Design Envelope

IPC 9521

ipc 9521 Sequence of operation
File No: 90.912 Name plate
Date: december 15, 2014 5x3
Supersedes: new
Date: new
RJ-45 Port
 Design Envelope
seq u en ce of oper at ion ipc 9521

list of abbreviations: 1 gener al sequence

adj: Field Adjustable 1.1 When the ipc9521 control system is set to Remote Start,
bas: Building Automation System two conditions are required to turn On the control system:
hmi: Human Machine Interface a command from the bas (digital input from ipc3500
or serial communication signal) and the ipc switch set
to Enable.
ipc 9521 control system 1.2 When the ipc9521 control system is set to Local Start, the
The ipc9521 is comprised of two control panels (ipc9521 & ipc will turn On as soon as the ipc switch is set to Enable.
itc3600) with the following functionality:
1.3 On both conditions (Remote and Local Start), the ipc will
• Operation of up to 5 chilled water pumps and up to 5 con- turn Off when the ipc switch is set to Off.
denser water pumps, (Single, DualArm or Twin). Configura- 1.4 Emergency shutdown: if a refrigerant leak is detected or
tion can be Headered or Dedicated (only Dedicated configu- if the Emergency Stop push button is pressed, all operat-
ration is available for DualArm and Twin pumps), and one ing chillers, pumps and fans are immediately stopped. An
pump can be selected as stand-by. alarm is issued (Refrigerant Leak alarm or Emergency
• Optional sensorless pump speed control for both set of Stop pressed), and the ipc is locked out of operation until
pumps and Parallel Sensorless™ sequencing if headered. manually reset.
• Control of up to 5 chillers.
1.5 The operator is able to force the plant to be always en-
• Control of up to 5 cooling tower fans. abled from the hmi.
• Monitoring of up to 5 zones.
1.6 The bas is also able to enable/disable the plant overriding
• i/o interface to chilled water pumps and chillers, condenser the ipc9521 logic.
pumps, cooling tower fans and sensors is capable of basic
standalone operation and graphic interface, in case the main 1.7 Once the ipc is On, the lead chiller isolation valve is
cpu becomes unavailable. opened and the lead chilled water pump is started.

• Software and firmware upgrades don’t require shutting 1.8 But the lead chiller is not started if the difference between
down the plant. supply set point and return temperature indicates there is
• Touch screen hmi with graphical displays of the control sys- little or no load.
tem, trends and configuration with three levels of password 1.9 Even if no chillers are running, as long as the ipc is enabled
protection. one distribution pump is kept running to circulate water.
• Option to control pumps, chillers and Chilled Water Set The pump speed is determined to maintain the differential
point from optimization module (Opti-Visor). pressure or temperature of up to 5 zones at or above set
• bas interface for Modbus rtu, Modbus tcp, BACnet ms/tp, point, or by SensorlessTM control.
BACnet ip or Lonworks. 1.10 The bypass valve regulates its position to maintain the
flow above one chiller minimum flow.

oper ation 1.11 The Chilled Water Set point can be determined by
3 options:
All equipment must be set in Auto mode for the plant to work
as described below. However, any individual equipment can be 1.11.1. Fixed (44°f adj.), manually entered on the hmi
set to Hand or Off mode. Any equipment in Hand or Off mode 1.11.2. Calculated based on the outdoor air temperature
is not operated by the automatic sequencing of the plant. Any
1.11.3. Written by an external optimization module or the bas
pump placed in Hand mode starts immediately as long as the
ipc is On. Any chiller placed in Hand mode immediately initi- 1.12 If the Supply Temperature climbs 1.5°f (adj.) over the
ates its startup sequence as long as the ipc is On. Any valve Chilled Water Supply Temperature Set point, the ipc starts
placed in Hand mode allows the operator to select its position: a chiller.
open or close. If any equipment or sensor malfunctions, an 1.13 The plant load (in % and Tons or kWR) is shown in the
alarm is time stamped and logged in the hmi and made avail- hmi. The ipc uses this value to optimally Stage On and
able to be read by the bas. Off chillers.
 Design Envelope
ipc 9521 sequ ence o f o p er a ti o n

1.14 To use ashrae 90.1 pressure reset, the position of the time elapses, the chiller status changes to ready and it is
most open cooling valve must be provided by the bas. incorporated into the sequencing.
Pressure/ temperature set points are then adjusted to 3.10 After a chiller is staged On or Off, no more chillers are
maintain this position at 95% open (adj.) staged until the time interval after chiller staging (10 min
adj.) expires.
2 chilled water pumps
3.11 Chillers are kept running for at least their minimum run
2.1 The ipc can operate up to 5 chilled water pumps. Pump time (10 min adj.), unless safeties require to stop them.
type can be single, DualArm or Twin. Their configuration
3.12 At any given time, the ipc maintains flow between the
can be headered or dedicated and, when it’s headered, 1
minimum and maximum required by the number of
pump can be selected as stand-by. Note: DualArm and
chillers running.
Twin pumps can only operate in dedicated configuration.
2.2 The pumps are rotated periodically to balance their 4 chilled water bypass and evapor ator
run hours. isolation valves
2.3 Pumps in alarm are skipped by the sequencing logic and
4.1 The chilled water bypass valve is controlled to maintain
locked out of operation until manually reset.
the minimum flow required by the running chillers.
2.4 Dual Arms are staged based on flow demand.
4.2 If the flow meter fails, the bypass valve will open, until the
2.5 Pump speed can be selected to be determined by Zone alarm is reset.
demand sensors (differential pressure or return water
4.3 The isolation valves open and close feedback can be
temperature), Sensorless Control or an External com-
enabled or disabled. If the open or close feedbacks are not
mand. In case of sensor fault, the speed is determined by
detected when expected, an alarm will be issued.
safety constrains.
2.6 In an emergency shutdown, all operating pumps are 5 condenser water pumps
stopped immediately.
5.1 The ipc9521 can operate up to 5 condenser pumps. Pump
type can be single, DualArm or Twin. Configuration can
3 chiller oper ation
be headered or dedicated and, in the case of headered,
3.1 The ipc can control up to 5 chillers. 1 pump can be selected as stand-by. Note: DualArm and
3.2 Once the plant is enabled and there is enough cooling Twin pumps can only operate in dedicated configuration.
demand, the Lead chiller is enabled. 5.2 The total condenser flow is determined by either a flow
3.3 The Lead chiller is rotated periodically. sensor, the condenser pumps Sensorless flow readings, or
3.4 Chillers in alarm are skipped by the sequencing logic and a heat balance.
locked out of operation until manually reset. 5.3 The condenser pumps speed is controlled to maintain the
3.5 The ipc stages On the chillers based on load, high supply total condenser flow at the design value of the running
temperature, high flow, high current and high kW. chillers, unless the condenser pumps are dedicated and
sensorless capable, in which case each pumps is con-
3.6 The ipc stages Off the chillers based on load, low return
trolled to maintain its flow at the design flow of its associ-
temperature, low flow, low current and low kW.
ated chiller.
3.7 Alternatively, if the user selects control from the optimiza-
tion module, the number of chillers to operate is deter- 5.4 If control from an optimization module is enabled, the ipc
mined by the module, overriding the ipc logic. condenser pump control is overridden.

3.8 Before a chiller is staged On, to prevent freezing the run- 5.5 Condenser pump speed is limited by the minimum and
ning chillers, their capacity is reduced via their demand maximum limits entered at the hmi.
limit input or by reducing the primary flow.
3.9 After a chiller is staged Off, it is kept out of the sequenc- 6 cooling towers
ing and its status is changed to Not ready, for the mini- 6.1. The ipc9521 can operate up to 5 cooling towers with 1 fan
mum time between chiller restarts (5 min adj.). After this drive each.
 Design Envelope
seq u en ce of oper at ion ipc 9521

6.2 When the lead chiller is enabled and the condenser water 7.1.21 Pump, Fan and chiller hours of operation, as well as
temperature exceeds the minimum the chiller can take, button to reset them
the lead tower fan is enabled.
7.2 Alarm Screens
6.3 The number of tower fans running is selected to match the
7.2.1 Alarms with time stamp
number of running chillers.
7.2.2 Alarm help
6.4 The ipc9521 stops all fans if the condenser water tempera-
ture drops below the minimum the chillers can take. 7.2.3 Alarm history

6.5 If all the fans fail, an emergency plant shutdown is initi- 7.2.4 Diagnostic screen indicating firmware and station
ated. version

6.6 Make up and the blowdown water volumes are measured. 7.2.5 Alarm silencer button or digital input (from
ipc3500) acknowledges alarms and silences horn
7 hmi. information to be displayed is divided in 7.3 Setup Screens. There should be three levels of access:
four categories:
7.3.1 Level 0. No password, allows view only access
7.1. Operator screens 7.3.2 Level 1. Operator use, allows changing the hoa
7.1.1 Source of control: Local or Remote mode of pumps and chillers and HA mode of
valves. Allows changing Local and Remote, turning
7.1.2 ipc9521 Status: On/Off
On and Off the ips and resetting alarms.
7.1.3 System overview graphic. This display adjusts to
7.3.3 Level 1. Allows operator use and modification of
the selected configuration (i.e. number of pumps,
all parameters. Allows Restoring previously saved
number of chillers, piping configuration, number of
values (no saving)
zones, number of towers)
7.3.4 Level 2. Allows operator use and modification of all pa-
7.1.4 Plant enabled/disabled indicator
rameters. Allows saving and restoring all parameters
7.1.5 Chilled water temperature set point
7.4. Trends
7.1.6 Chilled water supply and return temperatures
7.1.7 Condenser water leaving and entering temperatures 7.4.1 Temperature sensors

7.1.8 Primary and condenser (if enabled) flow 7.4.2 Zone Sensors

7.1.9 Plant efficiency 7.4.3 Load

7.1.10 Pump information: Running/Off/Alarm, Duty 1, 7.4.4 chw and cw Pump speed
Duty 2, Stand-by, etc. 7.4.5 Fan speed
7.1.11 Pump control: hoa switch, Set as Duty 1 button 7.4.6 Chiller & pump kW consumption
7.1.12 Fan control: hoa switch 7.4.7 Plant efficiency
7.1.13 Pump vfd information: Speed, Amps, Power, Volts
ac, head & flow 8 bas
7.1.14 Fan vfd information: Speed, Amps, Power, Volts ac 8.1 The ipc9521 will allow communication by any of the fol-
7.1.15 Chiller Information: Ready/Enabled/Started/Run- lowing protocols: Modbus rtu, BACnet ms/tp, BACnet ip,
ning/Shutdown/Alarm/Not Ready, Lead, Lag1, etc. BACnet Ethernet and Lonworks.

7.1.16 Chiller control: hoa switch, Set as Lead button 8.2 The following points will be available through all protocols:
7.1.17 Chiller Isolation valves status: Open/Close/Alarm, 8.2.1 Remote Start/Stop
Hand/Auto (for a header system only) 8.2.2 ipc9521 On/Off Status
7.1.18 Cooling tower Isolation valve status: Open/Close/ 8.2.3 Enable/Disable plant
Alarm, Hand/Auto
8.2.4 Chilled water supply and return temperatures
7.1.19 Bypass valve status: Hand/Auto, percent opening
8.2.5 Condenser water leaving and entering temperatures
7.1.20 All enabled zones present value, set point and
8.2.6 Chilled water and condenser flow
error. Indication of which one is the active zone
 Design Envelope
ipc 9521 sequ ence o f o p er a ti o n

8.2.7 chw & cw Pump information: Running/Off/Alarm,

hoa switch, Duty 1, Duty 2, Stand-by, etc.
8.2.8 Fan information: Running/Off/Alarm, hoa switch
8.2.9 chw & cw Pump vfd information: Speed, Amps,
Power, Volts ac, Head, Flow.
8.2.10 Fan vfd information: Speed, Amps, Power, Volts ac
8.2.11 Chiller Information: Ready/Enabled/Running/Shut-
down/Alarm/Not Ready, hoa switch, Lead, Lag1,
etc.
8.2.12 Chiller Isolation valve status: Open/Close/Alarm,
Hand/Auto
8.2.13 Cooling tower isolation valve status: Open/Close/
Alarm, Hand/Auto
8.2.14 Bypass valve status: Hand/Auto, percent opening
8.2.15 All zones present value, set point and error. If a
zone is not enabled the error should show 999.9
8.2.16 Active Zone present value, set point and error
8.2.17 Pump, fan and chiller hours of operation
8.2.18 Position of the cooling valve with the maximum
opening
8.3. The ipc has the following Digital Outputs for bas alarms
(through ipc3500):
8.3.1 Sensor Alarm (any sensor alarm)
8.3.2 General Alarm (any alarm in the ipc)
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