MicroTech Loop Water Controller (LWC)

Transcription

1 Installation & Maintenance Data IM 431 Group: Controls Part Number: Y-01Y Date: October, 1997 MicroTech Loop Water Controller (LWC) 1997 McQuay International

2 Contents Contents...2 Figures...3 Tables...4 Introduction... 5 General Description Of Loop Water Controller... 6 Installation Instructions... 8 Location & Mounting Of LWC Panel...8 Mounting Of Temperature Sensors...8 Location Of Temperature Sensors...10 Loop Supply Temperature Sensor (Standard)...10 Outdoor Air Temperature Sensor (Standard)...10 Loop Return Temperature Sensor (Optional)...10 Entering Tower Temperature Sensor (Optional)...11 Leaving Tower Temperature Sensor (Optional)...11 Entering Boiler Temperature Sensor (Optional)...11 Leaving Boiler Temperature Sensor (Optional)...11 Storage Tank Temperature Sensor (Optional)...11 Flow Switch...11 Tower And/Or Boiler Control Valves...12 Wiring Instructions Control Panel Power Wiring...14 Sensor Wiring Instructions...14 Flow Switch Wiring Instructions...15 Damper End-Switch Interlock Wiring...16 Alarm Silence Switch Wiring...16 Valve Feedback Potentiometer Wiring...16 Output Relay Wiring...16 Alarm Horn Output...17 Emergency Shutdown Output...17 Loop Pump #1 & #2 Outputs...17 Tower or Boiler Pumps #1 & #2 Outputs...17 Programmable Outputs...17 LWC System Pre-Start...18 Pre-Start...18 Checking for Proper Voltages on Daughter Board...18 LWC System Startup...19 Energizing The LWC Panel...19 Use of Keypad & LCD Display...19 General Description...19 Information Format of Display...21 Use of Menu and Item Selection Keys...21 Use of Status, Control, Alarm and Switch Selection Keys...22 Use of Action Keys...22 Setup of Options...24 Setting the Programmable Outputs...24 Setting Other Miscellaneous Setup Items...25 Heat Rejection Control...25 Heat Addition Control...26 Service Setpoints...26 Pump Selection...27 Valve Setpoints (Optional)...27 Pre-Cool & Pre-Heat (Optional)...28 Pump Schedule...28 Clock Setting IM 431

3 Daily Schedule #1 Through # Copy Schedule...30 Holiday Schedule...30 Dry Run Testing...30 Checkout of Heat Rejection Outputs...31 Checkout Of Heat Addition Setpoints...32 Actual Run Testing of the LWC...34 Preparation For Actual Run Test...34 Calibration of Valve Actuator Feedback Potentiometers...34 Actual Run Testing...34 LWC Service and Test Procedures The LWC Daughter Board...36 Daughter Board Power Supply...36 Daughter Board Digital Inputs...36 Daughter Board Analog Inputs...37 The LWC Microprocessor Controller Board...38 The LWC Keypad/Display Front Panel...38 Keypad/Display Board...38 LED and Alarm Indicators...39 The LWC Output Board Assembly...39 SSR Control Indication...40 Troubleshooting the OBA...40 DC Output SSR Modules...41 SSR Replacement Procedure...41 Appendix A. Keypad Display Summary Status Category...42 Control Category...43 Alarm Category...49 Appendix B. Explanation of Step-and-Wait Control For the Tower Valve Function the Parameters Used are as Follows:...50 For The Boiler Valve Function the Parameters Used Are As Follows:...52 Appendix C. Pre-Cool and Pre-Heat Modes Pre-Heat Mode...56 Pre-Cool Mode...56 Appendix D LWC Thermistors Resistance vs. Specified Temperatures Appendix E. Loop Water Controller Alarms Appendix F. The Optional Remote Alarm Panel Appendix G. The Optional Modem Appendix H. Pump Restart Relay Kit Appendix I. LWC-16 Schematic Appendix J. LWC -24 Schematic Appendix K. Loop Water Controller Parts List Figures Figure 1. Loop Water Controller Internal View...5 Figure 2. Immersion Sensor...9 Figure 3. Brass Thermowell...9 Figure 4. Outdoor Air Sensor...10 Figure 5. Flow Switch...12 Figure 6. Dual Flow Switch Schematic...15 Figure 7. Single Flow Switch Schematic...16 Figure 8. LCD Keypad Display...20 Figure 9. Menu Structure...20 IM 431 3

4 Tables Table 1. Flow Switch Parameters...12 Table 2. Maximum Wire Distances...14 Table 3. Acceptable Voltage Levels IM 431

5 Introduction The following pages provide information on the features, installation, operation and problem analysis of the MicroTech Loop Water Controller (LWC). Some discrepancy may exist between display statements, default setpoints, time intervals, and published data. The differences are minor and exist because of McQuay's avowed commitment to continually improve our products.! WARNING This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with this manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. McQuay lnternational disclaims any liability resulting from any interference or for the correction thereof. Figure 1. Loop Water Controller Internal View IM 431 5

6 General Description Of Loop Water Controller The MicroTech Loop Water Controller (LWC) is a microprocessor-based control panel designed to provide sophisticated control and monitoring of the loop water temperatures of a water source heat pump system. A summary of the primary control features offered by the LWC is as follows: 1. The LWC-16 provides up to 9 outputs for heat rejection, heat addition, and time clock control. The LWC-24 provides up to 17 outputs for heat rejection, heat addition, and time clock control. Both panels offer the following features: a. Individually adjustable setpoints (1 F resolution) with adjustable differentials. b. Ability to control a cooling tower valve and/or a boiler valve. The control valve must be a reversible, floating point, fully modulating valve with position feedback. c. Damper interlock circuitry is provided to prove tower fan discharge dampers have fully opened prior to energizing heat rejection stage 2. d. Programmable outdoor air reset of heat addition setpoints. 2. Main Loop Water Control a. Automatic pump sequencing - In the event that the lead pump fails to establish flow, the standby pump is automatically energized. b. Auto or manual selection of the lead circulating pump controller automatically starts the pump with the fewest operating hours or allows the operator to manually select the lead pump. c. Individual pump flow switches provide positive indication of flow and error free diagnostics. 3. Tower Loop Pump Control or Boiler Pump Control a. Control of cooling tower pumps for systems with open type cooling towers and water-towater heat exchangers, or control of boiler pumps for systems with circulation pumps for the boiler. b. Auto or manual selection of the lead circulating pump controller automatically starts the pump with the fewest operating hours or allows the operator to manually select the lead pump. c. Individual pump flow switches provide positive indication of flow and error free diagnostics. 4. Loop Circulating Pump Control Allows loop circulating pumps to be started via the Mark IV pump restart signal (contact closure) and/or by an 8-day programmable (one start and stop per day) time clock schedule. 5. Occupied/Unoccupied Time Scheduling Battery backed time clock provides contact closures for occupied/unoccupied time scheduling of heat pump zones or other auxiliary devices such as exhaust fans, lighting, etc. Up to six unique time clock outputs may be utilized. 6. Temperature Readouts of the following sensor points: a. Loop supply water temperature (standard) b. Outdoor air temperature (standard) c. Loop return water temperature (optional) d. Entering tower water temperature (optional) e. Leaving tower water temperature (optional) f. Leaving boiler water temperature (optional) g. Entering boiler water temperature (optional) h. Storage tank temperature (optional) 7. Alarm Indication a. Audible alarm horn is sounded when the loop water temperature exceeds the adjustable high temperature or low temperature warning setpoints or when the lead loop pump fails to establish flow. 6 IM 431

7 b. Auxiliary contact closure for interconnection to LWC remote alarm panel or building automation system. c. Alarm horn may be silenced by either the local keypad or via remote alarm panel (contact closure). 8. Emergency Shutdown Signal A contact closure is made when the loop water temperature exceeds the adjustable high temperature or low temperature compressor lockout setpoints or when the loop pump sensors detect lack of flow. 9. Precool Cycle Energy saving thermal storage technique provides precooling of the heat pump loop during nighttime (unoccupied) periods. 10. Preheat Cycle Energy saving thermal storage technique provides preheating of the heat pump loop during nighttime (unoccupied) periods. 11. Manual Control Allows operator to simulate loop supply water temperatures for panel commissioning, systems checkout, or for system override. 12. Communications Port Provides remote monitoring and control of the LWC via single twisted pair wire or phone modem to an IBM compatible computer using MicroTech Monitor software. IM 431 7

8 Installation Instructions Location & Mounting Of LWC Panel The LWC panel is designed for indoor use only. The panel should be mounted on the interior surface of a convenient sturdy wall with adequate clearance for the door swing. The LWC panel should be protected from direct sunlight, excessive moisture, dust or lint. The ambient environmental temperature and humidity specifications on the panel are: Operating: 32 F to 115 F (0-95% RH, noncondensing) Storage: -20 F to 140 F (0-95% RH, noncondensing) Mount the panel to the wall using screws or bolts (not provided). If it is necessary to drill other holes, you must temporarily remove the back plane of the LWC panel to protect all electrical devices from metal filings and debris.! CAUTION Electric static hazard. Can cause equipment damage. MicroTech systems contain static sensitive components. A static discharge caused by removing any board within the panel can cause damage to the electronic components. To prevent such damage during service involving board replacement, McQuay recommends the use of a static discharge wrist-strap which is to be grounded to the controller chassis. Verifying the panel is properly grounded and discharging any static electrical charge by touching the bare metal inside the panel should insure against component damage when service involving touching any devices inside the panel is performed. Never unplug any cables, printed circuit board terminal blocks, relay modules, or power plugs when power is applied. Mounting Of Temperature Sensors Figures 2 and 3 show the dimensions of the water temperature sensors and thermowell used with the LWC panel. All temperature sensors are negative temperature coefficient thermistors. See Appendix D for a temperature vs. resistance chart. The brass well screws into a 1/2 NPT saddle or Thredolet fitting furnished by the installing contractor. The brass well will withstand a maximum temperature of 250 F and a maximum static pressure of 250 psig. 8 IM 431

9 Figure 2. Immersion Sensor Figure 3. Brass Thermowell Figure 4 shows the dimensions of the outdoor air temperature sensor used with the LWC panel. IM 431 9

10 Figure 4. Outdoor Air Sensor 2.00" 4.82" 4.37" Long 2.87" 1.33 " Dia a0081 The temperature sensitive element is sheathed in a stainless steel tube, and mounted inside a ventilated, treated white PVC sun and wind shield to minimize the radiant energy and wind effects. The sun shield is mounted on a weatherproof outlet box for easy installation on an outdoor surface using screws or toggle bolts (not provided). Location Of Temperature Sensors Loop Supply Temperature Sensor (Standard) This sensor is installed in the hydronic loop supply line to all water source heat pumps and must be installed after all auxiliary heating and cooling equipment; e.g., boilers, heat exchangers, and cooling towers. This is the sensor which the LWC panel uses to determine if heat addition or heat rejection is required. Outdoor Air Temperature Sensor (Standard) The outdoor air temperature sensor should be mounted in the shade, away from all devices such as an exhaust fan that would disturb the normal outdoor environment. A preferred location would be under the eaves of a north facing wall. The sun shield fitting can be rotated by hand at the time of installation to face either right or left, depending upon the specific requirements of each situation. Loop Return Temperature Sensor (Optional) This sensor is to be installed in the hydronic loop return line from all water source heat pumps and must be installed before all auxiliary heating and cooling equipment; e.g., boilers, heat exchangers, and cooling towers. This is a monitoring only temperature sensor and is used simply for display of the return loop temperature to the building operation. 10 IM 431

11 Entering Tower Temperature Sensor (Optional) This sensor is normally used when there is an open type cooling tower and water-to-water heat exchanger. The sensor should be installed in water piping entering the cooling tower but before any cooling tower valve. This is a monitoring only temperature sensor and is used simply for display of the entering tower water temperature to the building operator. Leaving Tower Temperature Sensor (Optional) This sensor is normally used when there is an open type cooling tower and a water-to-water heat exchanger (see Figure 5). The sensor should be installed in water piping leaving the cooling tower sump. This is a monitoring only temperature sensor and is used simply for display of the leaving tower water temperature to the building operator. Entering Boiler Temperature Sensor (Optional) This sensor is normally used when there is a boiler blend pump circuit. The sensor should be installed in the hot water piping entering the boiler. This is a monitoring only temperature sensor and is used simply for display of the entering boiler water temperature to the building operator. Leaving Boiler Temperature Sensor (Optional) This sensor is normally used when there is a boiler blend pump circuit. The sensor should be installed in the hot water piping leaving the boiler. This is a monitoring only temperature sensor and is used simply for display of the leaving boiler water temperature to the building operator. Storage Tank Temperature Sensor (Optional) This sensor is normally used when there is a thermal storage tank in the hydronic loop. This is a monitoring only temperature sensor and is used simply for display of the storage tank water temperature to the building operator. Flow Switch See Figure 5 for dimensions of the flow switch used with the LWC panel. Install the flow switch, Penn Model F61KB-11 or McDonnell Miller Model FS4-3, per the manufacturer's instructions. Mount the flow switch in a section of pipe where there is a straight run of at least 5 pipe diameters on each side of the flow switch. The flow switch must not be installed in a vertical downflow line. Do not locate adjacent to valves, elbows, or orifices. The switch should be mounted so the terminals or wire leads are easily accessible for wiring. IM

12 Figure 5. Flow Switch Table 1. Flow Switch Parameters Pipe Size Dimension A Dimension B 1 inch inch 1 inch 2 inch inch inch 3 inch inch inch Tower and/or Boiler Control Valves Valves may be used for control of heat rejection or heat addition to the water source heat pump loop. The valve responds always with the first stage of heat rejection for the cooling tower and responds always with the first stage of heat addition for the boiler. The electric valves used with the LWC must meet the following specifications: 1. Reversible, floating type actuator. Actuator must be capable of moving the valve in either direction, or to stop it at any point in the stroke. 2. Drive open, drive close circuit must be 24 to 115 VAC,.030 amperes minimum, 1.5 amperes maximum. 3. Actuator timing from full open to full close and vice versa must be a minimum of 40 seconds a maximum of 120 seconds. 4. Spring return to normal position on loss of power is desired, but may not be mandatory depending on specific jobsite requirements. 5. Optional Feature: A feedback potentiometer (200 ohm minimum) is not required for control but is highly recommended for system checkout and operator monitoring. 12 IM 431

13 For cooling towers, the electric valve actuator should be mounted so that the valve is normally closed to the cooling tower; i.e., opening the valve increases the flow to the tower and subsequent heat rejection. For boilers, the electric valve actuator should be mounted so that the valve is normally closed to the boiler or heat addition device; i.e., opening the valve increases the flow to the boiler and subsequent heat addition. IM

14 Wiring Instructions Control Panel Power Wiring Do not penetrate the control panel cabinet anywhere but through the knockouts provided. Drilling holes in the cabinet can damage components. The cabinet is divided into a high voltage (115 VAC) section and a low voltage (24 VAC) section by a sheet-metal barrier. All control panel power must enter the panel through knockouts in the top, high voltage section. See Appendix K for layout of control panel. The control panel must be properly grounded. Run a separate copper ground wire (#14 AWG minimum size) from the GRD terminal to the earth ground; e.g., a water pipe or grounding rod. The panel requires a 115V/60/1 power source. Supply 115 volts to the Ll and L2 field wiring terminal. The panel is internally protected from short circuits with a 3 amp circuit breaker located in the bottom center section of the control panel. This circuit breaker can also be used as an on-off switch for the panel. To close the circuit or energize the panel, push the circuit breaker button until it is engaged in the retracted position. To open the circuit, push the button again and the button will pop out exposing the white sleeve of the button shaft. Sensor Wiring Instructions Make electrical connections to the sensor in accordance with the field wiring diagrams (Appendix I or J) for the job and in accordance with national and local electrical codes. The sensor wiring must be two-conductor, shielded, twisted and jacketed pair with drain wire. Belden 8762 or equivalent is recommended. The maximum wire distances are limited by the acceptable error introduced as a result of wire resistance. See Table 2 for error caused by wire resistance. Table 2. Maximum Wire Distances Error in Deg. F when Sensor is Measuring At Temps. 0 F Ohms per 32 F 75 F 115 F Wire Ga Cable Example: The relationship of the thermistor resistance to the temperature it is measuring is nonlinear; that is, over the span of measurable temperatures the resistance does not vary by a constant multiplicative or divisible value. The error in the above table is the number of degrees that should be added per specified length for the gauge of wire used to obtain the actual temperature measurement. To show how the above table is derived, we will use the Resistance vs. Temperature chart in Appendix D for the following example. An outdoor air temperature (OAT) sensor has the following connection characteristics: Wire gauge 20 Wire length 2500 feet Temp. at sensor 90 F From Appendix D the sensor resistance = 2199 ohms. The additional resistance due to the wire is 14 IM 431

15 20.6Ω 2500' = 51.5Ω 1000' Total resistance = = ohms. From Appendix D the corresponding temperature is approximately 89 F. Thus at 90 F the error introduced by 2500 feet of 20-gauge wire is 1 F. For 500 and 1000 feet the error is derived by: (1 F per 2500 feet)/5 =.20 F per 500 feet (1 F per 2500 feet)/2.5 =.40 F per 1000 feet When making electrical connections between the sensor and field cable wiring, use the full 8- foot lead furnished with the sensor to avoid condensation at the field terminals. Solder type connections are by far the most reliable and trouble-free over extended periods and thus are preferred. Crimp type butt splices are the second choice and usually prove satisfactory. Simple wire nut connections are an invitation to long term trouble. This is an electronic circuit, not a power hook-up. Note: Do not connect any voltage in excess of 5 volts AC or DC to the analog sensor inputs. Damage to the Daughter Board and/or Microprocessor Controller Board will result. Flow Switch Wiring Instructions The LWC is capable of controlling up to two (2) pump sets. The first pump set is the hydronic loop circulating pumps for the water source heat pumps and the second pump set is either the boiler pumps or the cooling tower pumps. The flow switch, a normally open switch, sends a closed circuit signal to the LWC when the contacts are closed due to water flow. Note: Do not connect any voltage sources rated in excess of 24±10% Vac to the digital inputs. Damage to the daughter board will result. The LWC was designed to accommodate a flow switch per pump as shown in Figure 6. Figure 6. Dual Flow Switch Schematic Pump 1 Pump 2 a0082 A flow switch per pump provides error free diagnostics by allowing the LWC panel to positively determine which pump has established flow. This insures that the pump run hours maintained by the panel are accurate. For applications as shown above, each flow switch is wired to the LWC digital inputs as shown on the field wiring schematic. If the LWC is to be installed on a project where there is a single flow switch per pump set as shown schematically in Figure 7, it is necessary to parallel the flow switch signal into both digital inputs for the pump set. For the hydronic loop circulating pumps, connect the flow switch wires between field terminals 59 and 52 and install a jumper between field terminals 52 and 53. IM

16 For the tower or boiler pump set, connect the flow switch wires between field terminals 61 and 54 and install a jumper between field terminals 54 and 55. Figure 7. Single Flow Switch Schematic Pump 1 Pump 2 a0084 Damper End-Switch Interlock Wiring If the first stage of heat rejection is to open the discharge dampers of the cooling tower, a control interlock feature (see Start-up and Checkout section of manual to activate/deactivate this option) of the LWC prevents any additional cooling stages from being energized until the interlock circuit proves that the cooling tower fan discharge dampers are fully open. Wire the discharge damper end switch to field terminals 56 and 63 as shown on the field wiring schematic. If the switch is open (dampers not fully open), the heat rejection stage 2 and above outputs will not be energized. When the end switch closes (dampers fully open), the heat rejection stage 2 and above outputs can be energized. Alarm Silence Switch Wiring If remote silencing of the audible alarm is desired, wire a momentary push-button switch to field terminals 57 and 64. The Remote Alarm Panel (RAP) features a momentary push-button switch for this purpose. This connection is also made when using the RAP option. Valve Feedback Potentiometer Wiring Feedback potentiometers should be wired as shown on the field wiring diagram. The sensor wiring must be two-conductor, shielded, twisted and jacketed pair with drain wire (Belden 8762 or equivalent). The minimum resistance of the feedback potentiometer is 200 ohms. Output Relay Wiring All outputs on the LWC are normally open, solid-state relays with replaceable 5 amp fuses. No power supply is provided for the output of these relays and thus the control circuit power should originate from the device being controlled. The output relays are rated for 24 to 140 volt AC. The maximum load current rating for each solid-state relay is 3 amps (temperature compensated) and the minimum load current rating is amps. All wiring for outputs is to the Output Board Assembly terminals located in the top section of the panel. 16 IM 431

17 Alarm Horn Output This output is energized when the LWC detects an alarm condition. It is connected to the alarm LED and alarm horn on the front panel display. An auxiliary connection can also be made at field terminal 49 when the Remote Alarm Panel (RAP) option is utilized. The Output Board Assembly can also supply this signal for a remote alarm horn or annunciator provided that a solid-state relay (part #492656B-01 for an AC load or part #492656B-02 for a DC load) is installed in the appropriate socket. Emergency Shutdown Output Field terminal 51 is connected to chassis ground when the loop temperatures exceed the emergency shutdown setpoints. This terminal was designed to interface with the E terminal of the Mark IV water source heat pump controller boards. An emergency shutdown override switch is provided and should only be used when servicing the LWC panel and while maintaining loop circulation by manual control. The Output Board Assembly can also supply a normally closed relay contact (due to the relay being normally energized) that will open in the event of an emergency shutdown signal. This is accomplished by the installation of a solid-state relay (part #492656B-01 for an AC load or part #492656B-02 for a DC load) in the appropriate socket which in a non-emergency shutdown mode will be energized. The emergency shutdown override switch will only affect terminal 51 and not the relay output or the LED indicator. Loop Pump #1 & #2 Outputs These outputs should be wired to water source heat pump circulating pumps #1 and #2. Tower or Boiler Pumps #1 & #2 Outputs These outputs are defined to control either the tower circulating pumps or the boiler circulating pumps. See System Start-up and Checkout section. Programmable Outputs The number of heat rejection stages, heat addition stages, and time clock outputs for the LWC are completely programmable within certain hardware restrictions. The restrictions are as follows. The maximum number of available outputs is 9 for the LWC-16 and 17 for the LWC-24. In addition, the maximum number of heat rejection stages cannot exceed 12, the maximum number of heat addition stages cannot exceed 12, and the maximum number of time clock outputs cannot exceed 6. The programmable outputs are assigned to the panel in the following order: 1. Tower Control Valve Always uses two outputs. The first output is the valve drive close signal and the second output is the valve drive open signal. 2. Heat Rejection Stages Uses one output per stage. 3. Boiler Control Valve Always uses two outputs. The first output is the valve drive close signal and the second output is the valve drive open signal. 4. Heat Addition Stages Uses one output per stage. 5. Time Clock Outputs Uses whatever outputs are remaining up to a maximum of six. For example, if an LWC-16 application requires a tower valve, three stages of heat rejection outputs, two heat addition outputs, and two time clock outputs, the outputs would be defined to be as follows: Output No. 7. Tower Valve Drive Close 8. Tower Valve Drive Open IM

18 See Setup Options section for more information on programmable outputs. 9. Heat Rej Stage Heat Rej Stage Heat Add Stage Heat Add Stage Heat Add Stage Time clock #1 15. Time clock #2 The programmable outputs should be wired per the job submittal drawings. Time clock outputs using the unoccupied ( U ) terminal of Mark IV water source heat pump controller boards require further modification. The AC output solid-state relay module (part #492656B-01) must be replaced with a DC output solid-state relay module (part #492656B-02). The earth ground connection required for this application should be wired to the odd numbered terminal of the programmable output. LWC System Pre-Start Pre-Start Prior to the LWC panel startup, all auxiliary control devices such as pumps, cooling tower, boilers, and valves should be checked, tested, and started in accordance with the manufacturer's instructions. Disable the LWC from energizing any auxiliary devices during system startup and check out by putting the motor control starter panel Hand, Off, Auto switch in the Off position or disconnect the wiring to the output board. Familiarize yourself with the panel interior using the parts explosion diagram in Appendix K. There are three main components labeled OBA, MCB, and db. The OBA (Output Board Assembly) is the solid-state relay output board. All solid-state relays are plugged into this board and provide all of the LWC output control. The MCB (Microprocessor Controller Board) contains the necessary software that runs the LWC. It processes input information and provides proper control signal to the OBA and the front panel keypad/display. The DB (Daughter Board) is the input conditioning board for the LWC. It converts input signals into usable information for use by the MCB and provides usable DC voltage by converting the input AC power. The Daughter Board has terminal strips (TS1, TS2, TS3, TS4) used for factory connection to the field terminals. Checking for Proper Voltages on Daughter Board As a precautionary measure, the terminal strips on the Daughter Board (TS1, TS2, TS3, TS4) have been disconnected at the factory to prevent any stray voltages from damaging the electronics. Before plugging the terminal strips into the appropriate header, energize the panel. Using a voltmeter, check for acceptable voltage levels on the removable terminal strips at the following terminals with respect to the LWC panel ground connector. After confirmation of acceptable voltage levels, de-energize the panel and plug in the above terminal strips. Each terminal strip has a polarizing pin (close to terminal #1) which correctly locates the terminal strip in relation to the Daughter Board pin receptacle. If any of the voltages are not within an acceptable range, consult the Service section of this manual. Table 3. Acceptable Voltage Levels Pins TS1-1,2 TS2-2,3 TS3-1 thru 10 Acceptable Voltage Levels -< 30 VAC 9 VAC VAC 5 VAC or VDC 18 IM 431

19 Pins TS4-5 thru 12 Acceptable Voltage Levels 5 VAC or VDC LWC System Startup Energizing The LWC Panel With the LWC circuit breaker in the off position (white sleeve exposed), apply 120 volts power to the panel. Next, energize the panel by depressing the circuit breaker button. The following should take place as noticed first on the microprocessor controller board (MCB) inside the panel and then on the front panel keypad/display: 1. The red LED on the MCB board should illuminate for approximately 5 seconds and then go off. 2. The green LED on the MCB board should then illuminate and stay on. 3. The yellow LED on the MCB board should begin blinking on and off at 1 second increments. 4. The green LED on the front panel should begin blinking at 1 second increments. 5. The LCD display on the front panel should show: 1. Unit Status Off: Manual Note: If the LEDs on the front panel fail to respond as described above consult the Service section of this manual. The function of the front panel LEDs are explained in the following section. Use of Keypad & LCD Display General Description The LWC front panel consists of a keypad/display for user interface (described in detail below), three status LEDs, and an alarm horn. The three LEDs shall indicate: Green Program Status (normally flashes in 1 second intervals of a 2 second period). Yellow Alarm Status (flashes in 1.5 second intervals of a 3 second period in the event of a warning alarm, flashes in 0.3 second intervals of a 0.6 second period in the event of a shutdown alarm). Red Emergency Shutdown (illuminates in the event of a shutdown alarm indicating that an output shut-down signal is being sent for Mark IV applications. This signal is not sent whenever the emergency shutdown override switch is in the off position. This switch does not affect the emergency shut-down LED indication). The alarm horn is a Piezo style with a sound level of 85 DB. It will sound in 1.5 second intervals of a 3 second period in the event of a warning alarm. It will sound in 0.3 second intervals of a 0.6 second period in the event of a problem alarm. It is silenced by pressing the Alarms key on the user keyboard interface. The user keypad/display consists of 12 pressure sensitive, tactile feedback, membrane switches and a 2 line by 16 character supertwist LCD display (see Figure 8). Each key is labeled for its function and falls under one of four main headings: Category, Menu, Item and Action. All but the Action heading is found in the structure of the controller programming. The keys found under the Action heading are used to make and enter changes into the user changeable sections of the LWC program contained in the controller. IM

20 Figure 8. LCD Keypad Display CATEGORY MENU ITEM ACTION STATUS ALARMS PREV. PREV. INCR. CLEAR CONTROL SWITCH NEXT NEXT DECR. ENTER A0085 The information in the controller is arranged in a treelike structure. It may be helpful to think of the information contained in the keypad as if it were a book. Categories are similar to the chapters of a book, Menus are similar to pages of a book, and Items are similar to the lines on a page. The example in Figure 9 shows the structure of a category with four menus and each menu has four items. The complete structure is described in Appendix A. Figure 9. Menu Structure Category Menu 1 Menu 2 Menu 3 Menu 4 Item 1 Item 1 Item 2 Item 1 Item 2 Item 3 Item 1 Item 2 Item 3 Item 4 Item 2 Item 3 Item 4 Item 3 Item 4 Item 4 a IM 431

21 Information Format of Display Menu Line Item Line 1. Unit Status Loop On - Recirc a0091 Information is always displayed on the 2 line by 16 character display with the current menu on the top line and the current item on the bottom line as shown below: Use of Menu and Item Selection Keys To familiarize yourself with the keypad, press the STATUS key which will always display the current unit status which is menu #1 and the current unit status item. Next, repeatedly press the NEXT MENU key to scroll through all the menus for the LWC panel. There are currently approximately 25 menus. Press the NEXT MENU key until you reach the message *End of Menus*. Below is the current list of menus for your reference. 1. Unit Status 14. Daily Sched#l 2. Temperatures 15. Daily Sched#2 3. Valve % Open 16. Daily Sched#3 4. PumpHours 17. Daily Sched#4 5. Control Mode 18. Daily Sched#5 6. Heat Rej Spts 19. Daily Sched#6 7. Heat Add Spts 20. Copy Schedule 8. Alarm Spts 21. Holiday Sched 9. Valve Spts 22. Prog Outputs 10. Pump Select'n 23. Misc Setup 11. Pre-Cool&Heat 24. Current Alarm 12. Clock Setting 25. PreviousAlarm 13. Pump Schedule *End of Menu's If you press NEXT MENU once more after reaching the *End of Menu's * message, you will wrap around to the beginning of the menus. Try this now so you are familiar with this feature. If, at any time, you want to back up one or more menus, press the PREV MENU key to display the previous menu. If you are at the beginning of the menus list and you press the PREV MENU key, you will wrap around to the end of the menus list. Thus the wrap feature works in both directions. Now that you are familiar with the menus selection, select menu #2 which is 2. Temperatures. The first item under the 2. Temperatures: menu is Loop Supply. To view other temperatures, press the NEXT ITEM key. This will display all other temperatures on the LWC. Below is a list of all items available for display under the Temperatures menu: LoopSupply = * F IM

22 OutdoorAir = ** F LoopReturn = ** F Ent Tower = Lvg Tower = Ent Boiler = Lvg Boiler = Tank Temp = *End of Temp's * Note: Some temperatures will display meaning Not Available since no sensor is present. When you have reached the end of all temperature items, the message *End of Temp's * will be displayed. If you want to back up one or more temperatures, press the PREV ITEM key. The wrapping feature also works with the items list, so if you reach the end of the items list and want to quickly reach the beginning, just press NEXT ITEM. Likewise, if you are at the beginning and want to reach the end of the items list, press PREV ITEM. This method of interface is typical of all menus. You may want to select another menu and display all the items associated with the menu. For a list of all the keypad menus and items, see Appendix A. Use of Status, Control, Alarm and Switch Selection Keys As shown in Figure 8, information contained within the controller has been broken up into three categories: Status, Control, and Alarms. The Status, Control, and Alarm keys allow you to quickly move from any position in the tree structure to the first menu and item associated with the beginning of the respective category. For example, if you want to move quickly to the beginning of the Control section, which is menu 5. Control Mode, press the CONTROL key. The STATUS key immediately selects the first menu (menu #1) and item associated with the Status category. The ALARMS key immediately selects the first menu (menu #24) and item associated with the Alarms category and is also used to silence the audible alarm horn. The SWITCH key allows you to jump from an item in a selected menu to the first item of another menu as designated in Appendix A. If you press the SWITCH key and no selection is available, the menu line of the display will respond with No Switch aval. and then return to the current menu. Use of Action Keys The action keys are used for the following purposes: 1. To CHANGE a control setpoint, timeclock schedule, or other changeable variable. 2. To CLEAR active alarms which may have been detected by the panel and require clearing. Use of Action Keys to Change Setpoint: As an example of how to use the action keys to change a control variable, perform the following: 1. Select the menu 6. Heat Rej Spts. 2. Select the item Stage 3 = 85 F. 3. Press the increase key + or the decrease key -. If the value you want to change is not changeable the menu line temporarily flashes Not Changeable and returns to the current menu. 22 IM 431

23 4. In this case the value is changeable so the display will prompt you with a two-line message. The menu line will read Password Entry while the item line will read Enter:. This password protection is to prevent unauthorized personnel from making changes to any changeable parameter. 5. Proceed by entering the password which is in the sequential presses of the following keys: ENTER, ENTER, ENTER, ENTER Upon successfully entering the correct password, the menu line of the display will read Passwd Verified and return you to the parameter you were about to change. If the password is incorrect, the item line will temporarily flash Invalid Password and return you to the menu and item you were attempting to change. Note: After entering the correct password, the controller grants the user 5 minutes of authorization to change any parameter. Any activity at the keypad resets the timer to 5 minutes so the operator is not bothered with having to enter the password more than once per session. 6. Once again press the increase key + or the decrease key -. The changeable parameter blinks indicating that you are in the process of changing the setpoint. 7. When the value shown on the display is the one you desire, press ENTER to permanently enter the new setpoint. All changeable parameters may only be changed within acceptable boundaries. The acceptable boundaries are referred to as Hi and Lo limits. When you have reached the Hi or Lo adjustable limit, the menu line will temporarily display Hi Limit Reached or Lo Limit Reached as appropriate and you will not be allowed to exceed the limits. See Appendix A for high and low limits of all changeable variables. If you ever want to cancel or escape from making a change when the changeable parameter is blinking, you can press the CLEAR key. This must be done before the ENTER key is pressed. Attempting to escape to another menu or item while in the changing process will result in the menu line temporarily displaying Use: +, -, =, Clr and the returning of the display to the changing mode. This prompts you to complete your change either with the ENTER key (denoted as an equal sign or the CLEAR key as described above. Start Hour (0 to 23) Start Minute (0 to 59) Stop Hour (0 to 23) Stop Minute (0 to 59) Mon 08:00-17:00 a0092 Sometimes, there is more than one changeable value on a line. A good example of this is a Daily Schedule which defines when a time clock output will be energized for each day of the week. The display will look like the following for Monday: The changeable variables are the start hour, the start minutes, the stop hour, and the stop minutes. In order to change the schedule, press the + or - key; note that the start hour starts blinking indicating that it is the current changeable variable. 8. Change the start hour to what is desired and press the ENTER key. The start hour is now set and the next changeable variable begins to blink, The process of changing the variable and then pressing the ENTER key is repeated until all changeable variables have been set. IM

24 This concludes the instructions on how to change a control variable using the Action keys. This procedure is typical of the process used to change any parameter in the keypad. Clearing An Active Alarm: When the LWC panel detects an alarm condition, the yellow LED on the front panel display will blink on and off and the Piezo alarm will sound on and off with the LED. Alarms will be annunciated based on their priority and type. A list of alarms, their types, and mode of annunciation is given in Appendix E. When an alarm of higher priority than the current alarm is received, the current alarm is transferred to the 25. Previous Alarm menu and the new alarm is annunciated in the 24. Current Alarm menu. If an alarm of higher priority is then received, the original alarm will be bumped from the 25. Previous Alarm menu and eliminated from accessible memory. The LWC can only retain for display one current and one previous alarm. If the condition that caused the original alarm to occur is still present it reappears as alarms of higher priority clear. Note: All alarms except Loop Sensor Fail are self-clearing. Normal operation of the LWC depends upon a fully operational supply water sensor. When this fault occurs, the sensor/connection must be repaired or replaced and the alarm cleared before the LWC can allow any functioning mode. If the condition that caused such a self-clearing alarm ceases to exist the alarm will automatically silence and clear. To silence the Piezo buzzer alarm all that is required is to press the ALARMS key. This will silence the alarm horn and the yellow alarm LED will no longer blink. The current alarm will be shown in the display window. The use of a Remote Alarm Panel (RAP) offers the same alarm indication and alarm silence feature from a remote site. To clear an active alarm, perform the following: 1. Press the ALARMS key to display the current alarm. 2. Press the CLEAR key and the current alarm information changes to none and the cleared alarm condition is stored as the previous alarm and is displayed under the 25. Previous Alarm menu. If the same alarm condition is still present, the panel will immediately detect its presence again. So the act of clearing an alarm should only take place after the problem has been eliminated. Setup of Options In this section you will be programming the controller to meet your job specific needs. Many of the following programmable parameter decisions should have already been made. Please refer to your project's LWC Field Wiring Schematic submittal drawings for the appropriate information. Setting the Programmable Outputs Select menu 5. Control Mode. Confirm that this setpoint reads Manual Off. If it does not, change the setpoint to Manual Off for the setting of programmable outputs. The recalculation of programmable options does not occur unless the controller is in a Manual Off control mode. Select menu 22. Prog Outputs:. Remember that the maximum number of available outputs for the LWC-16 is 9 and the maximum number of available outputs for the LWC-24 is 17. The maximum number of heat rejection stages cannot exceed 12, the maximum number of heat addition stages cannot exceed 12, and the maximum number of time clock outputs cannot exceed 6. The programmable outputs are assigned to the panel in the following order: 1. Tower Control Valve Always uses 2 outputs. The first output is the valve drive close signal and the second output is the valve drive open signal. 2. Heat Rejection Stages Uses 1 output per stage. 3. Boiler Control Valve Always uses 2 outputs. The first output is the valve drive close signal and the second output is the valve drive open signal. 24 IM 431

25 4. Heat Addition Stages Uses 1 output per stage. 5. Time Clock Outputs Uses whatever outputs are remaining. Now enter the appropriate settings for your job per the following instructions, using the + or - keys to scroll through available selections. Use the Enter key to select your choice. Display Prompts What To Enter Unit Type LWC ** 16 for a LWC for a LWC-24 To determine which LWC you have, simply look at the top of the wiring schematic on the hinged door. Alternately, look at the number of terminals on the output board. An LWC-16 has 32 terminals and an LWC-24 has 48 (do not count the two power terminals). Tower Valve = *** Yes if you want the LWC panel to control a tower valve; otherwise enter No. (Valves will require two output connections.) #Heat Rej Stg = ** The number of heat rejection stages for your application. Boiler Valve = ** Yes if you want the LWC panel to control a boiler valve; otherwise enter No. (Valves will require two output connections.) #Heat Add Stg = ** The number of heat addition stages for your application. Reconfigure? = ** Enter Yes to instruct the LWC to reconfigure its outputs according to the information just entered. After entering Yes the panel will reconfigure the outputs and change this variable to No. If this does not happen, you forgot to put the panel in a Manual Off mode. Now that the programmable outputs have been identified, it is recommended that the panel wiring be checked to make sure it matches the programmed outputs. The next 17 items under 21. Prog Outputs menu identify what the programmable outputs are. Scroll through the outputs list and check them against the unit wiring to verify that all output definitions match the panel wiring. Setting Other Miscellaneous Setup Items Select menu 23. Misc Setup. Display Prompts What To Enter 2nd Pump Set = *** If you want to provide pump control for the tower pumps, enter TWR, if you want to provide pump control for the boiler, enter BLR. means there is no control of a second pump set. (You may only control one set of auxiliary pumps.) Dmpr I'lock = ** Enter Yes if you have wired the tower fan discharge damper proving switch to the LWC as heat rejection stage 1 and want to check for a closed switch signal prior to energizing additional heat rejection stages. Note that the default is Yes. If this feature is not necessary, wire a jumper between terminals 63 and 56 as an added safeguard. MicroTechJob = *** Enter Yes if LWC is connected via communications to a MicroTech network. When in a MicroTech network, the LWC will send alarm signals and receive start/stop commands from the Network Master Panel. Enter No if the LWC is not part of a MicroTech network and is functioning as a stand-alone controller. Heat Rejection Control Select menu 6. Heat Rej Spts and set the control setpoints per the following instructions: Display Prompts What To Enter Stage 1 = *** Supply loop temperature at which the LWC is to energize the heat rejection stage 1 output. Stage 1 Dif = * The differential for heat rejection stage 1. Differential is subtracted from the stage setpoint to determine the temperature at which the stage is turned off. The process of entering the heat rejection setpoints should be repeated for all heat rejection outputs as defined via the 22. Prog Outputs menu. IM

26 The heat rejection stage setpoints should always be entered in increasing order. That is, Stage 1 -< Stage 2 -< Stage 3... etc.... If you fail to enter the setpoints in ascending order, you effectively eliminate the stage which is out of sequence. The differential setpoints must be coordinated so that the following condition holds true: (Stage 1 Spt - Stage 1 Dif) -< (Stage 2 Spt - Stage 2 Dif) < (Stage 3 Spt- Stage 3 Dif)... etc... All twelve possible heat rejection setpoints are displayed even though you may have only defined a few of them. Just ignore the unused heat rejection stages. Display Prompt What To Enter Inter Stg T = Min or Sec The minimum time the controller will wait between stage changes for both heat rejection and heat addition. If you want to slow down the rate at which the LWC makes stage changes, increase this setpoint. If you want to increase the rate at which the LWC makes stage changes, decrease this setpoint. When changing between minutes and seconds a value of 0 Min occurs. Due to controller timing interpretation, this value-is translated to 2 minutes, not 0 minutes. Heat Addition Control Select menu 7. Heat Add Spts and set the control setpoints per the following instructions: Display Prompts What To Enter Stage 1 = *** Supply loop temperature at which the LWC is to energize the heat addition stage 1 output. Stage 1 Dif = * The differential for heat addition stage 1. Differential is added to the stage setpoint to determine the temperature at which the stage is turned off. The process of entering the heat addition setpoints should be repeated for all heat addition outputs as defined via the 22. Prog Outputs menu. The heat addition stage setpoints should always be entered in decreasing order. That is, Stage 1 >- Stage Stage 3... etc... If you fail to enter the setpoints in descending order, you effectively eliminate the stage which is out of sequence. The differential setpoints must be coordinated so that the following condition hold true: (Stage 1 Spt + Stage 1 Dig -- (Stage 2 Spt + Stage 2 Dif) >. (Stage 3 Spt +Stage 3 Dif)... etc. All twelve possible heat addition setpoints are displayed even though you may have defined only a few of them. Just ignore the unused heat addition stages. Display Prompts What To Enter O.A. Reset = *** Yes if you want to reset the heat addition setpoints as the outdoor air temperature drops. No reset will take place at an OAT of 60 F and the maximum reset will take place at 0 F. Max. O.A.Reset = *** Enter the maximum number of degrees you want to reset the heat addition setpoints when the OAT is 0 F. Service Setpoints Select menu 8. Alarm Spts and set the control setpoints per the following instructions: Display Prompts HiTempShutDn = *** HiTempSDHeat = *** What To Enter Supply loop temperature at which the LWC energizes the emergency shut-down output. This output may be wired to the heat pumps with Mark IV controls to shut down all compressor operation. This setpoint is for MicroTech control systems only and is the supply loop temperature at which the LWC locks out heating operation of all MicroTech WSHP units. For non-microtech jobs the alarm will still sound. You may want to set this setpoint to the 26 IM 431