ClimateCraft MatrixMonitor V2 Manuale utente



Installation,Operationand

MaintenanceManual



MatrixMonitor™V2

Thisistheinstallation,maintenanceandoperationmanualfortheClimateCraft®MatrixMonitor™airflowmonitoringsystem

forfanarrays.



MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 1

Contents

Introduction .................................................................................................................................................. 3

 ...................................................................................................................... 3

Control Unit............................................................................................................................................... 3

Embedded Control System ....................................................................................................................... 3

Power Supply ............................................................................................................................................ 4

Key Pad Display ......................................................................................................................................... 4

Piezometric Pressure Port......................................................................................................................... 5

Fan Sensor................................................................................................................................................. 5

Fan Array Pressure Rise Sensor................................................................................................................. 7

User Interface ............................................................................................................................................... 8

Set Up Procedure ........................................................................................................................................11

Set the Array Data................................................................................................................................... 12

Set Up Array 1 .....................................................................................................................................12

Set the Number of Fans ...................................................................................................................... 12

Select the Fan Model .......................................................................................................................... 13

Select the Wheel Width...................................................................................................................... 14

Set the Array Name............................................................................................................................. 15

Set the Sensor Position ....................................................................................................................... 16

Set the Optional Dampers...................................................................................................................17

Set the Fan Status ...............................................................................................................................18

Set Up Array 2 .....................................................................................................................................19

Set the Control Data................................................................................................................................20

Scale the Flow Signal........................................................................................................................... 21

Scale the Pressure Signal ....................................................................................................................21

Select the Flow Units .......................................................................................................................... 22

Enable Modbus Communication with BMS ........................................................................................22

Set the Baud Rate for the RS485 communication line........................................................................23

Set Parity for the RS485 communication line .....................................................................................23

Set the device ID for BMS communication ......................................................................................... 24

Set the Vibration Alarm Limits............................................................................................................24

Grease Life Timer................................................................................................................................ 25

Starting the Grease Life Timer ............................................................................................................25

Set the real time clock ............................................................................................................................31

Time and Date.....................................................................................................................................31

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 2

Display Information..................................................................................................................................... 33

Display Airflow ....................................................................................................................................33

Display Individual Fan Details .............................................................................................................34

Display Time/Date...............................................................................................................................38

Communication Status........................................................................................................................ 38

Vibration Data..................................................................................................................................... 39

Motherboard Data..............................................................................................................................41

Lubrication Status ...............................................................................................................................41

Software Version................................................................................................................................. 42

Vibration Monitoring .................................................................................................................................. 43

Lubrication Monitoring ............................................................................................................................... 44

Throat and Cone Tap Flow Range ............................................................................................................... 46

Interface to Building Management System ................................................................................................47

Hard Wired Connections......................................................................................................................... 47

Modbus® Communications.....................................................................................................................48

Trouble Shooting Guide .............................................................................................................................. 54

Repair and Replacement............................................................................................................................. 58

Remove the Swing out Graphic Panel..................................................................................................... 58

Power Supply ..........................................................................................................................................59

Mother Board..........................................................................................................................................60

Clock Battery........................................................................................................................................... 61

Embedded Processor Board....................................................................................................................62

Keypad Display Unit ................................................................................................................................ 62

Fan Sensor............................................................................................................................................... 63

Array Pressure Rise Sensor .....................................................................................................................64

Replace or Install a Wiring Connector for an FSB ...................................................................................64

Replacement parts list ............................................................................................................................ 66

System Specifications.................................................................................................................................. 67

Sample Wiring Diagram ..............................................................................................................................68

Modbus® Register List.................................................................................................................................69

ClimateCraft® Service.................................................................................................................................. 75

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 3

Introduction

The ClimateCraft® is a digital instrument that monitors the operation of ClimateCraft®

FanMatrixfan arrays. A fan array will have two or more fans operating in parallel to provide airflow in

an air handling system. MatrixMonitorsolves the problems of monitoring the airflow of multiple fans

by combining the individual fan airflow readings into a combined reading for the array. MatrixMonitor

provides additional added value features to aid in the operation and maintenance of your fan array.

These features include fan failure detection, surge detection, vibration monitoring and lubrication

monitoring.

MatrixMonitor™ Components

Control Unit

The control unit contains the embedded control system, the

12VDC power supply and the keypad display unit. These parts

are enclosed in a polycarbonate NEMA 4X enclosure with a clear

hinged cover that allows visual inspection of the keypad display

unit while closed. The keypad display unit is mounted on a swing

out dead front panel. Opening the dead front panel allows

access to the embedded control system and power supply. The

parts in the control unit are described separately below.

Embedded Control System

The embedded control system used in the Matruses

a Rabbit® RCM3000 control module made by Digi International.

The control module is mounted on a custom motherboard that

provides all of the input and output connections. It is mounted on the back side of the swing out dead

front panel directly behind the keypad display unit. Swinging the panel out exposes the motherboard

and the control module that is mounted on it. The interface connections to the fan and pressure

transducers and the field connections to the building

management system (BMS) are made on the mother board

with the pull off terminal strips provided. This design provides

easy access to the wiring connections and internal components

of the control unit.

The control unit supplies power to the fan sensors and the

array pressure rise sensor and communicates digitally with

those devices over an EIA/TIA 485 2 wire multi-point

communication line. It can monitor one or two fan arrays with

as many as 49 fans in each array.

Control Unit

Embedded Control Module

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 4

A second EIA/TIA 485 (RS485) 2 wire multi-point communication line is provided for communication to

the building automation system (BMS) using the Modbus RTU protocol.

The control unit firmware is written to flash memory on the Rabbit RCM3000 module. It is self-

contained, universal and upgradeable on site



from set up menus accessed by the key pad display. There is only one active version of the firmware at

any given time and there are only a few parts necessary to make the system work. This makes it easy to

keep the system up and running with minimum number of spare parts. If your site has multiple air

regardless of how

varied the air handling units are in capacity and configuration.

Power Supply



system is a 100 watt Mean Well Direct model

RS-100-12. It is a switching power supply that

provides 12 volts DC to the embedded

control system, the fan sensor boards and the

array pressure rise transducers. It accepts

input voltage from 88 VAC to 264VAC at 47

Hz to 63 Hz. The power supply is mounted to

the backplane of the control enclosure. The

AC supply power connections are made

directly to the appropriate terminals on the

power supply.

WARNING

disconnected.

Failure to disconnect power before servicing can cause severe personal injury or death.

Key Pad Display

The key pad display unit has a backlit 122 x 32 pixel LCD graphic display, 7 signal

LEDS (1 red, 4 green, 2 yellow), and a 7 switch key pad. The unit plugs into the

backside of the motherboard through the onboard connectors.

The signal LEDS on the front of the key pad display unit are programmed to provide

specific information. The red LED is turned on if there is a fan failure. The 4 green



airflow analog output signal. The closer the actual array airflow is to the maximum

The first (left) yellow LED is turned on if one

Key Pad Display

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 5

or more fans go into surge. The second yellow LED (right) is turned on if the determines

that there is a problem in reading any of the transducers. If a transducer has gone bad or a signal has

reached the maximum making it impossible to calculate the actual flow or pressure this LED will be lit. It

will also light when the grease monitor trips or the fan vibration limits are exceeded.

The keys along with text prompts from the graphic display are used to configure the control to the

application through menu driven setup screens and display real time fan array performance information

screens.

Piezometric Pressure Port

The piezometric pressure port is a pressure tap that is usually inserted into

the throat of the fan inlet cone at its smallest diameter. The tap connection

fitting is on the high pressure side of the cone. The tap is piped from the

downstream side of the cone through the back plate of the fan so that

connection can be made to the pressure transducer located on the inlet

side of the fan air seal wall. If the design flow through the fan is higher than

the rating of the pressure transducer on the fan sensor board (FSB) an

alternate low pressure tap placed higher on the cone will be used. Only one

port will be connected to the pressure transducer on the FSB. The taps are

mounted on the inlet cone with the port end exposed to the flow side of

the inlet cone. They are press fit into the cone and the connection

side is on the

high pressure

side of the inlet cone. The fan sensors are mounted

on the inlet side of the fan back plate so the

pressure tubing that connects to the pressure tap is

routed to the inlet side of the back plate through a

bulkhead connector. The connection is made to the

low pressure side (negative side) of the pressure

transducer on the FSB. The high pressure side of

the pressure transducer is left open to sense the

fan inlet pressure. Throat and

Cone Tap Flow Range

information about when the throat tap or the cone tap should be

used.

Fan Sensor

The fan sensor is a custom assembly that contains the special MEMS pressure transducer, a temperature

transducer, a tri-axial accelerometer, and a high performance 32 bit RISC microcontroller to read and

process the transducer data and communicate with the host. The fan sensor board (FSB) has the

pressure transducer mounted on the top side and the components and connection points on the bottom

side. It is designed to mount on a standard 2 x 4 outdoor utility electrical box. The pressure transducer

Connection to Throat Tap

Location of Pressure Taps

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 6

ports are accessible for connecting to the piezometric port. The FSB acts as the box cover. When it is

removed the switches and connections are accessible.

The fan sensors are mounted on the entering air side of the fan back panel. There is one fan sensor for

every fan in the array. The low pressure port (-) of the pressure transducer is connected to the



is open to sense the air pressure at the inlet of the fan.

The fan sensor is mounted on the fan back plate so that the accelerometer can sense the fan vibration.

The FSB microcontroller continuously reads the tri-axial accelerometer data and performs a real time

FFT on the data stream to convert the information from the time domain to the frequency domain

where it can be analyzed. Each fan sensor has a temperature transducer and the host computer in the

control unit calculates the average of all of the sensors in the

array to determine the entering air density for the airflow

calculation. Only the system with the worst vibration needs to

be monitored, substantially reducing the data collection effort.

Each fan sensor board (FSB) is connected to the control unit

through a common dual twisted pair plenum rated cable

(Belden 1325A or equal). One twisted pair is used to supply

12VDC power to the FSB units. The other twisted pair is used

for digital communications between the FSB units and the



cable connection is made at the CPU which goes to the first

FSB on the chain. From there the cable goes to the next FSB

unit. This connection sequence continues until all if the FSB

units are connected. There is no need to maintain a particular

order of connection between specific FSB units because the

control unit can address each unit individually.

The connection from the cable to the FSB unit is

made with a 4 position feed through insulation

displacement connector. The cable wires run

unbroken from the control unit to the last FSB unit

on the chain. This insures the reliability of the

connections. Each twisted pair is foil wrapped and

there is a tinned copper bleed wire running through

the cable in continuous contact with the foil shields

on each twisted pair. At each FSB connection box

the cable jacket and the foils shields are removed to

give access to the conductors. The bleed wire is

never cut. It is connected to ground in the control

unit and runs continuously to the end of the cable where it is left unattached. Each 4 pin conductor has

Fan Sensor

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 7

a strain relief cover attached to keep incidental wire movement from pulling on the connection pins

which insures a good electrical connection between the cable conductors and the connector.

There is a dual DIP switch mounted on the component side of the FSB assembly. This switch is to

activate the line termination resistors.

NOTICE

The dual Dip switches should be in the off position on all of the FSB units except for the

last unit on the cable.

The last FSB unit on the cable should have the switches turned on to tie in the line termination resistors.

It is possible (but not necessary) to have two cables run out from the control unit. A unit with two arrays

might be wired where one cable goes to a first array and the second cable goes to the second array. This

architecture is important when large numbers of fans are used because it increases the ability to deliver

power to the FSB units. When two cables are used the line termination switches must be switched on

for the FSB units on the end of each line. In this case the FSB line termination jumpers on the mother

board in the control unit must be removed.

There are two rotary switches mounted on the component side of the FSB units. These switches provide

the FSB unit with an ID which it uses to communicate with the control unit. These switches must be set

in a specific sequence for the MatrixMonitorto function properly. For array 1, the fan sensor switches

49. The FSB unit on fan 1 



reserved for the array pressure rise sensor (see below). Each fan must have a fan sensor. The numbering



If the MatrixMonitorcontrol unit is tied to a second fan array, as might be the case if the AHU has a



reserved for fan array 2. ID 50 is reserved for the pressure rise sensor of the second fan array. To get the

switch setting for the FSB units in fan array 2 simply add 50 to the fan number. Otherwise the

sequencing and restrictions are exactly the same as for fan array 1.

Fan Array Pressure Rise Sensor

The same FSB assembly used for the fan sensor is also used for the fan array

pressure rise sensor. The pressure rise sensor is mounted to the fan air seal wall

on the air inlet side. The high pressure port (+) of the pressure transducer is

connected to the downstream side of the fan air seal wall with flexible tubing to

a bulkhead connector. The low pressure port is left open to reference the air

pressure entering the fan array.

Each array connected to the MatrixMonitorcontrol unit must have a pressure

sensor. The switch setting for the pressure rise sensor on array 1 is 00. If there

is a second array connected to the 

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 8

The pressure rise sensor FSB units are connected to the connection cable in exactly the same manner as

the fan sensor FSB units. They do not need to be located on the cable in any particular order.

User Interface

MatrixMonitoruses a hierarchical menu structure

to allow the user to access the considerable amount

of information available about the performance of

the fan array and to configure the unit to any

conceivable ClimateCraft® fan array.

When the unit powers up a sign on message appears.

The sign on message will display the ClimateCraft®

logo and the message string ClimateCraft

MatrixMonitor V2.nn scroll horizontally across

the screen from left to right. The last letters in the

scrolling message are the version level of the

software that is installed on your equipment.

MatrixMonitor is fully functional while this screen is

up and will perform all of its monitoring and

communication functions. Communications with the

building management system (BMS) are active.

The keys have graphic symbols on them that are designated in the software with the following meaning:

= Left  -= minus 1 + = plus 1

  = enter

These keys along with prompts given on the graphic display allow you to navigate the menu structure of

the MatrixMonitorin order to set up the system and display the performance information for the fan

arrays it monitors.

There are seven signal LED lamps on the front of the keypad display unit that

provide valuable information about the fan array. See the section above titled

“Key Pad Display” for a detailed description about the function of the signal

LEDs.

Press the(enter) key when the sign on message is active and you will get the main menu screen.

MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 9

The main menu is the highest menu in the structure and is your starting point for navigating through the

display and set up screens. The main menu of the is as follows:

Menu Lines Displayed ……………….. Screen Type (Screen Function)

<<< Main Menu >>>

1. Display Airflow (Airflow, Pressure Rise, Temperature, Fan Speed)

2. Array 1 Fans (Airflow & Piezometric Pressure by fan for array 1)

3. Array 2 Fans (Airflow & Piezometric Pressure by fan for array 2)

4. Array 1 Options  Setup submenu (Fan set up data for array 1)

5. Array 2 Options  Setup submenu (Fan set up data for array 2)

6. Control Setup  Setup Submenu (Control set up data)

7. Clock Settings  Setup Submenu (Set time and Date)

8. Display Time and Date (Current Time and Date)

9. Comm Status (Communication performance overall & each FSB)

10. Array 1 Vibration (Peak vibration levels per fan for array 1)

11. Array 2 Vibration (Peak vibration levels per fan for array 2)

12. Mother Board Data (Board temp, barometric press, FSB current & volts)

13. Grease Life Data (Airflow, Pressure Rise, Temperature, Fan Speed)

14. About (Sign on message with firmware version number)

Only 4 lines of data will fit on the graphic display so 11 of

the 15 lines of data are not visible. Use the  keys

to scroll through the main menu and expose all of the

menu items. As you scroll through the menu, the display

will invert the pixels for an individual menu line as you

scroll. In this text we will refer to that line as the

. There are four types of screens used



Submenu screens, and Setup screens. When you are in

the main menu or on any sub-menu, pressing the

(enter) key will close the menu you are in and open the

display, setup, or submenu screen that was highlighted.

Display screens are used to display useful information

about the performance for the fan arrays) attached to

The lay out and data presented

vary by screen type and function. Pressing thekey when on any display screen, will close the current

display screen and return to the main menu. On the display screens that provide data for individual fans

Array 1 Options and keys are used to scroll between fans. When multiple

Array 1 Vibration) the and 

scroll between data items. Each screen will give specific instructions on the navigation keys used in that

display function. The instructions are on the bottom 1 or 2 lines of the display.

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