Carrier AquaEdge 17DA Application Guide PDF

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Summary of Content for Carrier AquaEdge 17DA Application Guide PDF

Carrier ChillerVu Variable Flow Condenser Pump CARRIER CORPORATION 2020

Application Guide i All rights reserved

Carrier ChillerVu Variable Flow Condenser Pump

Application Guide

CARRIER CORPORATION 2020 Catalog No. 11-808-577-01 12/17/2020

Verify that you have the most current version of this document from www.hvacpartners.com or

www.accounts.ivusystems.com or your local Carrier office.

Important changes are listed in Document revision history at the end of this document.

CARRIER CORPORATION 2020. All rights reserved throughout the world. i-Vu is a registered trademark of Carrier

Corporation. All other trademarks are the property of their respective owners.

Contents What is the Carrier ChillerVu variable flow condenser water pump application? ............................................ 1

Theory of operation .............................................................................................................................................. 3

Variable flow, headered condenser pump control sequence ................................................................................... 4 Points and Properties ........................................................................................................................................... 5

Manager Status ..................................................................................................................................... 5 Staging of pumps .................................................................................................................................. 6 Staging Trip Points and Delays ............................................................................................................. 7 Pump VFD Control - Differential Pressure Control Loop...................................................................... 7 Individual Pump Control - Configuration .............................................................................................. 9 Common CW Entering Temperature .................................................................................................. 10 Individual CW Flow Valve Control ....................................................................................................... 11 Individual Chiller Flow Configuration - Chiller Flow Meter ................................................................. 12 Individual Pump Control - Configuration ............................................................................................ 13

Variable flow, dedicated condenser pumps control sequence .............................................................................. 14 Points and Properties ........................................................................................................................................ 15

Manager Status ................................................................................................................................... 15 Common CW Entering Temperature .................................................................................................. 16 Individual Pump Control - Configuration - Pump Control .................................................................. 17 Individual Pump Control - Configuration - Pump VFD Control ........................................................... 18 Individual Pump Command Points - Configuration ............................................................................ 19 Optional Flow Meter Properties .......................................................................................................... 20

Document revision history ........................................................................................................................................ 21

Carrier ChillerVu Variable Flow Condenser Pump CARRIER CORPORATION 2020

Application Guide 1 All rights reserved

The variable flow condenser pump sequence, available for both headered and dedicated pump arrangements,

allows you to stage up to 8 VFD-equipped condenser water pumps.

NOTES

Each pump must be equipped with a flow check valve device (or 2-position isolation valve) to prevent reverse

flow through pumps that are not currently operating.

Currently, the dedicated pump sequence supports equal- or dissimilar-sized pumps. The headered version

supports only equal-sized pumps, but dissimilar-sized pump logic will be available in a future release.

What is the Carrier ChillerVu variable flow condenser water pump application?

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Application Guide 2 All rights reserved

CAUTION You can use the following applications and equipment files with the Carrier ChillerVu controller

ONLY.

You can find detailed information on the capabilities of the Carrier ChillerVu hardware in the Carrier

ChillerVu Installation and Start-up Guide (#11-808-532-01).

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Application Guide 3 All rights reserved

Theory of operation

This theory of operation is based on the fact that condenser water Delta temperature (Delta T) across the

condenser barrel varies with the water flow rate through the condenser barrel.

The Variable Flow Condenser Loop Pump sequence saves condenser pump energy by reducing condenser

water flow through the chiller as machine load decreases.

Each chiller will have a design Delta T that represents the temperature rise through the condenser at full load

and the design condenser water flow rate. Varying the water flow rate as the load decreases, so that the

Delta T is maintained at the design value, can reduce pump energy consumption, while allowing the machine

to operate within its specified design parameters for heat rejection. You can set minimum and maximum

pump speeds and/or flow rates to ensure that maximum flow rate is never exceeded and a minimum flow

rate is maintained.

Example A machine with a 10F water temperature rise across the condenser barrel, under design

conditions, might only have a 5F rise at 50% load, if condenser water flow remains constant. By reducing

the condenser water flow in response to reduced Delta T, and causing it to increase to the original design

delta T of 10F, directly reduces pump energy consumption.

The system is designed to operate independently of tower control logic. During design conditions with high

outdoor wet bulb temperatures and high entering condenser water temperatures, the system has a safety

override that controls the pump VFD to maintain a maximum leaving condenser water temperature setpoint,

if the entering water temperature plus the delta T exceeds this value.

This causes the VFD to operate at higher speeds when the entering water is very high, or greater than the

allowable limit according to the machine design, and permits maximum flow through the condenser barrel,

until the leaving water temperature is brought down below the maximum setpoint. Once the entering

condenser temperature is below the specified high limit, the pumps' speeds and/or flow control valves will

again modulate to maintain the Delta T setpoint.

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Control sequence

1 The associated Chiller Manager (CM) program is linked to the Condenser Pump Manager (CPM) program

using a network point.

2 When chilled water is required, the CM signals the CPM, indicating how much condenser water flow is

required.

3 The CPM, based on the available capacity of its condenser pumps, starts the required number of pumps to

satisfy the CMs flow requirements. You can configure the run order and rotation behavior of the pumps.

4 Once the pumps are started, the VFD control sequence is enabled, which operates the pumps in unison to

maintain the required Delta P across the entire condenser system.

5 The 2-way, modulating flow control valve on each condenser inlet is regulated to maintain a target design

condenser Delta T for each chiller system.

6 If present, the optional flow meter on each branch will be used to set a minimum and maximum flow rate and

override the flow control valve output.

Variable flow, headered condenser pump control sequence

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Application Guide 5 All rights reserved

Points and Properties

The following pages show the drop-down sections on the Properties > Control Program tab in the i-Vu interface.

Most of the properties are self-explanatory, however, certain key features, functions, and specific parameters are

defined.

The properties are shown in the order that they appear in your i-Vu interface. Properties that are not unique to

this application, such as Rotation and Reset, are omitted.

The CPM program can support a maximum of 8 condenser pumps. This document shows 1 example of each

properties section, since pumps 2 through 8 are the same.

Manager Status

Manager Status provides a status matrix and the option to enable or disable the pump manager.

When Enable Pump Manager is Yes, the program controls the pumps as shown.

When No, all pumps are disabled.

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Staging of pumps

Required Flow from Chiller Mgr the required flow value linked to the CMP from the CM

The maximum flow rate for EACH pump is __ gpm you can specify the maximum flow rate available from

each pump, resulting in the sequence calculating the maximum system flow rate available, based on the

number of pumps.

Requested number of pumps is: indicates the requested and actual number of running pumps

Lock number of pumps to run to __: locks the sequence to operate a specific number of pumps

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Staging Trip Points and Delays

Displays the status and delays of the lead pump and first lag pump.

Stages 3 through 8 are listed in sequence.

Pump VFD Control - Differential Pressure Control Loop

The pump VFDs are controlled in unison to maintain the differential pressure setpoint you enter. The Delta P is

measured across the system headers.

VFD control parameters:

Diff Pressure setpoint

VFD Minimum Output speed

Control Output Override override values

High Differential Pressure Protection setpoints and actions

Alarms settings for the VFD control

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Application Guide 9 All rights reserved

Individual Pump Control - Configuration

These properties display each pump's operational status data with values you can configure.

Pump Maintenance Mode

Normal - pump remains under the control of the CPM program

Maintenance - pump is no longer under the control of the CPM program

Re-enable - re-starts operation

Convert the PID values in the range sets the scaling of the VFD output to match the prevailing frequency (50Hz

or 60Hz)

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Application Guide 10 All rights reserved

Common CW Entering Temperature

The key parameter in this section is the maximum entering condenser water temperature, which is used to

override the Flow Control Valve Output to 100%.

The maximum Flow Control Valve Output is overridden to 100% when the entering condenser water sensor

exceeds the high temperature limit the you specify.

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Application Guide 11 All rights reserved

Individual CW Flow Valve Control

Chiller 1 CW Flow Valve Control

The CW Flow Valve Effective Minimum and Maximum Position Setpoints only show if you select the optional Flow

Meters at build time.

The settings and status values related to the flow control valve for each condenser are displayed. If no flow meters

are installed, you can set a minimum valve position so that minimum flow is maintained during startup and low

loads.

You can set the following:

Delta Temperature Setpoint The Delta T is calculated from the common condenser entering water setpoint

and the individual condenser water leaving temperature.

CW Flow Valve Minimum Position Setpoint use when Flow Meters are not installed

CW Flow Valve Maximum Position Setpoint use when Flow Meters are not installed

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Application Guide 12 All rights reserved

Individual Chiller Flow Configuration - Chiller Flow Meter

You can select flow meters in EquipmentBuilder when making your control program. If you have not selected

them, this property section is absent.

If you use flow meters, the CPM calculates minimum and maximum flow valve positions, based on the measured

flow and the minimum and maximum flow setpoints you define.

The value that is assigned to the flow control valve will be:

The larger of the calculated minimum or your defined minimum flow value

The smaller of the calculated maximum or your defined maximum flow value

IMPORTANT

We highly recommend that when using flow meters, you set the Maximum Valve position to 100% and the

Minimum Valve Position to 10% to make sure that the condenser water flow values are used and not

overridden by the configured valve position limits.

You must set the Minimum and Maximum CW Flow Setpoint values in accordance with the chiller design

specifications, to ensure that acceptable levels of flow are always maintained whenever a chiller is operating.

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Application Guide 13 All rights reserved

Individual Pump Control - Configuration

All input and output points for the individual pumps are displayed and available as hardware or network points.

NOTE The Chiller Enable point provides chiller status to the CPM and should be connected to a point in the

system that can provide individual Chiller Run Status.

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Application Guide 14 All rights reserved

NOTES

The variable flow, dedicated condenser pump sequence is a simplified version of the Variable flow, headered

condenser pump control sequence (page 4).

Run order or rotation logic is not necessary because the sequence requires dedicated pumps (each pump is

directly linked to a specific chiller). Also, the associated Chiller Manager does not need to send flow

requirements to the Condenser Pump Manager.

Each pump must be equipped with a flow check valve device or a 2-position isolation valve to prevent reverse

flow through pumps that are not currently operating.

If you have specified optional flow meters, the configuration screens are shown at the end of this document.

Control Sequence

1 The associated Chiller Manager (CM) program is linked to the Condenser Pump Manager (CPM) program

using network or hardware points.

2 When the CM needs to start a chiller, the logic enables the corresponding Run Pump point, followed by

enabling the corresponding condenser pump.

3 Once a pump is started, the associated VFD control sequence is enabled, which operates the pump to

maintain your defined condenser Delta T.

NOTE Each chiller/pump pair operates independently.

4 For systems equipped with flow meters, you can specify minimum and maximum flow settings. These values

override the VFD settings selected by the temperature control logic. This ensures that minimum and

maximum flow values are never exceeded.

Variable flow, dedicated condenser pumps control sequence

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Application Guide 15 All rights reserved

Points and Properties

The following pages show the drop-down sections on the Properties > Control Program tab in the i-Vu interface.

Most of the properties are self-explanatory, however, certain key features, functions, and specific parameters are

defined.

The properties are shown in the order that they appear in your i-Vu interface. Properties that are not unique to

this application, such as Rotation and Reset, are omitted.

The CPM program can support a maximum of 8 condenser pumps. This document shows 1 example of each

properties section, since pumps 2 through 8 are the same.

Manager Status

Manager Status provides a status matrix and the option to enable or disable the pump manager.

When Enable Pump Manager is Yes, the program controls the pumps as shown.

When No, all pumps are disabled.

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Application Guide 16 All rights reserved

Common CW Entering Temperature

The key parameter in this section is the maximum entering condenser water temperature, which is use to override

the VFD Output to 100%.

The maximum VFD Output is overridden to 100% when the entering condenser water sensor exceeds the high

temperature limit that you specify.

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Application Guide 17 All rights reserved

Individual Pump Control - Configuration - Pump Control

These properties display each system pump's operational status data and values you can configure.

Pump Maintenance Mode

Normal - pump remains under the control of the CPM program

Maintenance - pump is no longer under the control of the CPM program

Re-enable - re-starts operation after failure

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Application Guide 18 All rights reserved

Individual Pump Control - Configuration - Pump VFD Control

In the Pump VFD Control parameters, you can configure settings that relate to the VFD control sequence,

including Delta T setpoint, and minimum and maximum output values. You must set the minimum and maximum

output values in accordance with the chiller design specifications to ensure that acceptable levels of flow are

always maintained whenever a chiller is operating.

Set the scaling of the VFD output to match the prevailing frequency (50hZ or 60hZ).

The settings are available in this properties section when flow meters were not selected in EquipmentBuilder.

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Application Guide 19 All rights reserved

Individual Pump Command Points - Configuration

All input and output points for the individual pumps are displayed and available as hardware or network points.

NOTE The Run Pump point provides a pump start to the CPM and should be connected to a point in the system

that signals the start of the corresponding condenser pump. On chillers with local pump control, a hardware or

network point typically starts the condenser pump.

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Application Guide 20 All rights reserved

Optional Flow Meter Properties

When optional flow meters are specified, the Pump VFD Control section replaces the previous page, and a new

Properties section for the actual flow meter is added to the program. This includes information relating to the flow

meter min/max flow override sequence.

IMPORTANT

We highly recommend that when using flow meters, you set the Maximum VFD Speed Setpoint to 100% and

the Minimum VFD Speed Setpoint to 10% to make sure that the condenser water flow values are used and

not overridden by the configured valve position limits.

You must set the Minimum and Maximum CW Flow Setpoint values in accordance with the chiller design

specifications, to ensure that acceptable levels of flow are always maintained whenever a chiller is operating.

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Application Guide 21 All rights reserved

Important changes to this document are listed below. Minor changes such as typographical or formatting errors are not

listed.

Date Topic Change description Code*

6/20/19 Entire book. Removed "Proprietary and Confidential" from the footer C-D

10/5/16 Common CW Entering Temperature -

Headered

Calrified explanation. X-AE-BL-E

Common CW Entering Temperature -

Dedicated

Screen capture corrected and text changed to reflect that

dedicated pumps do not have a flow control valve.

X-AE-BL-E

* For internal use only

Document revision history

CARRIER CORPORATION 2020 Catalog No. 11-808-577-01

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