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Honeywell W7100G - User Manual

Honeywell W7100G
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PRODUCT DATA
® U.S. Registered Trademark
Copyright © 2001 Honeywell • All Rights Reserved 63-4046—1
W7100G
Discharge Water
Temperature Control
APPLICATION
The microprocessor-based W7100G Discharge Water
Temperature Control maintains an average discharge
water temperature for reciprocating chiller applications, by
staging on and off compressors or unloaders as required.
The W7100 can provide up to 10 stages of cooling using a
W7101 Satellite Sequencer.
FEATURES
Up to six stages of cooling provided.
Expandable system up to 10 cooling stages using a
W7101.
Advanced proportional plus integral microprocessor
control algorithm minimizes droop.
Soft start to minimize compressor cycling during
system start up.
Adjustable minimum on/off timing and time delay
between stages of either 30 or 60 seconds.
Adjustable setpoint from 10 to 110°F (-12 to 43°C).
Adjustable reset differential from 5 to 20°F (3 to 11K).
Adjustable control band from 0 to 10°F (0 to 6K).
Reset signal from either an outdoor air or space
sensor.
C7170 sensor can be used for sensing water
temperature.
LED show which stages of cooling are energized.
Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Ordering Information ........................................................ 2
Installation ........................................................................ 3
Operation .......................................................................... 6
Settings and Adjustments ................................................. 8
System Checkout ............................................................. 9
Troubleshooting ................................................................ 10
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Summary

Features

Application

Specifications

Additional System Components

Lists system components required for proper operation of the W7100G.

Accessories

Lists optional accessories available for the W7100G controller.

Ordering Information

Installation

Location and Mounting

Guidance on selecting a location and physically mounting the controller.

Wiring

Details the W7100G wiring and hookup diagram for system connections.

Changing Number of Controlled Stages

Explains how to configure the controller for a specific number of cooling stages.

Operation

Discharge Water Temperature Control Operation

Describes the W7100G's control logic for stable discharge water temperature.

Reset of Discharge Water Temperature

Discusses adjusting setpoints based on space or outdoor air conditions.

Space Reset Algorithm

Illustrates the algorithm for setpoint reset based on space temperature readings.

Outdoor Resets

Covers using outdoor air temperature for setpoint reset and associated wiring.

W7100 LED Operation

Explains the function and meaning of the W7100 controller's status LEDs.

Reset Modifications

Details methods to adjust outdoor air reset start/stop temperatures using resistors.

Settings and Adjustments

Setpoint Knob

Provides typical setpoint ranges for HVAC and industrial applications.

Reset Knob

Offers recommendations for reset ranges in HVAC applications.

Control Band Knob

Explains how to set the control band for optimal system response and stability.

Fast Response Input

Details jumper settings to select minimum ON/OFF timings (30 or 60 seconds).

Number Of Stages

Instructs on selecting and installing resistors to define the number of controlled stages.

System Checkout

Troubleshooting

Summary

Features

Application

Specifications

Additional System Components

Lists system components required for proper operation of the W7100G.

Accessories

Lists optional accessories available for the W7100G controller.

Ordering Information

Installation

Location and Mounting

Guidance on selecting a location and physically mounting the controller.

Wiring

Details the W7100G wiring and hookup diagram for system connections.

Changing Number of Controlled Stages

Explains how to configure the controller for a specific number of cooling stages.

Operation

Discharge Water Temperature Control Operation

Describes the W7100G's control logic for stable discharge water temperature.

Reset of Discharge Water Temperature

Discusses adjusting setpoints based on space or outdoor air conditions.

Space Reset Algorithm

Illustrates the algorithm for setpoint reset based on space temperature readings.

Outdoor Resets

Covers using outdoor air temperature for setpoint reset and associated wiring.

W7100 LED Operation

Explains the function and meaning of the W7100 controller's status LEDs.

Reset Modifications

Details methods to adjust outdoor air reset start/stop temperatures using resistors.

Settings and Adjustments

Setpoint Knob

Provides typical setpoint ranges for HVAC and industrial applications.

Reset Knob

Offers recommendations for reset ranges in HVAC applications.

Control Band Knob

Explains how to set the control band for optimal system response and stability.

Fast Response Input

Details jumper settings to select minimum ON/OFF timings (30 or 60 seconds).

Number Of Stages

Instructs on selecting and installing resistors to define the number of controlled stages.

System Checkout

Troubleshooting

Overview

The Honeywell W7100G Discharge Water Temperature Control is a microprocessor-based device designed to maintain an average discharge water temperature for reciprocating chiller applications. It achieves this by staging on and off compressors or unloaders as required. The W7100G can manage up to six stages of cooling independently and can be expanded to control up to ten stages when used with a W7101A Satellite Sequencer.

Function Description:

The W7100G utilizes an advanced proportional-plus-integral (PI) microprocessor control algorithm to minimize temperature droop, ensuring precise and stable temperature control. It employs an integrating control band concept, which matches the required operating capacity to the chiller load and minimizes offset from the control setpoint. This control band is adjustable from 0 to 10°F (0 to 6°C) and is centered on the discharge water setpoint, allowing for stabilization of system operation.

The controller features a soft start function to reduce compressor cycling during system startup. It also offers adjustable minimum on/off timing and time delay between stages, configurable for either 30 or 60 seconds. These timings are crucial for protecting compressors from damage due to short cycling.

The W7100G's setpoint is adjustable from 10 to 110°F (-12 to 43°C). It supports a reset function for the discharge water temperature setpoint, which can be based on either space or outdoor air temperatures. This reset function, adjustable from 5 to 20°F (3 to 11K), helps save energy under lighter loading conditions by adjusting the setpoint upward as average space temperature drops or downward as outdoor air temperature rises. For space reset, multiple sensors (e.g., T7047C1025) can be used to measure average space temperature, with the reset potentiometer set at the lowest desired cooling temperature. Outdoor air reset (using a C7031G1016 sensor) adjusts the setpoint based on outdoor air temperature, with modifications possible using series and parallel resistors to define T-High (no reset) and T-Low (full reset) points.

The number of controlled stages is determined by a fixed resistor value placed across terminals 7 and 8 on the W7100G. This resistor informs the controller of the total number of cooling stages to be managed, influencing its control behavior. LED indicators on the W7100G light up simultaneously with the energization of each stage relay, providing visual feedback on system operation.

Important Technical Specifications:

  • Input Voltage and Frequency: 20 to 30 Vac at 60 Hz; 20 to 26.4 Vac at 50 Hz.
  • Power Consumption: Device: 12 VA at 24 Vac and 50 to 60 Hz. On/Off Stages (Cool 1-6) vary from 40 VA to 750 VA inrush and 30 VA to 75 VA running, depending on voltage (24 Vac or 120/240 Vac) and contact type (N.O. or N.C.).
  • Switching: SPDT relays.
  • Wiring Terminals: 1/4 inch quick-connect.
  • Sensor Input Signal: Positive temperature coefficient, 4.8 ohms/°F (2.6 ohms/°C). Resistance: 3484 ohms at 77°F (25°C). The C7170A1010 Discharge Water Sensor is used for water temperature sensing.
  • Temperature Ratings: Ambient: -40°F to +150°F (-40°C to +66°C). Shipping: -30°F to +150°F (-34°C to +66°C).
  • Humidity Rating: 5 to 90 percent RH noncondensing.
  • Mounting: Four mounting holes in base for No. 6 screws.
  • Approvals: Underwriter's Laboratories Inc. Component Recognized.
  • Additional System Components: Requires a 24 Vac transformer (sized to system load). Can be expanded with a W7101A Satellite Sequencer for up to 10 stages. Supports T7047C1025 Remote Temperature Sensors, S96381037 Reset Setpoint Potentiometers, and C7031G1016 Outdoor Air Sensors. Immersion wells (121371A Copper or 121371E Stainless Steel) and heat conduction compound (107406) are required for the C7170A sensor.

Usage Features:

  • Adjustable Setpoint: Allows precise control of discharge water temperature.
  • Adjustable Reset Differential: Fine-tunes the energy-saving reset function.
  • Adjustable Control Band: Modifies the controller's response speed and temperature deviation. A narrower band provides faster response and less deviation but risks hunting; a wider band slows response but increases stability.
  • Fast Response Input: Jumpering terminals 9 and 10 selects 30-second minimum on/off and inter-stage delays; leaving them open selects 60-second delays. This feature is critical for compressor protection.
  • Number of Stages Configuration: A resistor across terminals 7 and 8 (from the 4074EFV Resistor Kit) configures the W7100G for the total number of cooling stages in the system (1 to 10).
  • Remote Setpoint Control: Can be used with remote potentiometers (S96381037) for setpoint adjustment.
  • Reset Options: Supports both space temperature reset (using T7047C1025 sensors) and outdoor air temperature reset (using C7031G1016 sensors) for energy optimization.
  • LED Indicators: Provide clear visual status of energized cooling stages.

Maintenance Features:

  • Troubleshooting Guide: A detailed troubleshooting table helps diagnose common issues such as discharge temperature too high, no cooling, and short cycling, providing possible causes and corrective actions.
  • System Checkout Procedure: A step-by-step guide is provided for field testing the system, requiring specific resistor kits (4074EDJ, 4074EFV), a digital VOM meter, and a test plug (195770A). This procedure ensures proper installation and functionality, covering checks for power, sensor input, stage energization, and setpoint adjustments.
  • Wiring Practices: Emphasizes keeping wiring at least one foot away from large inductive loads and using shielded cable where necessary to prevent electrical interference.
  • Component Recognition: Underwriter's Laboratories Inc. Component Recognized status indicates adherence to safety and performance standards.

Honeywell W7100G Specifications

General IconGeneral
BrandHoneywell
ModelW7100G
CategoryTemperature Controller
LanguageEnglish

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