McQuay MicroTech II Manuale utente

Installation Manual IM 781-2

Group: Controls

Part Number: IM 781-2

Date: November 2005

Supersedes: IM 781-1

MicroTech II®

Chiller System Manager (CSM) Installation Manual

For

MicroTech II Chillers

Hardwired Chillers

Page 2 IM 781-2

Table of Contents

Figures ...................................................................................................................................................3

Tables ....................................................................................................................................................4

Notice ....................................................................................................................................................4

Reference Documents ............................................................................................................................4

Revision History ....................................................................................................................................5

Introduction............................................................................................................................6

Applying the CSM .................................................................................................................................8

Typical Chilled Water System ...........................................................................................................8

Chiller Evaporator Configuration ......................................................................................................8

Secondary Pump/Decoupler Line Configuration .............................................................................10

Loop Bypass Configuration .............................................................................................................11

General Description.............................................................................................................12

Panel Location and Mounting ............................................................................................13

Unpack the CSM Panel........................................................................................................................13

Physical Installation.............................................................................................................................13

Tools Required ................................................................................................................................13

Mounting..........................................................................................................................................13

Removing and Replacing the Cover.....................................................................................................16

Removing the cover of a CSM.........................................................................................................16

Replacing the cover of a CSM .........................................................................................................16

Sensor Installation................................................................................................................................16

Immersion Water Temperature Sensor ............................................................................................16

Outdoor Air Temperature and/or Relative Humidity Sensor ...........................................................18

Field Wiring ..........................................................................................................................19

Power Wiring.......................................................................................................................................19

About the CSM Transformer ...........................................................................................................19

Making the Power Connection to the CSM Transformer.................................................................19

Ethernet Communications to the User Interface and BACnet..............................................................20

LONWORKS Communications to Chillers and Remote I/O Modules ...................................................20

Free Topology Networks .................................................................................................................21

Free Topology Restrictions.......................................................................................................................... 22

Bus Topology Networks ..................................................................................................................22

Bus Topology Restrictions........................................................................................................................... 22

Network Cable Termination.............................................................................................................23

Qualified Cables ..............................................................................................................................23

AnaIog/Digital Inputs and Outputs Wiring..........................................................................................23

Onboard I/O Wiring.........................................................................................................................24

Temperature Inputs.................................................................................................................................. 25

0-10 VDC Inputs or 4-20 mA Inputs....................................................................................................... 26

Analog Input Cable Specifications.......................................................................................................... 28

Digital Inputs........................................................................................................................................... 28

Digital Outputs ........................................................................................................................................ 29

Remote I/O Wiring ..........................................................................................................................31

Analog Inputs .......................................................................................................................................... 31

Digital Inputs........................................................................................................................................... 32

Analog Outputs ....................................................................................................................................... 32

Digital Outputs ........................................................................................................................................ 33

Modems ................................................................................................................................39

Internal Modem ...................................................................................................................................39

External Modem ..................................................................................................................................39

Using the Admin Tool to Configure the CSM/Modem........................................................................40

About the Admin Tool .....................................................................................................................40

Configuring the CSM for Your Modem...........................................................................................40

Initial Checkout and Troubleshooting...............................................................................43

Checking the Heartbeat LED ...............................................................................................................43

About the Battery.................................................................................................................................43

Appendix A: Hardwired Chiller Control .............................................................................45

IM 781-2 Page 3

Hardwired Chiller Remote I/O Module Analog Inputs ........................................................................47

Chiller % RLA (AI 1) ......................................................................................................................47

Chillers With % RLA Output ...................................................................................................................... 47

Chillers Without % RLA Output................................................................................................................. 48

Chiller Leaving Evaporator and Leaving Condenser Water Temperatures (AI 3 and AI 4) ............49

Hardwired Chiller Remote I/O Module Digital Inputs.........................................................................50

Evaporator and Condenser Flow Proving (DI 1 and DI 2)...............................................................50

Hardwired Chiller Alarms (DI 3 and optionally DI 4) .....................................................................50

Hardwired Chiller Remote I/O Module Analog Outputs .....................................................................50

Hardwired Chiller Leaving Water Temperature Setpoint Reset (AO 1) ..........................................50

Hardwired Chiller Load Limiting (AO 2) ........................................................................................51

Hardwired Chiller Remote I/O Module Digital Outputs ......................................................................51

Evaporator and Condenser Pump Control (Relay 1)........................................................................51

Evaporator and Condenser Pump Control (Relay 2 and Relay 3) ....................................................51

Transformer Usage...............................................................................................................................51

Maintenance.........................................................................................................................54

Cleaning ...............................................................................................................................................54

Required Battery Maintenance.............................................................................................................54

Replacing the Battery...........................................................................................................................54

Parts List ..............................................................................................................................................55

Warranty...............................................................................................................................56

Warranty Return Material Procedure ...................................................................................................56

Replacement Parts................................................................................................................................56

Index.....................................................................................................................................57

Figures

Figure 1. System Architecture...............................................................................................................6

Figure 2. Typical Chilled Water System...............................................................................................8

Figure 3. Parallel Configurations ..........................................................................................................9

Figure 4. Series/Parallel Configurations ...............................................................................................9

Figure 5. Combination Configurations..................................................................................................9

Figure 6. Common Primary Pump with Separate Isolation Valves .....................................................10

Figure 7. Fixed-Speed Secondary Pump .............................................................................................10

Figure 8. Variable-Speed Secondary Pump ........................................................................................10

Figure 9. Lead/Standby Secondary Pumps..........................................................................................11

Figure 10. Sequenced Secondary Pumps ............................................................................................11

Figure 11. Pressure-Controlled Loop Bypass .....................................................................................11

Figure 12. Mounting Guide.................................................................................................................14

Figure 13. Mounting Detail.................................................................................................................15

Figure 14. Immersion Sensor ..............................................................................................................17

Figure 15. Brass Thermowell..............................................................................................................17

Figure 16. Outdoor Air and/or Relative Humidity Sensor ..................................................................18

Figure 17. Singly Terminated Free Topology.....................................................................................21

Figure 18. Combining Network Segments with a Repeater ................................................................22

Figure 19. Bus Network Topology......................................................................................................22

Figure 20. Thermistor wiring ..............................................................................................................25

Figure 21. Analog Input 0-10VDC Wiring .........................................................................................26

Figure 22. Analog Input 4 to 20 mA Wiring.......................................................................................27

Figure 23. Digital Input Wiring ..........................................................................................................29

Figure 24. CSM Field Wiring Schematic............................................................................................30

Figure 25. CSM Remote I/O Modules A and B Field Wiring Schematic ...........................................35

Figure 26. CSM Remote I/O Modules C and D Field Wiring Schematic ...........................................36

Figure 27. CSM Remote I/O Modules E and F Field Wiring Schematic ............................................37

Figure 28. CSM Remote I/O Modules G and H Field Wiring Schematic ...........................................38

Figure 29. Main Board Layout............................................................................................................44

Page 4 IM 781-2

Figure 30. Typical Hardwired Chiller Field Wiring Diagram..............................................................46

Figure 31. Direct % RLA Signal from Chiller .....................................................................................47

Figure 32. Measuring Compressor Amps with a Current Output Current Transducer.........................48

Figure 33. Hardwired Chiller’s Possible Hardware Requirements .....................................................53

Tables

Table 1. 120 VAC models building power termination ......................................................................19

Table 2. International Models - 240 VAC models building power termination..................................20

Table 3. Examples of Possible Ethernet Hardware.............................................................................20

Table 4. Analog/Digital Inputs and Outputs .......................................................................................24

Table 5. External Modem Hardware...................................................................................................39

Table 6. External Modem Modular Adapter Assembly Pin Assignments...........................................40

Table 7. Modem Configuration Parameters (ras.properties)...............................................................41

Table 8. Signal Averaging Device Specification ................................................................................48

Table 9. Current Transducer Specification ..........................................................................................49

Table 10. Temperature Sensor Specification .......................................................................................49

Table 11. Voltage to Current Converter (0-10 VDC to 4-20 mA) Specification .................................51

Table 12. Hardwired Chiller’s Hardware Transformer Usage ............................................................52

Table 13. Standard Replacement Parts ...............................................................................................55

Notice

McQuay International reserves the right to change any information contained herein without prior notice. The user is

responsible for determining whether this product is appropriate for his or her application.

The following are trademarks or registered trademarks of their respective companies. Windows and Internet Explorer from

Microsoft Corporation; BACnet from ASHRAE; LONWORKS and LonTalk from Echelon Corporation; Niagara Framework

from Tridium, Inc; Modbus from Gould, Inc.; HyperTerminal from Hilgraeve Inc.; McQuay and MicroTech II from

McQuay International.

Reference Documents

Company Number Title Source

McQuay International OM-780 MicroTech II Chiller System Manager Operation Manual www.mcquay.com

McQuay International IM783 MicroTech II Remote I/O Panel Installation Manual www.mcquay.com

McQuay International IM735 MicroTech II Chiller Unit Controller LONWORKS® Communication

Module

www.mcquay.com

McQuay International CD 112024501 MicroTech II Chiller System Manager Certified Drawing www.mcquay.com

McQuay International CD 112028701 MicroTech II Remote I/O Panel Certified Drawing www.mcquay.com

McQuay International CD 251740501 MicroTech II Chiller System Manager Remote I/O Module Certified

Drawing

www.mcquay.com

Tridium, Inc - Net Connect Guide www.mcquay.com

Tridium, Inc - Using the Admin Tool www.mcquay.com

Echelon 078-0156-01G LONWORKS FTT-10A Transceiver User’s Guide www.echelon.com/support/documentatio

n/Manuals/078-0156-01G.pdf

IM 781-2 Page 5

Revision History

IM 781-0 February 3, 2004 First release.

IM 781-0 April 6, 2004 Minor changes prior to Chinese translation.

IM 781-0 June 2004 Remove common supply control.

IM 781-1 November 2004 Added hardwired chiller appendix.

IM 781-2 November 2005 Added text in Modems section to clarify that

internal (vs external) modem is recommended.

Updated AdminTool installation instructions.

Page 6 IM 781-2

Introduction

The MicroTech IITM Chiller System Manager (CSM) software consists of a web User Interface (WebUI – Web-like pages

accessible with Microsoft Internet Explorer) and multiple chiller control strategies programmed for common control of

multiple chiller unit controllers. The browser-based User Interface is used to edit control parameters required for multiple-

chiller control algorithms and to set certain parameters in the chiller controllers as necessary for multiple-unit control.

The multiple-unit control strategies provide automatic control for chillers connected to the CSM. The CSM software

executes and communicates information using a LONWORKS® communication network between the CSM and the

associated chiller unit controllers. The CSM is capable of communicating with a connected building automation system

(BAS) using BACnet® (IP or Ethernet protocol as standard) or Modbus® (RTU or ASCII available as an option). For

additional information, see the BACnet or Modbus Protocol Information documents, ED 15075 and ED 15077

respectively.

For additional information about the CSM’s features, sequence of operation, and programmable options, refer to OM 780-

MicroTech II Chiller System Manager Operations Manual. For specific information about the chiller unit controllers, refer

to the appropriate unit controller installation and/or operation manual.

Figure 1. System Architecture

!WARNING

Electric shock hazard.

Can cause personal injury or equipment damage.

This equipment must be properly grounded to the MicroTech II control panel. Connections and service

must be performed by trained personnel with experience with the equipment being controlled.

IM 781-2 Page 7

NOTICE

The IP Address is provided is on the packing slip. An extra copy is provided in the envelope inside the shipping box. Keep

this information in a safe place and forward it to the future operator of the chiller system.

!CAUTION

Static sensitive components.

Can cause equipment damage.

Discharge any static electrical charge by touching the bare metal inside the control panel before performing any

service work. Never unplug cables, circuit board terminal blocks, or power plugs while power is applied to the

panel.

!CAUTION

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15

of the FCC rules. This equipment can interfere with radio communications, especially in a residential area. Installer

and user must prevent or correct any interference at their own expense. McQuay International disclaims any

liability resulting from any interference or for the correction thereof.

Page 8 IM 781-2

Applying the CSM

The CSM has been designed to control several common chiller plant configurations. Figure 2 shows a typical chilled water

system configuration. The following pages describe typical plant configurations that can be controller by the CSM and the

guidelines for applying the CSM in them. The chillers in these configurations can be all centrifugal, all reciprocating, all

screw, or a combination of centrifugal, reciprocating, or screw.

The CSM may be suitable for applications other than those shown. If your application does not match one of the listed

configurations, contact your McQuay sales representative for assistance.

Typical Chilled Water System

The typical chilled water system configuration is shown in Figure 2. The characteristics of this system consist of the

following: (1) a set of chillers, usually piped in parallel, (2) each chiller has its own primary chilled water pump, (3) the

system may or may not have a bypass line and valve that is controlled by a differential pressure controller, (4) the system

may have secondary pump(s) to distribute water to the cooling loads.

Figure 2. Typical Chilled Water System

Cooling Loads

Chiller #3

centrifugal

Chiller #2

centrifugal

Chiller #1

centrifugal

Chiller evaporator configuration

Loop bypass configuration

Return chilled water temperature

Supply chilled water temperature

Secondary pump/decoupler line configuration

a0093

Variations to the typical chiller system configuration can be controlled. Refer to Figure 3 through Figure 11. The options

described by inserting these figures into the dotted areas shown in Figure 2 above can also be controlled by the CSM.

Chiller Evaporator Configuration

In these systems (Figure 3 through Figure 6), the temperature of the water entering the loads will always be very close to

each chiller’s leaving evaporator water temperature setpoint. In Figure 6, all chillers share a common primary pump but

each chiller has an isolation valve.

IM 781-2 Page 9

Figure 3. Parallel Configurations

Chiller #12

screw

Chiller #3

centrifugal

Chiller #2

centrifugal

Chiller #1

reciprocating

Figure 4. Series/Parallel Configurations

Chiller #7

centrifugal

Chiller #5

centrifugal

Chiller #3

centrifugal

Chiller #1

centrifugal

Chiller #2

centrifugal

Chiller #4

centrifugal

Chiller #6

centrifugal

Chiller #8

centrifugal

C C

Figure 5. Combination Configurations

Chiller #11 & #12

dual centrifugal

C C

Chiller #5 & #6

dual centrifugal

C C

Chiller #1

reciprocating

Chiller #2

screw

Chiller #3

centrifugal

CChiller #4

centrifugal

Page 10 IM 781-2

Figure 6. Common Primary Pump with Separate Isolation Valves

Chiller(s)

!CAUTION

Significant changes in the chilled water flow rate through the evaporators can result when chillers in Figure 6 are

turned on or off. Large flow rate changes can cause erratic chiller control.

Secondary Pump/Decoupler Line Configuration

Figure 7 through Figure 10 represent the four secondary pump control options available using the CSM.

Figure 7. Fixed-Speed Secondary Pump

Decoupler line temperature

Uni-directional flow meter

(supply to return)

a0100

Figure 8. Variable-Speed Secondary Pump

Note:

A pressure-controlled loop bypass may not be used with a

variable-speed secondary pump.

DPT

Differential pressure transducer

Decoupler line temperature

VFD

Uni-directional flow meter

(supply to return)

Variable frequency drive

a0101

Using the variable-speed secondary pump maintains a desired pressure across the chilled water loop.

Note: A pressure-controlled loop bypass (see Figure 11) may not be used with variable-speed secondary pump(s).

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