Service Section Technical Training December 2005

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Loop Water ControllerLoop Water Controller

Service SectionService Section

Technical TrainingTechnical Training

December 2005 December 2005

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Loop Water ControllerLoop Water Controller(LWC)(LWC)

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Loop Water Controller

Water Source Solution

WSHP, WH-B/BR Series


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cooling towercooling tower pumpspumps

Water source heat pumpsWater source heat pumps

loopinglooping

waterwater

Expansion tankExpansion tank

boilerboiler

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LWC Control Box

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+12VGND

A B GND

SENSOR1,2,3,4 SENSOR5,6,7,8Temperature Temperature

CPU PROGRAM DOWN LOAD

power supply of LCD Panel

A B

communication to LCD panel and telephone dialer

N_COM

NL

TRA

NSF

OR

MER

POWER SUPPLY

220-240VAC1 PHASE

50HZ

LNE

FUSE

250

VAC

5A

220V

AC

50H

Z10

VAC

1A

220V

AC

50H

Z

24VA

C 0

.5A

TRA

NSF

OR

MER

SYMBOL DESCRIPTION

OUT1-12HEAT ADDITION

OR

WATER PUMP1PUMP1

ALARM

PUMP2

ALARM BUZZER

WATER PUMP2

SHUT DOWN

HEAT REJIECTION

EMERGENCY SHUT DOWN

RED LED GREEN LED

RED LED POWER LAMP

GREEN LED SYSTEM RUNSTATUS LAMP

S1

Shut Dow

n

PUM

P 2

+12V GND

Remoto reset input

water flow switch

GND+12V

IN3(S3)

IN2(S2)

ON/OFF

AIR SENSOR

WATER SENSOR

OU

T 1

OU

T 2

OU

T 3

OU

T 4

OU

T 5

OU

T 6

OU

T 7

OU

T 8

OU

T 9

OU

T10

OU

T 11

OU

T 12

PUM

P 1

ALA

RM

L

N


LWC Wiring Diagram

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1. Features

2. System Specification

3. Operation

Content

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1. Features

- Loop Circulating Pump Control

- Heat Rejection & Addition Output Stages

- Sensor

- Alarm / Indication

- Water Flow Switch Input

- High / Low Water Temp Protection

- Pre-cool / Pre-heat Protection

- Outdoor (OD) Air Reset

- Password Protection

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1. Features1. Features

- Loop Circulating Pump Control- Loop Circulating Pump Control> Allows 2 loop circulating pumps with manual or auto lead lag > Allows 2 loop circulating pumps with manual or auto lead lag control where operation is interchangeablecontrol where operation is interchangeable

- Heat Rejection & Addition Output Stages- Heat Rejection & Addition Output Stages> Total 12 sets of data output can be pre-set as heat addition > Total 12 sets of data output can be pre-set as heat addition or heat rejection stagesor heat rejection stages

- Sensor: - Sensor: (i) Outdoor (OD) Air Sensor(i) Outdoor (OD) Air Sensor

(ii) Water Sensor(ii) Water Sensor> 2 types of sensors used to sense the OD air temperature and > 2 types of sensors used to sense the OD air temperature and water temperaturewater temperature

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- Alarm / Indication- Alarm / Indication> Output signal if error occurs in the system> Output signal if error occurs in the system

> Buzzer in the LCD panel activated when error occurs> Buzzer in the LCD panel activated when error occurs

- Water Flow Switch Input- Water Flow Switch Input> To detect the availability of water supply to the system> To detect the availability of water supply to the system

- High and Low Water Temperature Protection- High and Low Water Temperature Protection> Measured by water sensor> Measured by water sensor

> When water temperature reached too high / low temperature, > When water temperature reached too high / low temperature, send signal and shut off the systemsend signal and shut off the system

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- Pre-cool & Pre-heat Protection- Pre-cool & Pre-heat Protection> To provide protection when the temperature exceeding the > To provide protection when the temperature exceeding the too high / low temperature (when system is OFF)too high / low temperature (when system is OFF)

- Outdoor (OD) Air Reset- Outdoor (OD) Air Reset> The heat addition ON / OFF limit setting of the system is able > The heat addition ON / OFF limit setting of the system is able to be increased in respond to a drop in the OD air temperatureto be increased in respond to a drop in the OD air temperature

- Password Protection- Password Protection> Password entry needed for authority to change / check the > Password entry needed for authority to change / check the setting and configuration of the systemsetting and configuration of the system

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2. System Specification 2. System Specification

2.1 System On/Off 2.1 System On/Off

2.2 2.2 Pump Control FunctionPump Control Function

2.3 2.3 12 Stages of Heat Rejection & Heat 12 Stages of Heat Rejection & Heat

Addition ControlAddition Control

2.4 2.4 Pre-cool & Pre-heat ProtectionPre-cool & Pre-heat Protection

2.5 Outdoor (OD) Air Reset

2.6 Emergency Protection

2.7 Error Description

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2.1 System On/Off 2.1 System On/Off

2 ways to turn on/off the system via remote ON/OFF switch (S1):2 ways to turn on/off the system via remote ON/OFF switch (S1):

(a) Standard Switch(a) Standard Switch

(b) Smart Manager(b) Smart Manager

If the remote ON/OFF switch (S1) is closed – System ONIf the remote ON/OFF switch (S1) is closed – System ON

If the remote ON/OFF switch (S1) is opened – System OFFIf the remote ON/OFF switch (S1) is opened – System OFF

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2 Mode Available:2 Mode Available:

i) Automatic Modei) Automatic Mode

ii) Manual Mode

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10s after System On

Sound Alarm

Lead Pump Off

Lag Pump On

Error System OffSound Alarm

Check water

flow for 15s

Normal

Check water

flow for 15s

Error

Normal

i) Automatic Mode:i) Automatic Mode:

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2.2 2.2 Pump Control FunctionPump Control Function ii) Manual Mode:ii) Manual Mode:

• Only 1 pump is operates • Either 1 pump can be set to operate as the system is on.

• The checking on the water flow switch is the same as the lead pump in automatic mode

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2.3 12 2.3 12 Stages of Heat Rejection & Heat Stages of Heat Rejection & Heat

Addition ControlAddition Control • 12 Output contacts (198-242 VAC) to switch ON/OFF the boiler and cooling tower.

• Each contact must be pre-set from the LCD keypad to select it either as a heat addition or heat rejection contact

• Heat rejection and heat addition temperature setting shall be distributed in sequence and continuous as pre-set from the LCD keypad

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2.3 2.3 12 Stages of Heat Rejection & Heat 12 Stages of Heat Rejection & Heat



Output Stages

On Limit Setting (°C)

Off Limit Setting (°C)

Function

1# (OUT1) 15 18 Heat add stage 42# (OUT2) 16 19 Heat add stage 33# (OUT3) 17 20 Heat add stage 24# (OUT4) 18 21 Heat add stage 1

5# (OUT5) 30 27 Heat reject stage 16# (OUT6) 31 28 Heat reject stage 27# (OUT7) 32 29 Heat reject stage 38# (OUT8) 33 30 Heat reject stage 49# (OUT9) 34 31 Heat reject stage 510# (OUT10) 35 32 Heat reject stage 611# (OUT11) 36 33 Heat reject stage 712# (OUT12) 37 34 Heat reject stage 8

Example:

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Condition of the above example setting:

(i) 4 heat addition output stages and 8 heat rejection output stages

(ii) Temperature hysterisys of 3°C (adjustable)

(iii) Heat addition stage temperature: 18°C Heat rejection stage temperature: 30°C

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Addition ControlAddition Control Example 1:

ON Temperature set-point SelectionOUT1 17°C Heat add stage 2OUT2 18°C Heat add stage 1

• The first boiler will cut in when the Tw drops below 18°C• The second boiler will cut in when the Tw is further reduce to 17°C

Note: Tw = water temperature

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ON Temperature set-point SelectionOUT3 30°C Heat reject stage 1OUT4 31°C Heat reject stage 2

• The first cooling tower will run when the Tw goes higher than 30°C

• The second cooling tower will run when the Tw is further increase to 17°C


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ON set-point OFF set-point SelectionOUT1 17°C 20°C Heat add stage 2OUT2 18°C 21°C Heat add stage 1

OUT3 30°C 27°C Heat reject stage 1OUT4 31°C 28°C Heat reject stage 2

• If Tw increase from 18°C to 21°C, the boiler will turn off

• If Tw decrease from 30°C to 27°C, the cooling tower will turn off

•If 18°C < Tw < 30°C, both cooling tower or boiler will not run


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• Function when the system is OFF• The function will active according to the Too High / Low temperature set• Pre-cool / heat temperature hysterisys = 5°C (fixed)

Open Heater 3

Open Heater 2

Open Heater 1

Close Heater 3

Close Heater 2

Close Heater 1

Pre_Tc: Pre_Cool Temperature

(Pre_Tc = Too low protect temperature)

Pre_Tc + 5

Pre_Tc + 3

Pre_Tc

Pre_Tc -2

Open Heat-reject 1

Open Heat-reject 2

Open Heat-reject 3

Pre_Th: Pre_Heat Temperature

(Pre_Th = Too high protect temperature)

Pre_Th + 2

Pre_Th

Pre_Th - 3

Pre_Th - 5

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Example:Too High Temperature: 43°C (adjustable)Too Low Temperature: 10°C (adjustable)

* When the water temperature is at or below 0°C, all the heating stages will be ON, regardless the ON/OFF temperature setting

Stage On Temp (°C) Off Temp (°C)Heating stage 3 8 13Heating stage 2 9 14Heating stage 1 10 15Cooling stage 1 43 38Cooling stage 2 44 39Cooling stage 3 45 40

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2.5 2.5 Outdoor (OD) Air Reset Outdoor (OD) Air Reset

• Applicable for Heat Add set points at very low outdoor air

temperature (start at 16°C)

• OD reset range: 1 – 5 °C (adjustable)

OD Air Temperature (°C)

-17 -8 0 8 16

OD Air Reset Range (°C)

0 - 5°C

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2.6 2.6 Emergency Protection Emergency Protection 2.6.1 Low / Too Low Temp Protection2.6.1 Low / Too Low Temp Protection

System On

Sound Alarm

System Continue Running

Yes System OffSound Alarm

TW ≤ TLW ?No

TW ≤ TTLW ?

Yes

No

Note:

TW = Water Temp

TLW = Low Water Temp

TTLW = Too Low Water Temp

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2.6 2.6 Emergency Protection Emergency Protection 2.6.2 High / Too High Temp Protection2.6.2 High / Too High Temp Protection

System On

Sound Alarm

System Continue Running

Yes System OffSound Alarm

TW ≥ THW ?No

TW ≥ TTHW ?

Yes

No

Note:

TW = Water Temp

THW = High Water Temp

TTHW = Too High Water Temp

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2.6 2.6 Emergency Protection Emergency Protection 2.6.3 Loss of Flow2.6.3 Loss of Flow

10s after System On

Sound Alarm

Lead Pump Off

Lag Pump On

Error System OffSound Alarm

Check water

flow for 15s

Normal

Check water

flow for 15s

Error

Normal

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2.6 2.6 Emergency Protection Emergency Protection 2.6.4 Sensor Error2.6.4 Sensor Error

• Either Water Sensor or OD Air Sensor fail will sound the alarm

• System will be shut off

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2.7 Error Description2.7 Error Description

Priority Error Description LCD Panel Code Reset Setting System Status

1 Water Sensor Error Water Sensor ERR Manual Shut down

2 Low Water Temperature Water Low Temp Automatic Running

3 High Water Temperature Water High Temp Automatic Running

4 Water Pump 1 Flow Failure Flow Error Pump1 Automatic

5 Water Pump 2 Flow Failure Flow Error Pump2 Automatic

6Too High Water Temperature Shutdown

Hi Temp Shutdown Automatic Shut down

7Too Low Water Temperature Shutdown

Lo Temp Shutdown Automatic Shut down

8 Outdoor Sensor Failure OD Sensor ERR Manual Shut down

Both Happen, Shut down

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3. Operation3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting

3.2 Operation Limits3.2 Operation Limits

3.3 Default Setting Reset Switch3.3 Default Setting Reset Switch

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting

EnterESC

LEFTRIGHT

DOWNUP

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.1 Main Menu3.1.1 Main Menu

By pressing the ButtonBy pressing the Button

ESC

Main Main

MenuMenu

ErrorError

TestTest

StatusStatus SettingSetting

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.2 Status3.1.2 Status

ESC

StatusStatus

Output StageOutput Stage

TempTemp

PumpPump Water Flow: Yes (No)Water Flow: Yes (No)

Pump Run TimePump Run Time

1# : On (Off)1# : On (Off)

1# : Cool (Heat) On (Off)1# : Cool (Heat) On (Off)

2# : On (Off)2# : On (Off)

Water Temp: xxx°C (°F)Water Temp: xxx°C (°F)OD Temp: xxx°C (°F)OD Temp: xxx°C (°F)

On : xxx Off : xxx°C (°F)On : xxx Off : xxx°C (°F)

On : xxx Off : xxx°C (°F)On : xxx Off : xxx°C (°F)2# : Cool (Heat) On (Off)2# : Cool (Heat) On (Off)

(3-12#): Unused(3-12#): Unused

Pump1: xxhrPump1: xxhr Pump2: xxhrPump2: xxhr

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.3 Setting3.1.3 Setting

• Password Protected

• During power ON, the ‘Setting’ can only be viewed.

• The system MUST be turned OFF in order to change the Setting parameters.

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3. Operation


ESC

SettingSetting

ODA reset Enable ODA reset Enable (Disable)(Disable)

TempTemp

PumpPump

Output ConfigOutput Config

OtherOther

Mode: Auto (Manual)Mode: Auto (Manual) Lead Pump: 1# (2#)Lead Pump: 1# (2#)

Password Password ProtectedProtected

Switch Cycle: xxxhrSwitch Cycle: xxxhr Pump Switch Check Time: Pump Switch Check Time: xxxsxxxs

Reset Run TimeReset Run Time

Min Run TM: xxxsMin Run TM: xxxs

ESC

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3. Operation


Pump• Mode: - Auto >The lead lag cycle operation is activated

- Manual >Only the lead pump is activated

• Lead Pump :1# / 2# >The 1st or 2nd pump can be set as lead pump in the operation

• Switch Cycle: xxxhr>The time for a pump to switch over to another pump

• Pump Switch Check Time: >The time to check the water flow after pump is On

• Reset Run Time:>To reset the record of the total pump run time

• Min Run TM: xxxs>The minimum time required for a pump to operate

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3. Operation


ESC

SettingSetting


TempTemp

PumpPump


OtherOther

Cool Stage: xxCool Stage: xx Heat Stage: xxHeat Stage: xx


Interstage Time: xxsInterstage Time: xxs

ESC

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3. Operation


Output Config•Cool Stage:

>To set the number of cool stage for the system operation

•Heat Stage:>To set the number of heat stage for the system operation

• Interstage Time: xxs>The delay time between every stages to start operation

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3. Operation


ESC

SettingSetting


TempTemp

PumpPump Output ConfigOutput Config

OtherOther

Water Temp Water Temp AlarmAlarm Temp Temp HysterysisHysterysis


High TMP: xxx°C (°F)High TMP: xxx°C (°F)

Too Hi TMP: xxx°C (°F)Too Hi TMP: xxx°C (°F)

Low TMP: xxx°C (°F)Low TMP: xxx°C (°F)

Too Low TMP: xxx°C (°F)Too Low TMP: xxx°C (°F)

OD reset TMP: xxx°C (°F)OD reset TMP: xxx°C (°F)

ESCSet Stage Set Stage TempTemp

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3. Operation


Temp(a) Water Temp Alarm

•High TMP: xxx°C / °F>Water temperature in warning temperature (system still on)

•Too Hi TMP: xxx°C / °F>Maximum allowable water temperature before system shut off

•Low TMP: xxx°C / °F>Water temperature in warning temperature (system still on)

•Too Low TMP: xxx°C / °F>Minimum allowable water temperature before system shut off

•ODresetTMP: xxx°C / °F>The temperature range for heat addition On/Off stages that

responding to the OD air temperature

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3. Operation


ESC

SettingSetting


TempTemp


OtherOther



Cool Stage: xxx°C (°F)Cool Stage: xxx°C (°F)

Heat Stage: xxx°C (°F)Heat Stage: xxx°C (°F)

ESCSet Stage Set Stage TempTemp

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3. Operation


Temp(b) Temp Hysterysis

•Cool Stage: xxx°C / °F>The temperature difference between ON and OFF of a

Cool Stage

•Heat Stage: xxx°C / °F>The temperature difference between ON and OFF of a

Heat Stage

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3. Operation


ESC

SettingSetting


TempTemp


OtherOther



Heat Rej: xxx°C (°F)Heat Rej: xxx°C (°F)

Heat Add: xxx°C (°F)Heat Add: xxx°C (°F)

ESC

Set Stage Set Stage TempTemp

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3. Operation


Temp(c) Set Stage Temp

•Heat Rej: xxx°C / °F>The first cool stage temperature setting

•Heat Add: xxx°C / °F>The first heat stage temperature setting

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3. Operation


ESC

SettingSetting


TempTemp

PumpPump


OtherOther


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3. Operation


ODA reset Enable / Disable

• To enable / disable the OD Air Reset function

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3. Operation


SettingSetting ODA reset Enable ODA reset Enable (Disable)(Disable)

TempTemp

PumpPump


OtherOther

New Password: xxxxNew Password: xxxx

Temp Unit: °C (°F)Temp Unit: °C (°F)

Key Back Light: Enable Key Back Light: Enable (Disable)(Disable)

LCD Back Light: Enable LCD Back Light: Enable (Disable)(Disable)

Buzzer: Enable (Disable)Buzzer: Enable (Disable)

Set Date: DD-MM-YYSet Date: DD-MM-YY

Set Time: hh:mm:ssSet Time: hh:mm:ss


ESC

ESC

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3. Operation


Other• New Password: xxxx

>To set new password. Default password = 8888

• Temp Unit: °C / °F>To set the temperature unit

• Key Back Light: Enable / Disable>To enable / disable the LCD panel key back light

• LCD Back Light: Enable / Disable>To enable / disable LCD panel screen back light

• Buzzer: Enable / Disable>To enable / disable the buzzer on LCD panel

• Set Date: DD-MM-YY>To set the date for the LWC system

• Set Time: hh:mm:ss>To set the time for the LWC system

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.4 Test3.1.4 Test

TestTest

1#Pump: On (Off)1#Pump: On (Off)2#Pump: On (Off)2#Pump: On (Off)1#Stage: On (Off)1#Stage: On (Off)2#Stage: On (Off)2#Stage: On (Off)3#Stage: On (Off)3#Stage: On (Off)4#Stage: On (Off)4#Stage: On (Off)5#Stage: On (Off)5#Stage: On (Off)6#Stage: On (Off)6#Stage: On (Off)7#Stage: On (Off)7#Stage: On (Off)8#Stage: On (Off)8#Stage: On (Off)9#Stage: On (Off)9#Stage: On (Off)10#Stage: On (Off)10#Stage: On (Off)11#Stage: On (Off)11#Stage: On (Off)12#Stage: On (Off)12#Stage: On (Off)Buzzer: On (Off)Buzzer: On (Off)Alarm Out: On (Off)Alarm Out: On (Off)


ESC

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.4 Test3.1.4 Test

• Must be operated only when the system is OFF or dry run

• To check the function ability of the system

• The display returns to default menu after 3 minutes when user stop operating the system or by pressing ESC button

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.5 Error3.1.5 Error

ErrorError HistoryHistory

DeleteDelete


ESC

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3. Operation

3.1 LCD Panel Interface & Setting3.1 LCD Panel Interface & Setting 3.1.5 Error3.1.5 Error

• To store the error records of the system

• Maximum 10 errors can be recorded or check

• Error records can be deleted

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3. Operation

3.2 Operation Limit3.2 Operation Limit

Lower Limit

DefaultUpper Limit

Lower Limit

DefaultUpper Limit

1°C 3°C 5°C 2°F 6°F 10°F6°C 13°C 18°C 42°F 55°F 64°F5°C 10°C 17°C 41°F 50°F 62°F

30°C 40°C 44°C 86°F 104°F 111°F31°C 43°C 45°C 87°F 109°F 113°F1°C 5°C 5°C 2°F 10°F 10°F

Heating Stage 7°C 20°C 43°C 44°F 64°F 109°FCooling Stage 7°C 30°C 43°C 44°F 86°F 109°F

8hr

Stage Temperature

30s

NA

12

60s

168hrAuto

40s

80

15s 15s

410s

0

15sTemp Unit (°C) Temp unit (°F)

Upper LimitLower Limit Default

200s

12

240s

NA88hr

Heat Add/Reject Interstage Timer

Number of heat rejection stage

Pump minimum run time

Pump: Auto/Manual

OD Air Reset Temperature

High Temperature

Low Temperature

Number of heat addition stage

Water flow detection check time after 1st pump On (Pump switch check time)

Pump switch cycle (Auto)

Description

Too High Temperature (emergency shutdown)

Too Low Temperature (emergency shutdown)

Stage differential temperature (hysterisys)

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3. Operation

3.3 Default Setting Reset Switch3.3 Default Setting Reset Switch

• To reset the system setting to default setting

• After the power supply is Off, switch the switch 1 to ON

81

SW1

ON

OFF

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Thank YouThank You

Service Section Technical Training December 2005

Documents

Transcript of Service Section Technical Training December 2005