Applica. First Edition uly 2005

Transcription

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2 McQuay y Smart t Manager er Chilled Water System Applica pplication Manual First Edition Jul uly 2005

3 Introduction Introduction... Introduction-1 Section 1: Networ ork k Interface Module (NIM) and Netwar are e About NIM Installation Address Assignment Master and Slave FCU About Netware Netware 2 and NIM Application NIM Wiring G-Way and Building Management System(BMS) Section 2: Chiller Control ol Panel 2.1 About Chiller Control Panel Installation Master and Slave Mini Chiller Chiller Control Panel Applications Wiring for Chiller Networking Section 3: Smart Manager 3.1 About Smart Manager Smart Manager Chilled Water System Applications Wiring for Smart Manager Chilled Water System Appendix Copyright c 2005 by McQuay International. All rights reserved. This publication is strictly confidential and is meant for DISTRIBUTORS of McQuay International only. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of McQuay International. The data and suggestions in this manual are believed current and accurate at the time of publication, but they are not a substitute for trained, experienced professional service. Individual applications and site variations can significantly affect the results and effectiveness of any information, the reader must satisfy him/herself regarding the applicability of any article and seek professional evaluation of all materials. McQuay disclaim any responsibility for actions based on this manual.

4 Introduction Today we offer a wide range of chilled water fan coil units and mini chillers to our valued customers. These fan coil units and mini chillers are used not only as HVAC equipment but also in various other applications. In order for us to serve such diversified fields of application we have designed various types of electronic module to help control and monitor these equipment either as individual equipment or collectively. These modules are designed to be easily linked to fan coil units and mini chillers. They have user friendly features plus they are economical and versatile. Firstly, we have the Chiller Control Panel which is used to control and monitor mini chillers operation.then we have the Network Interface Module (NIM) and Netware 2 which is used for fan coil units operation.these three electronic modules perform well but are specific to their functions only. We also have another type of electronic module which is specially designed to communicate with fan coil units and mini chillers. This type of module is the Smart Manager. Smart Manager has many interesting features such as programmable ON/OFF schedule, alarm alert and various parameter control settings and can be integrated with BMS. All these electronic modules are wire-linked to form an intelligent networking system. The networking system would made up of the Smart Manager, fan coil units, NIM, Netware 2, mini chillers and Chiller Control Panels. The network system runs on serial communication interface RS485. Some applications may not require all types of module. This manual would cover certain applications which require only certain modules and also applications which require all types of module. Applications examples are given to help users understand how they can apply these electronic modules to their work. Operation procedures are not within the scope of this manual but reference can be made to the individual electronic modules operating manual. Introduction - 1

5 Smart Manager > User friendly > Easy Installation > Networking capability up to 120 fan coil units and 50 mini chillers > Energy saving > Programmable Timer,Integration with BMS alarm alert and many more Netware 2 > User friendly > Easy Installation > Networking capability > Energy saving > Programmable Timer > System fault code display NIM > Compact > Easy Installation > Energy saving Chiller Control Panel > User friendly > Easy Installation > Networking capability up to 50 mini chillers > Energy saving > Programmable Timer > Alarm alert Introduction - 2

6 HydroIntel Smart Manager Networking between Smart Manager and Mini Chiller Smart HydroIntel Manager Networking between Smart Manager and Fan Coil Unit Introduction - 3

7 Section 1 Network Interface Module and Netware About NIM Network Interface Module or NIM acts as an interface to enable communcation between the Smart Manager, Fan Coil Unit (FCU) and display control panels. Bottom Casing Top Casing Unit Address Dip Sw itch Group Address Dip Sw itch CN3 Connector IC CN2 Connector CN1 Connector Network Interface Module This means that when FCU parameters are set using Smart Manager, datas are then sent via the communication cables to NIM which in turn are sent to FCU main control board and wired display control panel (if available ). The module package ( purchaseable from sales company ) consists of NIM controller, PCB Top and Bottom Casing, 4 or 5-Way shield wire ( 1 meter ) to be connected to the main control board and screws for installation of the NIM. Communication cables are not supplied ( Refer to Appendix 1 for cable specification ). Before commisioning the FCU, the group and unit address need to be set for each FCU. Refer to Address Assignment in this section. Main control board is connected ( use 4 or 5-Way shield wire as provided ) to CN1 connector, display control panel is connected (use control panel wiring supplied together with the panel) to CN2 and communication cables ( 2 wire ) is connected to CN3. (Refer to NIM Wiring in this section and Appendix 2 for example of wiring). 1-1

8 The NIM Version 1.2 is compatible with main control board U1.4, W1V3, W2 and L-Series Display control panel type Netware 2 and SLM3 or IR Remote control can be used as controllers to the fan coil units. The communication cable length are limited to ensure smooth communication runs through the whole network. ( Refer to Appendix 1 for recommended cable length ) 1.2 Installation tion The NIM is designed to ease installation in the field. The following steps can be used for installation. 1) Plug in the wires to connector CN1 and connector CN2 respectively. 2) Plug in communication cables to CN3 and ensure both end of the cable are of the same polarity. 3) Align the wires / cables on the hole slots of the NIM casing. 4) Snap the top casing and hook the claws into their slots. Make sure the wires are properly covered in the hole slots. 5) Screw the casing on the wall with screws provided. Completed NIM Installation The following precaution must be taken when selecting the location to install NIM a) Do not expose to direct sunlight b) Do not expose to electromagnetic waves c) Do not expose to heat source Whenever possible, it is recommended to install NIM next to the FCU. 1-2

9 1.3 Addr dress Assignment The uniqueness of the Smart Manager is that it is able to support up to 120 FCU in the same networking system. Each FCU must be given a unique address and no two or more FCU can share the same address. If a sharing occur, the Smart Manager will not be able to identify that particular address which is shared. Address is easily assigned by setting the Group and Unit Address Dip Switches found on the NIM. The Group Address Terminal ( labelled as DSW1 on the NIM ) consists of 8 dip switches numbering 1 to 8 while the Unit Address Terminal ( labelled as DSW2 ) consists of 4 dip switches numbering 1 to 4. The ON on top of the dip switches represents "1". This means that when we turn the dip switch to the top the setting changes to 1 and if the dip switch is at the bottom the setting is 0 This Group Address is which represents Group 1 Dip switch on top represents "1" Likewise, Setting represents Group Address 5 Setting represents Group Address 20 Setting represents Group Address 100 This Unit Address is 0111 which represents Unit 7 Dip switch on the bottom represents "0" Likewise, Setting 0000 represents Unit Address 0 Setting 0101 represents Unit Address 5 Setting 1111 represents Unit Address 15 Refer to Appendix 3 and Appendix 4 for dedicated address which are assigned to each FCU. Group Address that can be assigned are 0 to 254. Group Address 255 is reserved for PC Operation only ( this application is not covered in this manual ). Unit Address that can be assigned are 0 to 15. Unit address "0" is reserved for Master Unit only. ( For more details refer to Master and Slave FCU in this section ) 1-3

10 Example Group 1 Unit 7 When the above is set on the NIM, the FCU address is G1U7 in the network system. This address can be called from the Smart Manager and the FCU parameter can be monitored and set-able from the Smart Manager. ( Refer to Smart Manager Operating Manual for operation details ) 13/09/ am Status : ON Mode : Cool Set Temp : 24 C Fan : High Room Temp : 27 C Unit : G1U7 FCU Parameters are easily monitored FCU Address displayed on the Smart Manager Smart Manager displaying FCU parameters MAIN MENU Operation Menu Settings Menu Timer Menu Alarm Menu FCU Parameters are easily set-able with the Smart Manager Smart Manager displaying FCU Menus 1-4

11 1.4 Master and Slave e FCU Master Unit is a FCU with a unique address "0" assigned to it. Slave Unit is a FCU within the same network group as the Master Unit that has any address from 1 to 15 assigned to it. Master Unit is used to control all other Slave Units which are assigned to the same network group with it. Master Unit must be linked to Netware 2 for this purpose. Main Board NIM Main Board NIM Netware 2 Control Panel Netware 2 Control Panel Main Board NIM Main Board NIM Main Board NIM Netware 2 Control Panel. IR IR Remote No IR Remote / SLM3 / Netware 2 Master Slave 1 Slave 2 Master Slave 1 Group 1 Group 2 Typical Bus Structure For NIM Network These Slave Units will receive data from the Master Unit and change their parameters to follow exactly the parameters change of the Master Unit. This means that when the Master Unit is turn ON all Slave Units would turn ON too. When the Master Unit runs Cool Mode all Slave Units would run Cool Mode too. When the Master Unit is turn OFF all Slave Units are turn OFF too. When Master Unit room temperature is set to 24 C all Slave Units room temperature are set to 24 C. Note that a Group can only have one Master Unit and up to fifteen Slave Units. This type of Master and Slave Networking System is suitable for use in places with multiple FCU such as office building, cinemas,schools and lecture theatres. 1-5

12 1.5 About Netwar are e 2 Netware 2 is a wired LCD remote control panel used to control and monitor individual fan coil unit. When linked to NIM, Netware 2 can be used to control all other FCU in the same networking group. The advantages of Netware 2 are 1) Ability to ON / OFF up to fifteen fan coil units simultaneously under the same network group 2) Ability to control all fan coil units to run with the same parameters. 3) Ability to run or stop all fan coil units based on a 7 day programmable timer 4) Ability to display fault code when problem occur and in which fan coil unit However the disadvantages of Netware 2 ( as master display control panel ) are it is not able to set different parameters for each fan coil unit and is limited to display fault code only. This is where the Smart Manager has its advantage over the Netware 2 ( Refer to Section 3 for details on the Smart Manager application ) Display Control Panel Netware Netwar are 2 and NIM Applica pplications Netwar are 2 and NIM Applica pplication In Schools The Master and Slave System which uses Netware 2 and NIM is suitable for use in schools. This is because schools have multiple rooms and use multiple fan coils units. With this system in place, all fan coil units can be easily controlled. An example of this is School Z. It has five floors and each floor has seven class rooms. Each class room has two fan coil units. All the fan coil units in the same floor is placed in the same group. This means each group would have 14 fan coil units. Each group is controlled by one Netware 2 module. With this networking, it becomes an option to keep a handset or display control panel for each fan coil unit. This 1-6

13 may prevent any mishandling of fan coil units and ensure smooth operation of the HVAC system in the school. By using the Netware 2 all fan coil units are set to the same room temperature. An example is to set the room temperature to 24 C which could pose to be a good energy saver method. A 7 day programmable timer is set so that all fan coil units run and stop according to the school schedules. This will protect compressors from frequent ON/OFF cycle which could shorten their life cycle. The Netware 2 also displays individual fan coil unit fault code. This helps in troubleshooting the fan coil unit fault easily and immediate service can be carried out on the default unit. ( For meaning of fault code refer to relevant main control board specification ) 1-7

14 Netware 2 and NIM Application For Multiple Fan Coil Units In School Netware 2 NIM Master Unit Main Board / Display Control Panel to NIM Wiring Communication cables Slave Unit Slave Unit NIM NIM Slave Unit NIM Slave Unit NIM Slave Unit NIM Slave Unit NIM 1-8

15 Netwar are 2 and NIM Applica pplication In Office Building The Master and Slave System which uses Netware 2 and NIM is also suitable for use in office building. An example of this application is in the ' Y Corporate Center' Zone Five Zone Four Zone Three Zone Two Zone One The office building can be divided into few zones. Each zone is made up of one or few offices. Each zone has one Netware 2 module. The Netware 2 will be used to control all FCU in its zone. The advantage of this system is that it is flexible. Users in each zone can determine when to run or stop the FCU. An application example is Company X which makes up a zone. The office hour is from 8am to 5pm ( six working days per week ). The 7 day programmable timer is pre-set so that the fan coil units run at 8am and stop at 5pm every day for six days and stop on the seventh day. If certain fan coil units are required to run after 5pm, those fan coil units will be ON and OFF using the individual units handset or display control panel. This way Company X saves on power consumption. Besides this the programmable timer ensures all fan coil units stop as determined by the user. This will help as some users after a hard day at work may forget to switch off their HVAC system. 1-9

16 Netware 2 and NIM Application For Multiple Fan Coil Units in Office Building Netware 2 NIM Master Unit NIM Z O N E Slave Unit Slave Unit NIM 1 Slave Unit NIM Netware 2 Z O N E Master Unit SLM NIM 2 Slave Unit NIM Main Board / Display Control Panel to NIM Wiring Communication cables 1-10

17 1.7 NIM Wiring CN3 For Communication Cables Connection CN2 For Display Control Panel Wire Connection CN1 For Main Control Board Wire Connection The other end of the communication cables are connected to punch boards to ensure wiring is fitted correctly. 1-11

18 1.8 G-Way y and Building Management System ( BMS ) G-Way has almost the same outlook as NIM but it has a different function compared to NIM. It is designed to link FCU to BMS. When FCU is used with G-Way and BMS it can be remotely ON/OFF and monitored for alarm and operation status ( ON/OFF ). To be connected to Display Control Panel CN2 CN3 Use 5-Way Wire to connect to FCU Main Control Board CN1 CN4 CN5 Link to BMS Dip Switch G-Way has a Dip Switch ( DSW2 ) to enable user to set the type of operation they prefer. DSW2 Setting Type of Operation 0000 Control and Monitoring ( External Switch Closes to ON FCU, Opens To OFF FCU ) 0010 Control and Monitoring ( External Switch Opens to ON FCU, Closes To OFF FCU ) 0001 For Monitoring Only. No ON/OFF via BMS The ON on top of the dip switches represents "1". This means that when we turn the dip switch to the top the setting changes to 1 and if the dip switch is at the bottom the setting is 0. When DSW2 is set to 0000 or 0010, FCU can only be ON/OFF via BMS. No display control panel/handset will be able to ON/OFF the FCU. However when FCU is ON, FCU parameters are set-able using display control panel/handset. When DSW2 is set to 0001, FCU can be ON/OFF using display control panel/handset and BMS cannot ON/ OFF the unit. However all three settings allow for monitoring of the alarm or operation status of the FCU (ON/ OFF) 1-12

19 CN3 ON/OFF Dry Contact Input FCU ON/OFF Indicator CN4 240VAC/24VDC Dry Contact Output 1 Alarm Indicator CN5 240VAC/24VDC Dry Contact Output 2 G-Way BMS Refer to Appendix 1 for recommended cables length. G-Way is suitable for use in office building, supermarkets and hotels where FCU can be alarm can be easily monitored via BMS. turn ON/OFF and However each G-Way module can only be linked to one fan coil unit. This module is not designed for networking purpose and it cannot be linked to the Smart Manager. 1-13

20 Section 2 Chiller Control Panel 2.1 About Chiller Control ol Panel Chiller Control Panel is a wired LCD remote control panel used to control and monitor mini chiller parameters. All Mini Chiller C-Series come with Chiller Control Panel. Chiller Control Panel outlook is close to the Smart Manager but Chiller Control Panel is used specifically to communicate with mini chillers only and not with FCU. User can easily differentiate these two wired control panel. The Smart Manager front cover displays the name "Smart Manager" while Chiller Control Panel does not have this display. Besides this, Smart Manager has additional terminals for connection to NIM,mini chiller and BMS but Chiller Control Panel does not have these additional terminals. Chiller Control Panel is factory installed in the mini chiller. The communication cable length is 2 meter. If user need to have longer cables, it is recommended to follow specifications in Appendix 1. A terminal block is found on the mini chiller main control board ( for Mini Chiller C-Series only ) for field communication cables connection. Terminal block has four poles namely A,B,+12V and Ground (GND). A and B poles are for communication cables. Ensure polarity is right, cable connection at two ends must be A to A and B to B. If the polarity is wrong, there will not be any communication and no display will be found on the control panel. 2-1

21 For field wiring, connect communication cables here The Chiller Control Panel runs on 12VDC. The low voltage is supplied from the main board. If longer cables is required, ensure that the polarity is right. 12V must be connected to 12V and GND to GND. If the polarity is wrong, the control panel will burn. The Chiller Control Panel can be linked with Main Control Board MC01 EC MC1.0 2CP DX ( For Mini Chiller 4AC/AC C ), MC01 HP MC1.0 2CP DX ( For Mini Chiller 4AC/AC CR ) MC01 EC MC1.0 1CP DX ( For Mini Chiller 4AC/AC C ) and MC01 HP MC1.0 1CP DX ( For Mini Chiller 4AC/AC CR) Refer to Mini Chiller Technical Manual or Operation Manual for Chiller Control Panel operation guide. (For wiring example refer to Wiring for Chiller Networking in this section) 2.2 Installation tion When need arises to install the Chiller Control Panel remotely from the mini chiller, the following steps can be used to correctly install the Chiller Control Panel. 1) Open the rear panel of the Chiller Control Panel. User may insert a flat-head screwdriver in the top joint of the main casing and the rear panel. Push the rear panel backward and remove the panel from the main casing. 2) Place the rear panel flat support on a mounting bracket and mark four holes ( according to the four screw hole position found on the support ) on the bracket. 3) Pass the necessary cables through the square opening found on the rear panel. 4) Drill four holes according to the mark holes on the bracket. Fasten the rear panel to the bracket with screws. Then fasten the bracket to the wall. 5) Connect the power supply and communication cables to the right terminal. Ensure the polarity is the same. 6) After the wiring is completed close the Chiller Control Panel by aligning the bottom joint of the main casing to the bottom joint of the rear panel. Then align the other joints. Lastly fasten the main panel to the rear panel using the two hooks on top. 2-2

22 It is recommended that the Chiller Control Panel be installed in a place that could avoid the following: a) Exposure to shock. Do install the Chiller Control Panel in a casing that could prevent any external force that could damage it. b) Exposure to electromagnetic waves. c) Exposure to extreme ambient condition and relative humidity. The Chiller Control Panel can operate between an ambient of 0 C to 50 C. d) Exposure to direct sunlight and rain. 2-3

23 2-4

24 2.3 Master and Slave e Mini Chiller Master Unit is a mini chiller unit with a unique address "0" assigned to it. Slave Unit is a mini chiller unit within the same network group as the Master Unit with any address from 1 to 50 assigned to it. Master Unit is used to control and monitor all the Slave Units which are assigned to the same network group with it. Master Unit is linked to Master Chiller Control Panel for this purpose. The Chiller Control Panel has a Panel ID which is set-able. The default Panel ID from factory is "0". With the "0" Panel ID the Chiller Control Panel acts as a Master Panel. It can be used to view and set parameters of the Master mini chiller unit with which it is attached to as well as to view and set parameters of other mini chillers within the same network group. Ensure that all mini chillers' addresses in the network system is assigned correctly. Each mini chiller must be given a unique address and no two or more mini chiller can share the same address. If a sharing occur the Master Chiller Control Panel will not be able to identify that particular address which is shared. For details on networking and address assignment refer to Mini Chiller Technical Manual Mini Chiller Main Control Board Typical Bus Structure for Mini Chiller Network 2.4 Chiller Control ol Panel Applica pplications The advantages of the Chiller Control Panel are 1) Remote monitoring via a centralised control room 2) Alarm alert ( with buzzer ) and display of specific mini chiller fault help to ease troubleshooting. 3) 7day programmable timer ( 2 timer each day ) to ON/OFF each mini chiller 4) Economical and low operating cost. 5) No complicated wiring helps in easing installation 6) Specific temperature setting for each mini chiller 7) One Chiller Control Panel acting as a Master Panel can support up to 50 units of mini chiller This type of Master and Slave System is suitable for use in multiple mini chillers system such as factory process cooling, lecture theatres, hotels and office buildings. 2-5

25 Chiller Control ol Panel Applica pplication In Process Cooling Besides being a HVAC equipment, mini chiller is also used for process cooling such as hydraulic oil cooling, beverage industry and food industry. Most of these processes are found in factories. Some of these factories have large built-up area. The Chiller Control Panel helps to control and monitor mini chiller which are used in process cooling. An example of this application is in Factory XYZ. Ten units of mini chiller are installed in this factory for process cooling. Each mini chiller has a Chiller Control Panel. The mini chiller operating parameters are set during commisioning. All Chiller Control Panel are linked for networking purpose. One of the Chiller Control Panel acts as a Master Chiller Control Panel. This Master Panel is rewired to be located in the process control room. The Master Panel is used to ON/OFF all mini chillers used in the plant. This is done by pre-setting the programmable timer for each mini chiller. Timer 1 Timer 2 ON OFF ON OFF Two setable Timer Sun Mon Tue Wed The Master Panel is used to monitor alarm. The fault and default mini chiller address will be displayed on the LCD. This helps the factory to troubleshoot the problem easily. Alarm Number 1 The fault for Chiller 1 is Compressor 1 Overload Alarm 1 Comp 1 overload [Ch 1] Default chiller is Chiller 1 17/09/04 4:00am Date and time alarm occur 2-6

26 Chiller Control Panel Application for Multiple Mini Chillers in Process Cooling Master Chiller Control Panel placed in the Process Control Room Master Unit Slave Unit Slave Unit Slave Unit Communication cable Water piping 2-7

27 Chiller Control ol Panel Applica pplication for Multiple Mini Chillers Used in Offices In Section 1, we have seen how Netware 2 and NIM are used to control FCU in offices. Likewise, Chiller Control Panel is suitable for use to control and monitor mini chillers. A Master Chiller Control Panel is rewired and located inside the HVAC central control room. User can easily control the mini chillers from this room. The ON/OFF schedule can be pre-set for the mini chillers according to the users requirement. All Mini Chiller C Series allow an external alarm indicator to be installed with simple wiring. The Chiller Control Panel is used to activate this function when external alarm is required. This external indicator will help alert user that the mini chiller is faulty. The fault and default mini chiller is displayed on the Chiller Control Panel. This helps in identifying the mini chiller fault and service or preventive maintenance can be carried out accordingly. User will no longer have to tolerate discomfort due to chiller breakdown. When the office has low occupancy, the Mini Chiller Dual System (4AC/AC C/CR) runs one compressor alternately. This helps to reduce energy consumption and prolong the compressors life cycle. The Chiller Control Panel also displays the compressor running time which helps in maintenance planning. Master Chiller Control Panel placed in the HVAC centralised control room Communication cable 2-8

28 Advance Par arameter ameters Mini Chiller is designed with special feature to enable it to be integrated with auxilliary heater and boiler. The auxilliary heater is field installed and placed in the water storage tank to heat water to higher temperature. In other word the auxilliary heater supports the chiller to bring up the water temperature.the boiler is also field installed and can be used together with mini chillers. Together they form a HVAC system. Mini Chiller C Series Main Board has output terminals VAC for auxilliary heater and boiler applications. Boiler Terminal Auxilliary Heater Terminal Boiler Contactor Auxilliary Heater Relay Mini Chiller Main Control Board N N Mini Chiller Terminal Block Field Wiring for boiler ( for Cooling & Heatpump ) Field Wiring for auxilliary heater ( for Heatpump model only ) When use boiler or auxilliary heater the model must be set. This setting is found in the following menu. Screen 1 MAIN MENU Operation Menu Setting Menu Timer Menu Alarm Menu Display Menu 2-9

29 Screen 2 SETTING MENU Set Parameter Change Password Panel Option Screen 3 1. General 2. Sensor 3. Regulator 4. Compressor 5. Defrost 6. Antifreeze 7. Alarm and Contact All Advance Parameter is found here Screen 4 G1 Model : Chiller G2 No. Comp : 1 Comp G3 On/Off In : Disable G4 Co/Heat In : Disable G5 Ext Alarm In : Disable G6 Water Sys : Isolated G7 Unit No. : 0 Model is set according to users requirement Model Selection Chiller When this option is selected boiler would not operate. This selection only allows for operation with mini chiller only. Heatpump When this option is selected and mini chiller runs cooling mode auxilliary heater and boiler would not operate. When mini chiller runs heating mode, auxilliary heater can operate based on auxilliary heater set temperature and temperature of water entering the mini chiller. Example The Heating Set Point, A is set to 50 C while the auxilliary heating set-point, B is set to 5 C and the auxilliary heating differential, C is set to 2 C. When the water entering temperature reaches 45 C, ( A-B ) the auxilliary heater operates to heat up the water. When the water entering temperature reaches 48 C, ( A-C ) the auxilliary heater stops operation. 2-10

30 Chiller / Boiler When this option is selected and mini chiller runs cooling mode the boiler would not operate. When mini chiller runs boiler mode ( press Heat Key twice ) the boiler will operate when the water entering temperature is below the heating set point temperature. Example The Heating Set Point is set to 50 C. Boiler mode is selected by pressing the Heat Key twice when water entering temperature is 25 C. The boiler starts to operate. The boiler will stop operation when the water entering temperature reaches 50 C. Chiller + Boiler This option allows boiler to operate all the time. Mini chiller runs cooling mode based on cooling set point and water entering temperature. Heatpump / Boiler This option is like the Heatpump option except it has boiler option. During heating mode, boiler will operate based on auto boiler set point and auto boiler differential. This gives user option to use auxilliary heater or boiler as booster to help heat up the water. When boiler mode is selected boiler will operate when the water entering temperature is below the heating set point temperature. Example The Heating Set Point, A is set to 40 C while the auto boiler set point, B is set to 5 C and the auto boiler differential, C is set to 0 C. Mini chiller runs heating mode. When the water entering temperature reaches 35 C, ( A-B ) the boiler will operate. When the water entering temperature reaches 40 C, ( A-C ), the boiler will stop operation. When mini chiller switches to boiler mode the water entering temperature is 30 C. The boiler will operate. The boiler stops operation when water entering temperature reaches 40 C. 2-11

31 Heatpump + Boiler When mini chiller runs cooling mode, boiler is always on. When mini chiller runs heating mode it will operate like Heatpump/ Boiler option as mentioned above. A summary of the model selection is as follows: Model Selection Chiller Heatpump Chiller / Boiler Heatpump / Boiler Chiller + Boiler Heatpump + Boiler Mode Cooling Heating Boiling o x x o o x o x o o o o o x Auto o o Auto o = operational mode x = non-operational mode Auto = Boiler is always on during cooling mode and boiler operates based on auto boiler set-point and auto boiler differential when running heating mode. Note that the difference between Chiller + Boiler and Chiller / Boiler is that Chiller + Boilerallows boiler to always ON during cooling mode while Chiller / Boiler allows mini chiller to run either cooling mode ( without boiler ) or boiler mode ( without running compressor ). The difference between Heatpump + Boiler and Heatpump / Boiler is that Heatpump + Boiler allows boiler to always ON during cooling mode or allows boiler to operate based on auto boiler set-point and auto boiler differential during heating mode while Heatpump / Boiler allows mini chiller to run cooling mode ( without boiler ), heating mode ( boiler operates based on auto boiler set-point and autoboiler differential ) or boiling mode ( without running compressor ) 2-12

32 Piping System Configuration The piping system can be 2 pipe system or 4 pipe system. 2 pipe system is more economical compared to 4 pipe system. In 2 pipe system chilled water and hot water are mixed together. In 4 pipe system chilled water and hot water are in different pipe lines. However when use two pipe system, one design consideration is to ensure that that temperature of water entering the mini chiller does not exceed 15 C when mini chiller is running cooling mode or 50 C when mini chiller is running heating mode. This could cause compressor high pressure. Expansion tank Boiler Mini Chiller FCU Water Storage Tank An example of 2 pipe system This type of 2 pipe system is suitable for use when boiler is not running during cooling mode and temperature of water entering mini chiller does not exceed the limit as above. This is done by setting the cooling set-point and heating set-point below these limit. ( Refer to Regulator Parameter in this section ). For this type of 2 pipe system the recommended model selection would be Chiller/Boiler, Heatpump and Heatpump/Boiler ( For wiring examples refer to Wiring for boiler and auxilliary heater in this section ). Expansion tank Mini Chiller FCU Boiler Water Storage Tank An example of 4 pipe system This type of piping system is suitable for use for all types of model. The FCU consists of one cooling coil and one heating coil. Ensure temperature of water entering mini chiller does not exceed the above limit. 2-13

33 Regulator Parameter Cooling Set-point When a cooling set point is set say 12 C, the compressor cuts off when the water entering sensor senses the water temperature to be 12 C. Cooling differential When the cooling differential is set to say 1.5 C, the compressor that has cut off at 12 C as mentioned above will cut in at ( = 13.5 C ). This is for the one compressor system. As for the dual compressor system it is slightly different. One compressor system Temperature Cooling set-point + differential Comp on Cooling set-point Comp off Two compressor system Temperature Cooling set-point + differential 2 Comp on Cooling set-point + 1/2 differential 1 Comp on 1 Comp off Cooling set-point 2 Comp off When the cooling set-point is set to 12 C and the cooling differential is set to 3 C, one compressor cuts off at ( =13.5 C ) while the second compressor cuts off at 12.0 C. When the water entering sensor senses the water temperature at 13.5 C, one compressor will cut in. The other compressor will cut in at 15 C Heating Set Point When a heating set point is set say 40 C, the compressor cuts off when the water entering sensor senses the water temperature to be 40 C Heating differential When the heating differential is set to say 1.5 C, the compressor that has cut off at 40 C as mentioned above will cut in at ( = 38.5 C ). This is for the one compressor system. 2-14

34 One compressor system Temperature Heating set-point Comp off Heating set-point - differential Comp on Two compressor system Temperature Heating set-point 2 Comp off Heating set-point - 1/2 differential 1 comp off Comp on Heating set-point - differential 2 comp on When the heating set-point is set to 40 C and the heating differential is set to 3 C, one compressor cuts off at ( =38.5 C ) while the second compressor cuts off at 40.0 C. When the water entering sensor senses the water temperature at 38.5 C, one compressor will cut in. The other compressor will cut in at 37.0 C Compressor Parameter Compressor minimum run time The compressor must run for a minimum of this set time after it has start to run. This applies to compressor cycle on when water temperature is met. Compressor minimum stop time The compressor must stop for a minimum of this set time after it has stop. This applies to compressor cycle off when water temperature is met. Time interval between two starts The compressor ON-OFF cycle must at a minimum equal this set time. In other word if the compressor ON- OFF cycle exceeds this time interval another compressor ON-OFF cycle can begin. Refer to the following examples. 2-15

35 Examples A dual compressor system runs cooling mode. When the compressors start the water temperature is 25 C. The compressor minimum run time is 1.5 minute while the compressor minimum stop time is 1 minute. The time interval between two starts is 5 minutes. Temperature 25 90% load m 4m 1 m 4m Time The system runs with 90% load. During startup, both compressors run until 13.5 C whereone compressor cuts off. The compressor cuts off for a minimum stop time of 1 minute. Then it cuts in again because water temperature went over 15 C. Both compressors run until water temperature reaches 13.5 C again.then the other compressor which has yet to to stop will stop for 1 minute. From this example the compressor ON/OFF cycle time is higher than the minimum time interval between two starts which is 5 minutes. Let's consider when the system starts with 10% load. During startup, both compressors run until 13.5 C where one compressor cuts off. As the load is small water temperature continues to go down to 12 C. Then the second compressors cuts off. Water temperature goes up to 13.5 C and the first compressor that cut off, cuts in. This compressor must run for minimum time of 1.5 minutes before it cuts off. At the cut off point, the water temperature has reached 10 C. It will take 6 minutes to rise to 13.5 C before the second compressor cuts in. Again the compressor ON/OFF cycle has exceeded the minimum time interval of 5 minutes. Temperature 25 10% load m 1.5 6m m m Time 2-16

36 Defrost Parameter Start Defrost Temperature All heatpump has a defrost sensor to measure the coil temperature. The HydroIntel and Chiller Control Panel display this temperature in the Display Menu. During heating mode, once the defrost sensor senses <= Start Defrost Temperature for example <= 0 C it will initiate a defrost cycle with condition the defrost interval time is met. End Defrost Temperature, maximum duration of defrost cycle and defrost end contact open The defrost cycle can terminate when any of the following conditions is met 1) End Defrost Temperature - The defrost sensor senses the End Defrost Temperature for example 14 C and defrost cycle is terminated 2) Maximum duration of defrost cycle - This sets the maximum allowable defrost cycle duration. Once ths duration is elapsed for example 10 minutes the defrost cycle will terminate. 3) Defrost end contact open - This is a dry contact ( 12VDC ) which is wired parellel with the high pressure switch. Once the high pressure switch opens defrost end contact opens and defrost cycle is terminated. 2-17

37 Wiring for boiler and auxiliary heater Expansion tank Boiler Mini Chiller FCU Water Storage Tank with Auxilliary Heater When the above 2 pipe system is used, the following wiring will help to energize the contactor and 3-way valve when boiler operation is required. Alternatively a separate wiring as shown is used to energize a relay when auxilliary heater operation is required. R S T N Boiler Terminal Auxilliary Heater Terminal Boiler Contactor Power supply to boiler Mini Chiller Main Control Board 3 Way Valve N N Mini Chiller Terminal Block Auxilliary Heater Relay C VAC C1 Auxilliary Heater 2-18

38 2.5 Wiring for Chiller Networ orking Master Chiller Control Panel Mini Chiller Main Board Panel ID 0 Unit ID 0 4 pole terminal block for networking cable Slave Chiller Control Panel Mini Chiller Main Board Panel ID 1 Unit ID 1 Slave Chiller Control Panel Mini Chiller Main Board Panel ID 2 Unit ID 2 Factory Installed Cable Networking cable 2-19

39 Section 3 Smart Manager 3.1 About Smart t Manager er Smart Manager is a wired LCD remote control panel. It is designed to aid users in controlling and monitoring both fan coil units and mini chillers used in the hydronic system. In other word, Smart Manager acts as a centralized controller. It is wire-linked to all fan coil units and mini chillers. Smart Manager has many user friendly features. Among the Smart Manager main features are 1) Operation Status Display for each unit in the networking system 2) Unique Parameter Setting for each unit / grouping / all units in the networking system 3) Air-conditioning System Fault Display for each unit in the networking system 4) Unique Address Assignment to each unit in the networking system The advantages of Smart Manager over other type of controls are 1) It is economical 2) It has a low operating cost 3) It enables air-conditioning system troubleshooting to be carried easily with the system fault display 4) It has a programmable timer which is set-able to ON / OFF each unit as per users requirement 5) It is designed to support up to 50 units of mini chiller and 120 units of fan coil unit 6) It can be integrated with BMS Smart Manager 3-1

40 The Smart Manager menu consists of Fan Coil Unit, Chiller or Settings. Fan Coil Unit Chiller Settings The Settings Menu allows users to determine how they would like to control the hydronic system operation. Settings Priority : None Cool threshold : 50% Heat threshold : 50% This is set-able under Priority as follows: Priority Setting None FCU Chiller System Configuration ON/OFF of FCU and mini chiller is independent FCU controls mini chiller ON/OFF Mini Chiller enables FCU to ON and controls FCU OFF Examples Scenario 1 A hydronic system in an office consists of 10 FCU and 1 mini chiller. The Priority Setting is FCU. In the morning no FCU is ON. The mini chiller is OFF automatically. Later in the afternoon, five FCU is ON, the mini chiller ON automatically ( power supply to mini chiller is on standby ). Scenario 2 The same hydronic system is used as in Scenario 1. The Priority Setting is Chiller. When the mini chiller is OFF, all FCU is OFF automatically. When there is a requirement mini chiller is turn ON by user. FCU can now be ON by user via remote controllers. Besides this when the Priority Setting is FCU, the mini chiller can switch operating mode based on threshold setting value. Cool threshold allows mini chiller to run cooling mode when the threshold value is met. Heat threshold allows mini chiller to run heating mode when the threshold value is met. 3-2

41 Examples Scenario 1 A hydronic system in a school consists of 10 FCU and one mini chiller. Six of the FCU are running cooling / dry mode while four of the FCU are running heating mode. The Cool threshold is 50% while the Heat threshold is 50%. The mini chiller will run cooling mode as the threshold value 50% has been met. ( 60% of the FCU is set to run cooling mode ) Scenario 2 A hydronic system in a school consists of 10 FCU and one mini chiller. Five of the FCU are running cooling / dry mode while five of the FCU are running heating mode. The Cool threshold is 50% while the Heat threshold is 50%. The mini chiller will run cooling mode too as priority is given to cooling. Scenario 3 A hydronic system in an office building consists of 10 FCU and one mini chiller. Five of the FCU are running cooling / dry mode while four of the FCU are running heating mode. The Cool threshold is 70% while the Heat threshold is 70%. Although the threshold values are not met, mini chiller will run based on mini chiller last run mode. 3-3

42 Smart Manager is designed to control and monitor individually, as a group or collectively all the FCU in the network system. To choose one of this option, go to Unit Selection screen on the Smart Manager and select the desired group address or unit address. Unit Selection: Select All Select Group Select One Selection for FCU Smart Manager can control and monitor individually or collectively all the mini chillers in the network system. To choose either one of this option, go to Unit Selection screen on the Smart Manager and select the desired unit address. Unit Selection: Select All Select One : 0 Mini Chiller Unit Address is selected here Selection for Mini Chiller Example In Hotel X,rooms are grouped according to floors. The hotel has ten floors and each floor has ten rooms. Smart Manager is used to control all the FCU ( 100 units ) and mini chillers ( 10 units ) used as HVAC equipment in the hotel. The hotel manager uses the Smart Manager to ON / OFF the FCU as well as to set FCU parameters such as room temperatures and fan speed. He wishes to ON all the FCU ( 100 units ) and set all the FCU to operate at 25 C and run the fan at high speed. He can easily do this within a short time via the Smart Manager. 3-4

43 Screen 1 Unit Selection: Select All Select Group Select One Select all FCU Selection for FCU Screen 2 OPERATION MENU Status : ON Mode : Cool Set parameters Set Temp : 25 C in the Operation Fan : High Menu Screen 3 20/09/ am Status : ON Mode : Cool Parameters Set Temp : 25 C setting as shown Fan : High on display Room Temp : - - screen Unit : All Smart Manager comes with programmable timer for FCU and mini chillers. Two types of programmable timer are available. One is the Timer Schedule while the other is the Holiday Schedule. FCU Timer Schedule There are five programmable timer schedules ( Schedule 1 to Schedule 5 ). Each schedule has two ON/OFF timer each day. This is a 7 day timer schedule. User can select which schedule to run for each fan coil unit and the timer must be enabled from the Operation Menu. 3-5

44 Example College Y has fifty lecture rooms. The HVAC equipment in these lecture rooms run on a programmable timer. Screen 1 Timer Menu Clock Setting Date Setting Timer Schedules Holiday Select Timer Schedules Screen 2 SCHEDULE SETTINGS Schedule 1 Schedule 2 Schedule 3 Schedule 4 Schedule 5 Select Schedule Screen 3 Timer 1 Timer 2 ON OFF ON OFF Sun Mon Set Timer Tue Wed Screen 4 OPERATION MENU Swing : No Sleep : No Schedule : 1 Select Schedule Timer : Enable to run the FCU Enable Timer 3-6

45 Mini Chiller Timer Schedule Mini Chiller programmable timer schedule has two ON/OFF timer each day. This is a 7 day timer schedule. Screen 1 TIMER MENU Set Time Set Date Set Schedule Select to set Timer : Disable schedule Screen 2 Timer 1 Timer 2 ON OFF ON OFF Sun Mon Set Timer Tue Wed Screen 3 TIMER MENU Set Time Set Date Set Schedule Timer : Enable Enable Timer 3-7

46 Holiday Schedule The Holiday Schedule is used to OFF all FCU and mini chillers during a defined period. During this time, all timer schedules will be de-activated. Screen 1 Timer Menu Clock Setting Date Setting Timer Schedules Holiday Select holiday schedule Screen 2 HOLIDAY SETTINGS Holiday 1 Holiday 2 Holiday 3 Holiday 4 Holiday 5 Select schedule Set Holiday 1 Month : 1 Day : 20 Set schedule Duration : Enable This feature helps user to OFF the HVAC equipment during long holidays. The holiday schedule will be terminated once user trigger the ON/OFF or change any mode using HydroIntel. 3-8

47 Advance Settings The Smart Manager is designed with BMS ready feature. This feature allows all FCU to be integrated with BMS ( Building Management System ) Screen 1 SETTING MENU Advance Setting Change Password Panel Option Screen 2 ADVANCE SETTING BMS Global ON : Enable : Enable Enable all FCU to ON automatically When BMS setting is enabled, all FCU in the network system is controlled by BMS. Smart HydroIntel Manager BMS SYSTEM BMS ALARM SWITCH GND ALARM INPUT ONOFF INPUT ON/OFF ALARM OUTPUT OUTPUT +12VDC BMS ON/OFF SWITCH GND +12VDC H/C AUX OUTPUT OUTPUT ALARM INPUT CONTACT ON/OFF INPUT CONTACT ON/OFF OUTPUT CONTACT ALARM OUTPUT CONTACT ON/OFF INPUT CONTACT ALARM INPUT CONTACT Smart Manager with Building Management System 3-9

48 Input Contact (Connect to BMS) Alarm +12VDC On/Off +12VDC When BMS is set to Enable: If On/Off input contact is closed. (+12VDC is supplied to the dry contact) All FCU is not able to be turned On. All the FCU will be turned Off if the FCU is currently In running status. On/Off output contact will be opened If On/Off input contact is opened (No +12VDC is supplied) All FCUs remain current state (FCU can be turned On or Off individually) If Global On is set Enable, all the FCU will be turned On automatically On/Off output contact will be closed If Alarm input contact is closed. (+12VDC is supplied to the dry contact) All the FCU will be turned Off Alarm output contact will be closed If Alarm input contact is opened. (No +12VDC is supplied) All the FCU remain as the current state. Alarm output contact will be opened. Note 1: The +12 VDC is from other peripheral device as long as the +12VDC and GND must come from the same source. Note 2: Global On. With BMS is set to Enable (a) Global ON is set Disable When On/Off input contact is opened, all the FCU can be turned On individually. (b) Global ON is set Enable When On/Off input contact is opened, all the FCU will be turned On automatically. 3-10

49 Output contact (Connect to BMS) Indicator Indicator On/Off Alarm Heating/ Cooling Indicator The output contact is controlled by relay with the load rating of 30VDC,1A or 125VAC,0.5A 1)On/Off contact (a) On/Off contact will be opened when On/Off Input contact is closed. when All the FCUs are Off. (b) On/Off contact will be closed. when On/Off Input contact is opened. when at least one FCU is On. 2) Heating / Cooling Contact (a) H/C contact will be opened when FCU running Cooling (b) H/C contact will be closed when FCU running Heating Basically, the contact Open or Close depend on the heat and cool threshold Triggering 3) Alarm Output Contact (a) Alarm Contact will be opened when Alarm input contact is opened. (b) Alarm Contact will be closed when Alarm input contact is closed. All the output contacts are usually linked to indicators like LED, light bulb etc. Refer to Appendix 1 for maximum allowable cable length. 3-11

50 Example To other FCU Building Management System Communication Cable Punch Boards Smart HydroIntel Manager NIM Netware 2 FCU An Office XYZ uses BMS to control the operation of the HVAC. The Priority Setting is FCU. The BMS setting is enabled. During day time, the ON/OFF input contact switch is opened to enable all the FCU to ON. The Global On setting is enabled to automatically ON all FCU in the building. All the mini chillers will ON automatically when all the FCU turned ON. The ON/OFF output contact closes and the LED lit to show that FCU is ON. At the same time when an emergency occur in the building like fire, the fire alarm input contact closes and all FCU will turn OFF. This in turn will turn OFF all mini chillers The alarm output contact closes and the LED lit to show that alarm has triggered. 3-12

51 3.2 Smart t Manager er Chilled Water System Applica pplication When Smart Manager is used together with NIM, Netware 2, FCU, Chiller Control Panel and mini chiller they form an intelligent networking system known as Smart Manager Chilled Water System. The advantages of Smart Manager Chilled Water System are as follow: 1) Centralised control of all FCU and mini chillers via the Smart Manager. 2) Easy wiring to help ease installation. 3) Compact and user friendly electronic modules 4) Alarm alert ( with buzzer ) and display of specific FCU or mini chiller fault help to ease troubleshooting. 5) Economical and low operating cost 6) Unique parameter setting for each FCU and mini chiller in the network system. 7) Ability to be integrated with BMS Smart Manager Chilled Water System gives the flexibilty to user to control and monitor the HVAC system and Applied system together.one example is a single Smart Manager can be used to control and monitor all FCU and mini chillers in the office building as well as to control and monitor mini chillers used for process cooling in the factory. Smart Manager System can also be used to control and monitor the HVAC system in a hotel. The mini chiller reclaimed heat can be used to heat up water for shower, dish washing, cleaning etc. Smart Manager Chilled Water System can be used to control and monitor equipment used in supermarket operations. Supermarket operation would require cooling and heating simultaneously for HVAC and refrigeration purposes. Smart Manager Chilled Water System also provide the flexibility to colleges which require cooling and heating simultaneously in various parts of the college. 3-13

52 Smart Manager Chilled Water System Application In Factory for HVAC and Process Cooling NIM Bus Chiller Bus Smart HydroIntel Manager NIM Netware 2 Mini Chiller for HVAC Ducted FCU to Office 1 Netware 2 Mini Chiller for HVAC Ducted FCU to Office 2 Communication Cables Water Piping Machine Mini Chiller for Process Cooling 3-14

53 Smart Manager Chilled Water System Application in College Mini Chillers FCU FCU FCU FCU Chiller Bus NIM Bus Smart HydroIntel Manager The above diagram is an illustration of how Smart Manager Chilled Water System can be used to control and monitor HVAC system in a college environment. The control and monitoring of FCU and mini chillers is easily carried out from the centralised control room. The following application example in college requires cooling and heating simultaneously during winter. 3-15

54 Smart Manager Chilled Water System Application for Cooling and Heating with 4 pipe system Hot water boiler FCU for HVAC To other FCU FCU for machine cooling Netware 2 NIM Netware 2 NIM For cooling and heating For cooling purpose only NIM Bus Smart HydroIntel Manager Chiller Bus Communication cable Water Piping This application uses 4 pipe system. During summer only the mini chillers will operate in cooling mode to cool all lecture rooms and machine rooms while boiler stops. However during winter mini chiller operates in heating mode and boiler will operate as supplement to mini chiller to heat all lecture rooms. Mini Chiller is used to control boiler operation ( Refer to Section 2 for details on boiler application with mini chiller ). Another mini chiller will operate in cooling mode ( with field installed fan speed controller ) to cool machine rooms like computer rooms, generator rooms etc. 3-16

55 Smart Manager Chilled Water System Application In Supermarket for Cooling and Heating purpose Hot water boiler FCU for HVAC Chiller for HVAC Netware 2 NIM NIM NIM NIM NIM Bus Smart HydroIntel Manager Chiller Bus Communication cable Water Piping Chiller for low temperature application Freezer Freezer Freezer 3-17

56 Smart Manager Chilled Water System Application In Hotels for Cooling & Heating Heat reclaim piping Chiller for Clean water supply HVAC Heat reclaim piping Hot Water Storage Tank Hot Water Storage Tank Kitchen for dish washing, cleaning Bathroom for shower Chiller for HVAC Chiller Bus NIM Bus Clean water supply Smart HydroIntel Manager FCU for HVAC NIM FCU for HVAC NIM Netware 2 Communication cable FCU for HVAC NIM Water piping 3-18

57 3.3 Wiring for Smart t Manager er Chilled Water System Slave Chiller Control Panel Mini Chiller Main Board Panel ID 1 Unit ID 1 4 pole terminal block for networking cable Master Chiller Control Panel Mini Chiller Main Board Panel ID 0 Unit ID 0 NIM Smart HydroIntel Manager To FCU Main Board To display control module Factory Installed Cable Networking cable 3-19