive maintenance
and troubleshooting.

4
Master Temperature Sensor
This section only applies to installations where
multiple chillers are in a common system where one
chiller is the master with the other chillers serving as
slaves. In those situations, a field-installed master
fluid-temperature sensor is required in the common
process fluid supply and return piping. Install the
sensor downstream of all individual chilled water
supply streams. Position the temperature sensor to
read the mixed supply temperature. The supply
temperature sensor is normally the control sensor
for the chiller system set point and determines the
loading/unloading of the compressors of the system.
Mount the temperature sensor in a ½” NPT coupling
in a minimum pipe size of 3”. The probe sheath is ¼”
OD x 3” in length and is equipped with a ½” NPT
male fitting for direct mounting in a coupling. Use
direct immersion mounting for the most accurate
reading and quickest response time. If direct
immersion mounting is not possible, mount the
sensor inside a thermowell to aid in maintenance
and or repair of the sensor if opening of the process
piping is not possible. Use a suitable heat transfer
compound with a thermowell. Wire from the
temperature sensor to the chiller electrical enclosure
and land at the designated terminal blocks within
the enclosure. Please see the chiller electrical
schematic provided for further detail.
Installation - Electrical
All wiring must comply with local codes and the
National Electric Code. Minimum circuit amps (MCA)
and other unit electrical data are on the unit
nameplate. A unit specific electrical schematic ships
with the unit. Measure each leg of the main power
supply voltage at the main power source. Voltage
must be within the voltage utilization range given on
the drawings included with the unit. If the measured
voltage on any leg is not within the specified range,
notify the supplier and correct before operating the
unit. Voltage imbalance must not exceed two
percent. Excessive voltage imbalance between the
phases of a three-phase system can cause motors to
overheat and eventually fail. Voltage imbalance is
determined using the following calculations.
% Imbalance = (Vavg –Vx) x 100 / Vavg
Vavg = (V1 + V2 + V3) / 3
Vx = phase with greatest difference from Vavg
For example, if the three measured voltages were
442, 460, and 454 volts, the average would be:
(442 + 460 + 454) / 3 = 452
The percentage of imbalance is then:
(452 –442) x 100 / 452 = 2.2 %
This exceeds the maximum allowable of 2%.
There is a terminal block for main power connection
to the main power source. The main power source
should be connected to the terminal block through
an appropriate disconnect switch. There is a separate
lug in the main control panel for grounding the unit.
Check the electrical phase sequence at installation
and prior to start-up. Operation of the compressor
with incorrect electrical phase sequencing will result
in mechanical damage to the compressors. Check
the phasing with a phase sequence meter prior to
applying power. The proper sequence should read
“ABC” on the meter. If the meter reads “CBA”, open
the main power disconnect and switch two line leads
on the line power terminal blocks (or the unit
mounted disconnect). Do not interchange any load
leads that are from the unit contactors or the motor
terminals.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains refrigerant under
pressure. Accidental release of refrigerant under
pressure can cause personal injury and or property
damage.
WARNING: This equipment may contain fan blades or
other sharp edges. Make sure all fan guards and other
protective shields are securely in place.
WARNING: The exposed surfaces of motors, refrigerant
piping, and other fluid circuit components can be very
hot and can cause burns if touched with unprotected
hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Electric power at the main disconnect should be shut
off before opening access panels for repair or
maintenance.

5
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wire the unit ground in compliance with
local and national codes.
Compressor Control Logic
The chiller controls the leaving chilled water
according to the chilled water set point. A
temperature sensor is field installed in the supply
water at the exit of the chiller and sends information
to the PLC. When the temperature rises above the
set point, the PLC will start the compressor when
there is enough process heat load to support the
operation of the compressor. The compressor, once
running, will modulate its capacity to precisely
control the to process water temperature. If the
process heat load drops below the minimum loading
capability of the compressor, the compressor will
cycle off. Operation of the compressor will resume
once adequate heat load exists.
Master/Slave
It is possible to link together multiple chillers to form
a single system, with a maximum of six compressors
connected. Any chiller can be set up to be a master
or a slave. The master chiller controls the staging
order of the compressors and the running demand
of all the compressors in the system in order to
maintain the common chilled water set point. A slave
chiller becomes dependent on the master only for its
compressor staging order and running demand. The
slave chiller PLC performs all other operations. The
chilled water piping must be manifolded together
and the supply sensor must be positioned
downstream of all individual chilled water streams to
read a mixed water temperature. Wire the supply
and return water temperature sensors in the
common return chilled water piping to the chiller
PLC designated as the master.
General Control Operation
System Initialization
Upon power-up, the first screen to appear is the
Start-Up Splash Screen. This screen will display while
the Programmable Logic Controller (PLC) and
Human-Machine Interface (HMI) establish
communications. The control system version is
located on this start-up screen.
Figure 1 –Start-Up Splash Screen
Once the HMI has completed its power on sequence
and PLC to HMI communication is established, the
HMI should automatically switch to the Home screen
as shown in Figure 2 for water-cooled condenser
chillers.
Home - System Overview
System Overview
The System Overview Screen provides an overall
synopsis of the chiller system. It also provides quick
links to other views as well as additional useful
information.
Figure 2 –Water-Cooled Chiller Home Screen

6
Table 1 –System Overview Functions
Function
Description
Screen
Reference
Alarm
Messaging
Provides information about any
warnings or alarms which may
have occurred.
N/A
Setpoint
This is the Setpoint temperature.
Touch the temperature to
change. An authorized security
level password is required to
enter a new Setpoint.
N/A
Evaporator
Fluid In
This is the chiller entering fluid
temperature.
N/A
To Process
Fluid
This is the chiller leaving fluid
temperature.
N/A
Process
Delta T
This is the difference between
entering and leaving
temperatures.
N/A
Demand %
This shows the actual demand
requested by the compressor.
N/A
Evap Out
This shows the Evaporator leaving
coolant temperature.
N/A
Menu Button
Touching this button
navigates to the Menu 1 screen.
Figure 4
Figure 9
Full Screen
Display
Pressing this button displays the
set point and process
temperatures in a large font.
Figure 3
Alarms
Button
A listing of active and prior alarm
history
Figure 5
Figure 6
Detail
Provides additional circuit and
compressor information.
Multiple
Start/Stop
Pressing the green Start button to
start the chiller and any slave
units connected to the chiller.
Once started, the Start button
disappears. Press the red stop
button to stop the chiller and any
slave units connected to the
chiller.
N/A
Home - Full Screen
The Full Screen (Figure 3) provides a simplified view
of the TC Chiller. The SETPOINT and PROCESS
temperatures display in a large font easily seen from
a distance, providing a “quick glance” look to
validate proper operation.
Figure 3 –Full Screen Display Mode
Pressing the SETPOINT value shown will allow for
quick set point modification. Once the new set point
has been entered press the Enter button to confirm
set point. Proper security level must be valid prior to
entering a new set point.

7
Menu 1 - Overview
The Menu 1 Screen (Figure 4) provides a common
location for most setting adjustments. Some
parameters are password protected. The main user-
level password is 9999 used for gaining access to
changing the main system set point and various
other warning and alarm settings. A few higher-level
areas require a high-level user password that is 7720.
If you are attempting to access an area where
neither of these passwords is accepted, you may
require a technician level password. For access to
these areas of the program, contact our Customer
Service Department for assistance.
To get the Menu 1 screen, it is necessary to press the
three horizontal lines on the left upper corner.
Figure 4 –Menu 1 Screen
Table 2 –Menu 1 Functions
Function
Description
Screen
Reference
Alarms
A listing of all active, history, and
frequency of system alarms.
Figure 5
Figure 6
Circuit Details
Additional circuit and compressor
related information
Figure 7
Figure 8
Figure 9
Figure 10
Circuit
Demand
Shows the circuit demand
Figure 11
Logging
Start / Stop logs data / alarm and
export to thumb drive
Figure 12
Trending
Graphical display of critical
process values
Figure 13
Input /
Output
The Input / Output screens
provide the status of all digital
inputs, outputs, RTD inputs and
analog outputs.
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Hot Gas
Bypass
Hot Gas Bypass Setup (Load
Balance Valve) (Optional)
Figure 19
EXV Control
Electric Expansion Valve Setup
Figure 20
Discharge
Control
Water Regulating Valve Setup
(Discharge Pressure Control)
Figure 21
Modbus
Compressor(s)
This shows the Modbus
communication status and
parameters.
Figure 22
Units
Imperial or Metric units can be
selected directly from this screen.
Touch the UNITS button to
toggle the selection between
Imperial or Metric units
N/A
Auto Start
Touch this button to enable or
disable the automatic start. If the
option is enabled, the chiller is
set to start automatically.
N/A
Flow /
Capacity
Provides information about the
process fluid flow and cooling
capacity.
Figure 23
Pumps
This shows the configuration of
the pumps and timers.
Figure 24
Staging
Compressor staging options.
Figure 25
Stage Order
Stage order setup.
Figure 26
PLC / HMI
Settings
IP addresses HMI and PLC Setup
Figure 27
Login
Touch this button to access the
different user-level.
N/A
Logout
Sign out session.
N/A

8
Menu 1 - Alarms
Alarms Active
When a critical system fault occurs, the controller
activates the HMI alarm handler (Figure 5). The alarm
screen will display the current faults. To silence this
alarm, press the ALARM SILENCE button. If multiple
alarms are active at once, use the DOWN and UP
buttons to view all alarms. When no alarms are
active, the white portion of the display will be blank.
All alarms must be resolved and reset using the
RESET ALARM button.
Figure 5 –HMI Alarm Handler
Note: The above shows there are no alarms; if an alarm condition
was present, it would appear in this window.
Alarm Setup
Alarm set points and timers are modifiable on this
screen.
Figure 6 –Alarm Setup
Menu 1 –Circuit Details
Circuit Details Screen
To access the Circuit Details Screen (Figure 7) use
Menu 1 (Figure 4) or touch the option Details on the
Home Screen (Figure 2). This screen provides
additional information relative to the circuit.
Figure 7 –Circuit Details Screen
Circuit Details Screen –Turbocor
Touching the Compressor button on the bottom of
the Circuit Details Screen displays the Turbocor
information.
Figure 8 –Turbocor Screen

9
Circuit Details Screen –Interlocks
Touching the I-LOCK button of the Circuit Details
Screen displays the Interlocks Screen shown in
Figure 9.
Figure 9 –Interlocks
Touching the CRITICAL button opens the Critical
Interlocks Screen (Figure 10). A critical interlock fault
shuts down the entire system and must be resolved
prior to a restart.
Figure 10 –Critical Interlocks
Menu 1 –Circuit Demand
Circuit Demand Screen
Figure 11 –Demand Circuit
Menu 1 –Logging
The HMI is constantly logging key registers internal
to the HMI. In the event that the data and/or alarm
logs require review, it is possible to export data to an
external thumb drive. Data logging occurs every two
seconds in a FIFO methodology for a total of 24
hours.
Figure 12 –Logging Screen
Menu 1 –Trending
The trending screen (Figure 13) displays the setpoint
temperature, process temperature, demand,
expansion valve, and optional hot gas bypass valve
(if present) resisters for easy analysis of the system
operation. Trending is always enabled and always
running.
Figure 13 –Trending Screen

10
Menu 1 –Inputs / Outputs
Inputs / Outputs Screens
The Inputs/Outputs screens provide the status of all
digital inputs, digital outputs, analog inputs, and
outputs. When the PLC input LED is on, the
corresponding input or output is on. The inputs and
outputs numbers are hex base numbering system.
The following screens show a full complement of
inputs and outputs. Note: Your screen may differ
depending on machine type and options.
Figure 14 –Digital Inputs Screen
Figure 15 –Digital Outputs Screen
Figure 16 –Analog Outputs Screen
Figure 17 –Analog Inputs Screen
Figure 18 –RTD Inputs Screen

11
Menu 1 –Hot Gas Bypass
Hot Gas Bypass Setup Screen
Figure 19 –Hot Gas Bypass Screen
Table 3 –HGBP Setup Parameters
Menu Item
Description
Default Value
Mode
Selection
AUTO MODE: The valve will
always respond relative to the
demand PID regardless of how
many compressors are running.
MANUAL MODE: The manual
mode value percent will be the
output to the valve.
AUTO
ON
Minimum
Position
The minimum percent the valve
will go to.
0%
Maximum
Position
The maximum percent the valve
will go to.
100%
Kp
Proportional PID value
100
Ti
Integral PID value
250
Td
Derivative PID value
0
Start Position
This sets the valve to a pre-start
position for a given period.
100
Start Delay
This is the delay time from
compressor start-up to hold the
valve at the start-up percent open
position
180 seconds
Menu 1 –Expansion Valve Setup
EXV Control Setup Screen
Figure 20 –EXV Control Screen
Table 4 –EXV Setup Parameters
Menu Item
Description
Default Value
Mode
Control
In Auto Mode, the control system
adjusts the valve to maintain
liquid level. In manual mode, the
system drives the valve to a fixed
position and holds it there for
service diagnostic purposes.
AUTO MODE
Maximum
Position
The maximum percent the
expansion valve will go to.
100%
Liquid Level
Setpoint
The valve meters the amount of
refrigerant into the evaporator in
the precise quantity in order to
maintain liquid level. Only a
trained refrigeration service
technician should adjust this
valve.
96.5
Kp
Proportional PID value
6
Ti
Integral PID value
20
Td
Derivative PID value
0

12
Menu 1 –Discharge Control Setup
Discharge Control Setup Screen
An electric condenser water-regulating valve is
standard on chillers with a water-cooled condenser.
The valve is a butterfly type valve with a modulating
actuator and is located in the condenser water
piping at the outlet of the condenser. The valve
regulates the flow of cooling water through the
condenser in order to maintain the discharge
refrigerant pressure set point.
Figure 21 –Discharge Control Screen
Table 5 –Discharge Setup Parameters
Menu Item
Description
Default Value
Mode
In Auto Mode, the valve adjusts
to maintain optimum
performance. In manual mode, it
holds to the input valve.
Automatic
Manual
Mode Value
This is only visible when the
discharge pressure control is in
manual mode. To place the
discharge pressure control into
manual mode, press the MODE
button to display the manual
percent output. Press the area
next to the % sign and enter a
value between 0 to 100% to
change the analog output value.
There is a short time delay before
the analog output begins to
change. This feature is for testing
purposes.
N/A
Control
Mode
Floating or
Fixed
This button switches between a
preset entered discharge pressure
set point (Fixed) and a calculated
one (Floating). The calculated
discharge pressure set point is
determined based upon the
saturated pressure value as a
function of temperature. The
default selection is Floating and
seeks to obtain maximum
efficiency. The Manual selection
allows alteration of the discharge
PX set point within the acceptable
range.
Floating
Fixed
Discharge
Pressure SP
This is the fixed set point to
control the discharge pressure.
105psig
Start Up %
This value equals the percentage
of maximum voltage sent from
the terminals of the Compressor
Interface Module to the variable
speed fan on compressor start-
up. The analog output will hold at
this position until the start delay
timer has expired (Note: The
operating range must be set to 0-
10V (DEFAULT) via jumpers on
the Compressor Interface
module).
50%
Start Up
Delay
This is the time in seconds that
the output starting percent is
held upon compressor start-up
60 sec.
Kp
Proportional Gain –Adjust for
stable PID control.
250 (TCR)
75 (TCW)
Ti
Integral Gain –Adjust for stable
PID control.
500 (TCR)
250 (TCW)
Td
Derivative PID value
0

13
Menu 1 –Modbus Compressor(s)
Compressor Modbus Screen
The controller communicates with the compressor
via Modbus communications. This communication is
critical for compressor operation.
Figure 22 –Circuit 1 Additional Detail
Table 6 –Modbus Setup
Menu Item
Description
Operation Mode
Touching the Circuit Enabled will toggle it
between enabled (Green) and disabled
(Yellow). If you choose to disable the circuit
then disable it here. Modbus
communication to the compressor will also
stop once disabled.
Read Count
The number of successful read attempts
from the Compressor.
Write Count
The number of successful writes to the
Compressor.
Fault Count
The number of failed read or write attempts
from/to the Compressor. An alarm occurs
after five failed attempts.
Reset Time
If the compressor is enabled and there is a
Modbus fault, the system will retry to
establish communications every 60 seconds.
Communication
Fault
If a Modbus error occurs, the FAULT
indicator and alarm display. The fault will
display just below the CIRCUIT label.
Menu 1 –Flow / Capacity
Flow/Capacity Screen
The graph displays trend data for the process fluid
flow measured at the outlet of the evaporator on
each chiller circuit. In addition, there is a display of
an approximation of chiller cooling capacity
calculated by the process fluid flow rate and
temperature difference.
Figure 23 –Flow / Capacity Screen

14
Menu 1 –Pump Control
Pump Control Screen
This screen displays pertinent pump status
information for a system with the optional integral
pump controls and provides the ability to change
mode selection.
Figure 24 –Pump Control Screen
Table 7 –Pump Setup Parameters
Menu Item
Description
Default Value
Mode
AUTOMATIC: Allows for
automatic timer enable of the
pumps.
MANUAL: Requires manual
enable of the pumps.
AUTOMATIC
Recirc On
Delay
Delay duration before the
Recirculation Pump starts.
0 sec
Recirc Off
Delay
Delay duration before stopping
the Recirculation Pump after
initiation of a system stop.
5 sec
Process On
Delay
Delay duration before the Process
Pump starts.
0 sec
Process Off
Delay
Delay duration before stopping
the Process Pump after initiation
of a system stop.
30 sec
Menu 1 –Staging
Compressor Staging Setup Screen
Figure 25 –Compressor Staging Screen
Table 8 –Compressor Staging Parameters
Menu Item
Description
Default Value
Stage Up
Trigger
This parameter in conjunction
with the Stage Up Delay
determines at what percent the
next compressor will stage.
95%
Stage Up
Delay
Once the demand reaches the
Stage Up Trigger, this value
determines the time delay before
staging the next compressor.
60 sec.
Stage Down
Trigger
This parameter in conjunction
with the Stage Down Delay
determines when a compressor
will de-stage.
35%
Stage Down
Delay
Once the demand reaches the
Stage Down Trigger, this value
determines the time delay before
de-staging a compressor.
60 sec.
Stage DT
This set point works in
conjunction with the Chilled
Water Set Point to limit short
cycling. The first compressor will
not stage until the Chilled Water
Set Point + ΔT Stage Set Point is
satisfied. Only applies if one
compressor is running.
2°F
De-stage DT
This parameter de-stages a
compressor when the Chilled
Water Set Point less the ΔT De-
stage Set Point is met. This only
applies if one compressor is
running.
3°F
Staged
Compressors
This is the number of
compressors that initially start
when the system has a demand.
1

15
Menu 1 –Stage Order
Compressor Staging Setup Screen
Figure 26 –Compressor Stage Order Screen
Table 9 –Compressor Staging Local Parameters
Menu Item
Description
Default Value
Stage Mode
Automatic: calculates the stage
order by the AUTO STAGE
HOURS parameter
Manual: Manually enter the stage
order
AUTOMATIC
Trigger
Trigger will immediately
recalculate the stage order
instead of waiting for the
automatic trigger to occur.
None
Minutes Until
Auto stage
Minutes remaining until the stage
calculation occurs
None
Menu 1 –PLC/HMI Settings
This screen allows you to change the PLC and HMI IP
Addresses.
Figure 27 –PLC IP Address
Note: If this procedure is not performed correctly, it could cause
communication loss between the PLC and HMI.
Menu 2 –Overview
Figure 28 –Menu 2 Screen
Table 10 –Menu 2 Functions
Function
Description
Screen
Reference
Defaults
Provides the ability to restore the
control system back to factory
defaults in the case that an
unknown setting occurred and
the system now behaves
unexpectedly.
Figure 29
Figure 30
Remote
Mode
Touch this button to enable or
disable external digital remote
START/STOP
N/A
Modbus
Control
Modbus RTU (Building
Automation System) Setup
Default Modbus Settings: Baud-
19200, Data Length-8, Parity-
Odd, Stop Bits-1
Figure 31
Evacuation
Mode
Allows a full equalization of
refrigerant pressure during a
remote startup evacuation.
N/A