351579-YTS-C-0111 TECHNICAL APPLICATION AND PROGRAMMING GUIDE MILLENNIUM® SINGLE PACKAGE ROOFTOP UNITS 25, 30 & 40 TON EQUIPPED WITH SIMPLICITY® ELITE CONTROLS MILLENNIUM® 25-40 TON SINGLE PACKAGE COMMERCIAL ROOFTOP UNIT EQUIPPED WITH SIMPLICITY® CONTROLS This manual includes application, programming and service procedures for the Millennium® 25-40 Ton Single Package Commercial Rooftop Unit equipped with Simplicity® Controls.
351579-YTS-C-0111 TABLE OF CONTENTS MILLENNIUM® 25-40 TON SINGLE PACKAGE COMMERCIAL ROOFTOP UNIT EQUIPPED WITH SIMPLICITY® CONTROLS . . . . . . . . . . . . . . . . . . . . 1 RECOMMENDED TECHNICAL AND INSTALLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . 1 THE MILLENNIUM® SIMPLICITY® CONTROL . . . . 3 INTRODUCTION AND OVERVIEW . . . . . . . . . . . . . . . . . DIGITAL LINGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANALOG TO DIGITAL CONVERTER . . . . . . . . . . . . . . .
51579-YTS-C-0111 THE MILLENNIUM® SIMPLICITY® CONTROL INTRODUCTION AND OVERVIEW Welcome to the new Millennium® Simplicity® control, a digital control system designed specifically for the Millennium® 25 to 40 Ton single package rooftop unit. The Simplicity® is composed of 72 monitored and controlled input and output points.
351579-YTS-C-0111 alarms, it will overwrite the oldest alarm after the history buffer becomes full. depending on how long the sensed value remains away from its desired setpoint. Some system errors will initiate a controlling response as well as being stored in the error memory buffer. See the “Troubleshooting” chapter in this manual for a detailed description of how controller errors are handled.
351579-YTS-C-0111 EPROM - This is “nonvolatile” memory, meaning it will not be erased on a power loss. This memory is usually programmed prior to assembly of the controller. Since this memory is not changed during normal operation of the Simplicity® control, only basic operation instructions are stored in this type of memory. OPTIONAL Simplicity® LINC TRANSLATOR OVERVIEW EEPROM (Double “E” Prom) - Is also non-volatile, but this type of memory requires a special process to be written to.
351579-YTS-C-0111 monitoring and control. Much like we need a unique street address in our homes so we can receive our postal mail or emergency services, these units also need a unique address so the central Facilities Management System (FMS) can “talk” to each unit individually. The Simplicity® board has the model and serial number of the specific unit and has a memory space for a customer name to be applied.
351579-YTS-C-0111 ANALOG INPUTS (AI) Analog inputs require parameters that define the input’s characteristics. Attributes of an AI include the linear range, alarm limits, alarm differential, change of state (COS) enable, and filter weight. The input values may be overridden by a external system command or by using the input buttons on the Simplicity® board. This is useful to override current conditions to test certain control functions or modes.
351579-YTS-C-0111 thermostat. If a thermostat is installed on the system, these inputs are connected to the thermostat interface board just as are the cooling/heating calls. These inputs are connected through the Tstat Interface board directly to the respective binary inputs of the Controller. These signals are, however, each loaded with a resistor to maintain voltage levels and to prevent “floating” of signals.
351579-YTS-C-0111 Table 3: Simplicity® Control Inputs Name Range Resolution Precision Y1 18 - 30 VAC On - Off +/- .5 VAC Request for the first stage of Cooling (24 VAC sense) Tstat Screw Terminal Description Y2 18 - 30 VAC On - Off +/- .5 VAC Request for the second stage of Cooling (24 VAC sense) Tstat Screw Terminal Y3 18 - 30 VAC On - Off +/- .5 VAC Request for the third stage of Cooling (24 VAC sense) Tstat Screw Terminal Y4 18 - 30 VAC On - Off +/- .
351579-YTS-C-0111 Table 3: Simplicity® Control Inputs (Continued) Name Range Resolution Precision Demand Ventilation Input 0 - 10 VDC 0 - 2000 PPM of CO2 Description 1 PPM 20 PPM 1% Across Range Remote Control 0 - 10 VDC .05 VDC 0.01 Dirty Filter Switch (FILT) 18 - 30 VAC On - Off +/- .5 VAC Low Voltage Detection 12 - 35 VAC .1 VAC .5 VAC Return Air Humidity (RAH) 0 - 5 VDC0 - 100% RH .05 VDC1% RH .
351579-YTS-C-0111 SIMPLICITY® PROGRAMMING OPTIONS The paragraphs below provide a definition of, and specify the function related to, each of the parameters that are fieldadjustable using the interfaces available. The Millennium® Unit is shipped from the factory with the necessary options preprogrammed as indicated by the model nomenclature. It is always a good practice, though, to verify that the correct parameters are properly configured for the unit you are commissioning.
351579-YTS-C-0111 Power Exhaust - (ON) - This tells the control if it has the Power Exhaust option installed. Economizer Damper Position for Exhaust Fan to turn ON (Non-Modulating PE Only) - (60%) - This tells the control the Economizer Damper position to turn on the Exhaust Fan. This value is based on the 0%-100% output drive signal from the controller to the economizer damper actuator.
351579-YTS-C-0111 be turned off by turning off the RAH Sensor Enable option. Thus, the option setting is used to reflect the desired operation and mainly to control sensor failure alarms. Economizer Loading to Control SAT - (ON) - This tells the control if it is going to use Economizer Loading to control excessive SAT [supplying warmer outside air to keep SAT from going too low]. This parameter is only applicable outside the normal Economizer operation.
351579-YTS-C-0111 Heating Lockout on OAT - (75 °F) - This is the Outside Air Temperature Setpoint that the control will use to lock out Heating when the OAT is above this setpoint. There is a one-degree hysteresis on each side of the setpoint. This parameter is adjustable between 0 °F and 100 °F with the default set to 75 °F. Heating Lockout on OAT affects only staged heating, it does not affect hydronic heat.
351579-YTS-C-0111 Once the Unoccupied Override mode is initiated, it will continue until the programmed Unoccupied Override Time Limit is reached. The Override mode can not be cancelled by, for example, a change of state of the Occupied input to ON (occupied) and then back to OFF (unoccupied). This parameter is adjustable from 0 to 240 minutes. The default is 60 minutes. Fan Delays (ON) & (OFF) - Any time the control starts a compressor it will load the Fan On Delay for Cool with the programmed value.
351579-YTS-C-0111 Table 5: Settable System Parameters 16 Address Function 1 Run test 2 Fan on delay-Heating 3 Fan off delay-Heating 4 Unit Range Default ON-OFF OFF Sec 0-30 30 Sec 0-255 60 Fan on delay-Cooling Sec 0-30 0 5 Fan off delay-Cooling Sec 0-255 30 6 Factory setting - - 1 7 Suspend Cont Fan when starting Heating ON-OFF OFF OFF 8 Construction Mode - ON-OFF 9 Unoccupied Override Time Period Minutes 0-240 60 10 Occupied Cooling Setpoint °F 45-99 72
351579-YTS-C-0111 Table 5: Settable System Parameters (Continued) Address Function Unit Range Default 47 Exhaust Damper Position for Exhaust Fan to Turn Off (Modulating Only) % Of Damper Position 0-100 20% 48 Economizer Damper Position for Exhaust Fan to Turn On (Non-Modulating Only) % Of Damper Position 0-100 60% 49 Economizer Damper Position for Exhaust Fan to Turn Off (Non-Modulating Only) Percent of Economizer Position 0-100% 20% 50 APS Data Open-Closed Open-Closed Open Your Set
351579-YTS-C-0111 MILLENNIUM® SEQUENCE OF OPERATION OVERVIEW The Millennium® Simplicity® control has comprehensive rule sets to respond to heat and cool calls, provide anti-shortcycle and other safeties, date / time clock, and other features making the programmable thermostat unnecessary. The Millennium® Simplicity® extends on the rules of the Synthesys digital control. With an attached (optional) Room Sensor, the control provides calls for heating and cooling and occupied override.
351579-YTS-C-0111 2. Mechanical cooling stages have two monitoring circuits: low pressure and high pressure. They are connected to the control through the LPSx and HPSx terminals. These allow the control to track specific error alarms, and let the control energize the next available compressor. denser fan 1). On 25 ton units, condenser fan 2 (contactor 7M) is brought on by PS5 if discharge pressure on compressor 1 exceeds 280 psi R22 (360 psi R-410a).
351579-YTS-C-0111 9. Modulating Gas Heat Option: The modulating gas heat option uses a slave control, “MFC” Modulating Furnace Control, that receives the heat calls from the UCB and then controls up to 17 Steps of gas heat in a similar manner. 10. Electric Heat Option: The Millennium® Simplicity® control allows staging electric heat. On units with the Electric Heat Option, a call for heat (W1) will initiate the main supply fan.
351579-YTS-C-0111 determined by the status of the internal clock and the internal schedules. OCCUPIED / UNOCCUPIED / MORNING WARM-UP OCCUPIED In Occupied mode, all installed options enabled by the parameter settings are available. The supply fan is operated [controlled to the duct pressure setpoint if a VAV], optional unit heating is available at full capacity, the optional power exhaust system is enabled, the economizer outside air dampers go to their minimum position or open for free cooling.
351579-YTS-C-0111 (optional) are disabled, so cooling is disabled and the optional economizer outside air dampers are closed. energized, duct pressure control is activated. The optional power exhaust system is activated. 3. When the return air temperature climbs above the MWUP setpoint, heating is disabled, VAV and the economizer are enabled. 4. A call for first stage cooling initiates the cooling sequence. The optional economizer is enabled, and drives the damper to the minimum open position.
351579-YTS-C-0111 Pressure Switch - The pressure switch closes on a drop below a specific pressure. On a call for heat, the ICB checks the pressure switch for open state before it energizes the draft motor. If it is closed, then the ICB will lock out the furnace and flash a code (Table 7). If open, then the ICB will energize the draft motor and verify that the switch closes before initiating the purging and ignition sequence.
351579-YTS-C-0111 Table 8: Modulating Gas Heat Stages of Gas Control (% of Full Heat Output) Gas Heat Module 1 Gas Heat Module 2 Gas Heat Module 3 24 Gas Valve Signal for High and Low Fire Step Input Output % of Total Output LF1 HF1 LF2 HF2 1 69,333 55,466 26% Off Off On Off 2 106,666 85,333 40% Off Off On On 3 165,332 132,266 62% On Off On Off 4 202,665 162,132 76% On Off On On 5 229,332 183,466 86% On On On Off 6 266,666 213,333 100% On On On
351579-YTS-C-0111 Table 9: Modulating Gas Heat Control Board Flash Codes Flash Code Description Heart Beat Normal Operation 1 Flash Not Applicable 2 Quick Flashes Followed By Module Limit Switch Failure 1 Slow Flashes Module 1 Limit Switch 2 Slow Flashes Module 2 Limit Switch 3 Slow Flashes Module 3 Limit Switch 4 Slow Flashes Module 4 Limit Switch 3 Quick Flashes Followed By Module Gas Valve Failure 1 Slow Flashes Module 1 Gas Valve 2 Slow Flashes Module 2 Gas Valve 3 Slow Flashes M
351579-YTS-C-0111 Single Enthalpy: the control will consider, along with outside temperature, outside air humidity [OAH sensor; parameter must be set to ON] in enabling free cooling. The outside air enthalpy setpoint parameter [BTU per pound] must also be set. Dual Enthalpy (Comparative/Differential Enthalpy): Both the Outdoor Air Enthalpy and the Return Air Enthalpy [RAH sensor, option parameter must be set to ON] are connected to the control.
351579-YTS-C-0111 As the ambient temperature dips below 40 °F the 1 condenser fan will slow to the minimum speed. The circuit 2 condenser fan will disengage when the discharge pressure drops below 180 psi R22 (300 psi R410a) as the ambient temperature falls. The discharge pressure of system 1 and/or 2 will increase when condenser fan 2 stops, consequently causing an increase in the speed of condenser fan 1.
351579-YTS-C-0111 FAN DELAYS There are separate Fan ON and OFF delay periods for heating and cooling, to reduce the momentary change in SAT. COMFORT VENTILATION MODE Comfort Ventilation is a control mode that uses the economizer to modulate SAT. Where possible, the economizer will modulate the outside / return air mix to keep SAT within the upper and lower Comfort Ventilation setpoints.
351579-YTS-C-0111 mizer damper and using more outdoor air. However, if the economizer algorithm can not prevent the SAT from increasing above the top control band limit by closing the economizer damper to its programmed minimum position, one or more compressors may need to be turned on. Similarly, if the economizer algorithm can not prevent the SAT from dropping below the bottom control band limit by opening the economizer damper, one or more heating stages may need to be turned on.
351579-YTS-C-0111 modes are controlled by an internal time clock. If a thermostat is connected in addition to the space sensor, it takes priority over the space sensor. overrun time, or only the supply fan continues to operate (in case G=ON).
351579-YTS-C-0111 TYPES OF SPACE SENSORS No Sensor- The system will internally detect the presence of space sensors. Sensor with Unoccupied Override Button - This Sensor has a Thermistor and an Override button that shorts the Sensor when pushed. If the Override button is pushed the unit will go into the Unoccupied Override mode for the Unoccupied Override Time (note that the control must not recognize the short as a sensor failure).
351579-YTS-C-0111 first stage until the Space temperature reaches the Setpoint and then it will turn off the entire stage one compressor. If the unit starts with a demand greater than 2.0 °F, the control will stage up first stage and wait 5 minutes. The control will continue operating first stage until the Space temperature reaches the Setpoint and then it will turn off all the stage one compressors with a 30 second delay between them.
351579-YTS-C-0111 UNOCCUPIED HEATING WITH A THERMOSTAT This operation is identical to the Occupied heating, except the unit mode is in Unoccupied mode from the internal control Occupied/Unoccupied table. The economizer damper remains fully closed in the unoccupied mode. OCCUPIED COOLING WITH A THERMOSTAT In this mode, the control uses a thermostat for cooling and fan operation.
351579-YTS-C-0111 free cooling is available (economizer operation) and the other one for mechanical cooling only. First, when free cooling is available ("economizer suitable"), the SAT control algorithm is as described in the Economizer Operation section later in this document, except the programmed Economizer First Stage Setpoint and Economizer Second Stage Setpoint are replaced by the programmed VAV Upper Cooling SAT Setpoint and VAV Lower Cooling SAT Setpoint.
1579-YTS-C-0111 Table 12: Holiday Schedule Number Start Day Start Time of Days of Month Holiday Number Start Month Holiday 1 00 00 00:00 00 Holiday 2 00 00 00:00 00 Holiday 3 00 00 00:00 00 Holiday 4 00 00 00:00 00 Holiday 5 00 00 00:00 00 Holiday 6 00 00 00:00 00 Holiday 7 00 00 00:00 00 Holiday 8 00 00 00:00 00 Holiday 9 00 00 00:00 00 Holiday 10 00 00 00:00 00 Holiday 11 00 00 00:00 00 Holiday 12 00 00 00:00 00 Holiday 13 00 00 00:00 0
351579-YTS-C-0111 SAT CONTROL FOR COOLING This control has priority over any other zone temperature or SAT control and is used at all times, during CV as well as VAV operation. The Excessive SAT Control state is entered any time the SAT drops below the trip point of a compressor (as the trip points are programmed in an ascending sequence, the compressor that trips will always be the highest- numbered one).
351579-YTS-C-0111 The RAH sensor, if available in addition to the OAH sensor, allows use of Differential Enthalpy method for deciding on free cooling availability. See paragraphs OAH Sensor Enable and RAH Sensor Enable in Settable Parameters, Table 5 in this document. If the selected method is using an enthalpy, the enthalpy is calculated in the controller from sensed temperature and humidity of the respective air stream.
351579-YTS-C-0111 Turning on compressors #2 through #4: Economizer Loading Option If the economizer controller is saturated High (i.e. the economizer is 100% open while one or more compressors are running and the control can no longer maintain the active SAT setpoint requested by the zone control), This is a programmable option. The user has the ability to turn this function off. It is automatically disabled if the unit does not use an economizer.
351579-YTS-C-0111 for economizer loading arises in Communicating Zoning System applications (“VVT” systems) using supply air bypass when heating load in the zones is low and a large amount of hot supply air is bypassed back into return and mixed air temperature is very high. Economizer loading may also be needed when supply air flow across the heat exchanger is lower than expected (e.g. wrong setting of fan speed, plugged air filters).
351579-YTS-C-0111 programmed Maximum Economizer Position for Demand Ventilation. The algorithm is deactivated, and the previous, normal mode of economizer position control resumed when the IAQ level becomes 50 ppm lower than the setpoint.
351579-YTS-C-0111 time 60 seconds (Non-adjustable). With this type of control, the Power Exhaust fan cycle, as its operation directly influences the building static pressure that controls it. The cycling rate is limited by these minimum ON and OFF time settings. The Building Pressure Setpoint default is 0.100" w.g. does not need to rotate; the wheel will cycle on schedule to keep the air passages blown clean.
351579-YTS-C-0111 Table 13: Alarm Default Codes Code 42 Cause 1 Compressor number one locked out on High Pressure Control 2 Compressor number two locked out on High Pressure Control 3 Compressor number three locked out on High Pressure Control 4 Compressor number four locked out on High Pressure Control 5 Compressor number one locked out on Low Pressure Control 6 Compressor number two locked out on Low Pressure Control 7 Compressor number three locked out on Low Pressure Control 8 Compres
351579-YTS-C-0111 TROUBLESHOOTING A MILLENNIUM® Simplicity® CONTROL STATUS LED CHART The Status LED mounted on the controller PC board will flash specified flash patterns to indicate rooftop unit status. See Table 14.
to the active space temperature setpoint. If there is no RAT Sensor, the control will shut down all outputs. If the detected sensor failure is a short circuit, the error can be declared only if the short persists for several minutes, in order to distinguish a sensor failure from a short caused by somebody pushing on Unoccupied Override button. VAV operation: If the space temperature sensor fails, the control will continue normal function, only SAT reset from space temperature will be disabled.
