Acson Hydrotech Chilled Water System Solution Application Manual

7/26/2019 Acson Hydrotech Chilled Water System Solution Application Manual

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CHILLED WATER

SYSTEM SOLUTION

APPLICATION MANUAL


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AAAAACSON HyCSON HyCSON HyCSON HyCSON HydrdrdrdrdroToToToToTececececechhhhhChilledChilledChilledChilledChilled WWWWWaaaaater Systemter Systemter Systemter Systemter System

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FirFirFirFirFirst Editionst Editionst Editionst Editionst Edition

JJJJJulululululy 2005y 2005y 2005y 2005y 2005


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IntrIntrIntrIntrIntroductionoductionoductionoductionoduction

Introduction ................................................................................................................ Introduction-1

Section 1:Section 1:Section 1:Section 1:Section 1:NetwNetwNetwNetwNetwororororork Interfk Interfk Interfk Interfk Interface Module (NIM) and Netwace Module (NIM) and Netwace Module (NIM) and Netwace Module (NIM) and Netwace Module (NIM) and Netwararararare 2e 2e 2e 2e 2

1.1 About NIM ................................................................................................................ 1-1

1.2 Installation ................................................................................................................ 1-2

1.3 Address Assignment ................................................................................................ 1-3

1.4 Master and Slave FCU............................................................................................. 1-5

1.5 About Netware 2 ...................................................................................................... 1-6

1.6 Netware 2 and NIM Application ................................................................................ 1-6

1.7 NIM Wiring ...............................................................................................................1-11

1.8 G-Way and Building Management System(BMS) ................................................... 1-12

Section 2:Section 2:Section 2:Section 2:Section 2:Chiller ContrChiller ContrChiller ContrChiller ContrChiller Control Pol Pol Pol Pol Panelanelanelanelanel

2.1 About Chiller Control Panel ...................................................................................... 2-1

2.2 Installation ................................................................................................................ 2-2

2.3 Master and Slave Mini Chiller .................................................................................. 2-5

2.4 Chiller Control Panel Applications ............................................................................ 2-5

2.5 Wiring for Chiller Networking................................................................................... 2-19

Section 3:Section 3:Section 3:Section 3:Section 3:HyHyHyHyHydrdrdrdrdroInteloInteloInteloInteloIntel

3.1 About HydroIntel ...................................................................................................... 3-1

3.2 HydroTech System Applications.............................................................................. 3-13

3.3 Wiring for HydroTech System.................................................................................. 3-19

AAAAAppendixppendixppendixppendixppendix

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. ACSON International disclaim any

responsibility for actions based on this manual.

Copyright c 2005 by ACSON International. All rights reserved. This publication is strictly confidential and is meant

for DISTRIBUTORS of ACSON 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 ACSON

International.


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Introduction - 1

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 HydroIntel. HydroIntel 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 HydroIntel, 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


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HydroIntel

> 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


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HydroIntel

HydroIntel

Networking between HydroIntel and Mini Chiller

Networking between HydroIntel and Fan Coil Unit

Introduction - 3


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Section 1

Network Interface Module and Netware 2

1.1 About NIM1.1 About NIM1.1 About NIM1.1 About NIM1.1 About NIM

Network Interface Moduleor NIMacts as an interface to enable communcation between the HydroIntel,Fan

Coil Unit (FCU) and display control panels .

CN2

Connector

CN1

Connector

CN3

ConnectorUnit

Address

Dip

Switch

Group Address

Dip Switch

IC

Bottom Casing Top Casing

Network Interface Module

This means that when FCU parameters are set using HydroIntel, 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 ofwiring).

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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 Installa1.2 Installa1.2 Installa1.2 Installa1.2 Installationtiontiontiontion

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.

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1.31.31.31.31.3 AdAdAdAdAddrdrdrdrdressessessessess AssignmentAssignmentAssignmentAssignmentAssignment

The uniqueness of the HydroIntel 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 HydroIntel 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 number ing 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

Dip switch on top

represents "1"

This Group Address

is 10000000 which

represents Group 1

Likewise, Setting 10100000 represents Group Address 5

Setting 00101000 represents Group Address 20

Setting 00100110 represents Group Address 100

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 )

Dip switch on the

bottom represents "0"

This Unit Address

is 0111 which

represents Unit 7

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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 HydroIntel and the FCU parameter can be monitored

and set-able from the HydroIntel.

( Refer to HydroIntel Operating Manual for operation details )

13/09/2004 11.00am

Status : ON

Mode : Cool

Set Temp : 24C

Fan : High

Room Temp : 27C

Unit : G1U7

HydroIntel displaying FCU parameters

FCU Parameters are

easily monitored

FCU Address displayed

on the HydroIntel

HydroIntel displaying FCU Menus

FCU Parameters are

easily set-able with the

HydroIntel

Operation Menu

Settings Menu

Timer Menu

Alarm Menu

MAIN MENU

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1.4 Master and Sla1.4 Master and Sla1.4 Master and Sla1.4 Master and Sla1.4 Master and Slavvvvve FCUe FCUe FCUe FCUe 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.

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 24C all Slave Units room temperature are set to 24C.

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.

No IR Remote /

SLM3 / Netware 2

Slave 1

Group 1 Group 2

Master Slave 1 Slave 2 Master

NIMMain

Board

Control

Panel

Netware 2

NIMMain

Board

Control

Panel

Netware 2

NIMMain

Board

.IR

NIMMain

Board

Control

Panel

Netware 2

NIMMain

Board

IR Remote

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1.51.51.51.51.5 About NetwAbout NetwAbout NetwAbout NetwAbout Netwararararare 2e 2e 2e 2e 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 group2) 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 HydroIntel has its

advantage over the Netware 2 ( Refer to Section 3 for details on the HydroIntel application )

Display Cont rol Panel Netware 2

1.6 Netw1.6 Netw1.6 Netw1.6 Netw1.6 Netwararararare 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIM AAAAApplicapplicapplicapplicapplicationstionstionstionstions

NetwNetwNetwNetwNetwararararare 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIM AAAAApplicapplicapplicapplicapplication In Sction In Sction In Sction In Sction In Schoolshoolshoolshoolshools

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

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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 24C 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 )

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NIM

NIM

NIM

NIM

NIM

NIM

NIM

Main Board / Display Control

Panel to NIM Wiring

Communication cables

Netware 2 and NIM Appl ication For Mult iple Fan Coil Units In School

Netware 2

Master Unit

Slave Unit

Slave Unit

Slave Unit

Slave Unit

Slave Unit

Slave Unit

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NetwNetwNetwNetwNetwararararare 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIMe 2 and NIM AAAAApplicapplicapplicapplicapplication In Oftion In Oftion In Oftion In Oftion In Offffffice Buildingice Buildingice Buildingice Buildingice 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 One

Zone Three

Zone Two

Zone Four

Zone Five

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.

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NIM

NIM

NIM

NIM

NIM

NIM

Main Board / Display Control

Panel to NIM WiringCommunication cables

Z

O

N

E

1

Z

O

N

E

2

Netware 2 and NIM Appl ication For Multip le Fan Coil Units in Office Build ing

Netware 2

Master Unit

Slave Unit

Slave Unit

Slave Unit

Netware 2

SLM

Master Uni t

Slave Unit

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1.7 NIM1.7 NIM1.7 NIM1.7 NIM1.7 NIM WWWWWiringiringiringiringiring

CN3 For

Communication

Cables

Connection

CN1 For Main Control

Board Wire Connection

CN2 For Display

Control Panel Wire

Connection

The other end of the communication cables are connected to punch boards to ensure wiring is fitted correctly.

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1.8 G-W1.8 G-W1.8 G-W1.8 G-W1.8 G-Waaaaay and Building Manay and Building Manay and Building Manay and Building Manay and Building Managggggement System ( BMS )ement System ( BMS )ement System ( BMS )ement System ( BMS )ement 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 ).

Use 5-Way

Wire to

connect to

FCU Main

ControlBoard

To be

connected

to Display

Control

Panel

Link to BMS

CN1

CN2

CN5

CN4

CN3

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)

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CN3

CN4 240VAC/24VDC

Dry Contact Output 1

CN5 240VAC/24VDC

Dry Contact Output 2

ON/OFF Dry Contact Input

FCU ON/OFF Indicator

Alarm Indicator

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 turn ON/OFF and

alarm can be easily monitored via BMS.

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 HydroIntel.

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Section 2Chiller Control Panel

2.12.12.12.12.1 About Chiller ContrAbout Chiller ContrAbout Chiller ContrAbout Chiller ContrAbout Chiller Control Pol Pol Pol Pol Panelanelanelanelanel

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 HydroIntel 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 HydroIntel front cover displays the name " HydroIntel" while Chiller Control Panel does not have

this display. Besides this, HydroIntel 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 wil l be found on the control panel.

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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/AC080-150C ), MC01 HP MC1.0 2CP DX ( For Mini Chiller 4AC/AC080-150CR ) MC01 EC MC1.0 1CP

DX ( For Mini Chiller 4AC/AC020-060C ) and MC01 HP MC1.0 1CP DX ( For Mini Chiller 4AC/AC020-060CR)

Refer to Mini Chiller Technical Manual or Operation Manual for Chiller Control Panel operation guide. (Forwiring example refer to Wiring for Chiller Networking in this section)

2.2 Installa2.2 Installa2.2 Installa2.2 Installa2.2 Installationtiontiontiontion

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.

For field wiring, connect

communication cables

here

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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 0C to 50C.

d) Exposure to direct sunlight and rain.

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2.3 Master and Sla2.3 Master and Sla2.3 Master and Sla2.3 Master and Sla2.3 Master and Slavvvvve Mini Chillere Mini Chillere Mini Chillere Mini Chillere 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

2.4 Chiller Contr2.4 Chiller Contr2.4 Chiller Contr2.4 Chiller Contr2.4 Chiller Control Pol Pol Pol Pol Panelanelanelanelanel AAAAApplicapplicapplicapplicapplicationstionstionstionstions

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.

Mini Chiller

Main Control

Board

Typical Bus Structure for Mini Chiller Network

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Chiller ContrChiller ContrChiller ContrChiller ContrChiller Control Pol Pol Pol Pol Panelanelanelanelanel AAAAApplicapplicapplicapplicapplication In Prtion In Prtion In Prtion In Prtion In Process Coolingocess Coolingocess Coolingocess Coolingocess 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

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100

Tue 0800 1800 1900 2100

Wed 0800 1800 1900 2100

Two set-

able Timer

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.

[Ch 1]

Alarm 1

Comp 1 overload

17/09/04 4:00am

Default chiller

is Chiller 1The fault for

Chiller 1 is

Compressor 1

Overload

Alarm Number 1

Date and time

alarm occur

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Chiller Control Panel Application for Multiple Mini Chillers in Process Cooling

Slave Unit

Master Unit

Slave Unit Slave Unit

Communication cable Water piping

Master Chiller

Control Panel

placed in the

Process Control

Room

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Chiller ContrChiller ContrChiller ContrChiller ContrChiller Control Pol Pol Pol Pol Panelanelanelanelanel AAAAApplicapplicapplicapplicapplication ftion ftion ftion ftion for Multiple Mini Chilleror Multiple Mini Chilleror Multiple Mini Chilleror Multiple Mini Chilleror Multiple Mini Chillers Used in Ofs Used in Ofs Used in Ofs Used in Ofs Used in Offfffficesicesicesicesices

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/AC080-150C/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.

Communication cable

Master Chiller Control Panel

placed in the HVAC centralised

control room

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AdAdAdAdAdvvvvvance Pance Pance Pance Pance Parararararameterameterameterameterametersssss

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 220-240VAC for auxilliary heater and boiler applications.

When use boiler or auxilliary heater the model must be set. This setting is found in the following menu.

Mini Chiller Main Control Board

Mini Chiller Terminal Block

Field Wiring for boiler ( for Cooling & Heatpump )

Field Wiring for auxilliary heater ( for Heatpump model only )

Auxilliary

Heater

Terminal

Boiler

Contactor

Boiler

Terminal

N N

Auxilliary Heater

Relay

Screen 1

Operation Menu

Setting Menu

Timer Menu

Alarm Menu

Display Menu

MAIN MENU

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Screen 2

Set Parameter

Change Password

Panel Option

Screen 3

1. General

2. Sensor

3. Regulator

4. Compressor

5. Defrost

6. Antifreeze

7. Alarm and Contact

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

SETTING MENU

Model is set

according to users

requirement

All Advance

Parameter is foundhere

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 50C while the auxilliary heating set-point, B is set to 5C and the auxilliary

heating differential, C is set to 2C.

When the water entering temperature reaches 45C, ( A-B ) the auxilliary heater operates to heat up the water.

When the water entering temperature reaches 48C, ( A-C ) the auxilliary heater stops operation.

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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 50C. Boiler mode is selected by pressing the Heat Key twice when water

entering temperature is 25C. The boiler starts to operate. The boiler will stop operation when the water entering

temperature reaches 50C.

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 operatebased 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 40C while the auto boiler set point, B is set to 5C and the au to bo iler

differential, C is set to 0C. Mini chiller runs heating mode.

When the water entering temperature reaches 35C, ( A-B ) the boiler will operate. When the water entering

temperature reaches 40C, ( A-C ) , the boiler will stop operation.

When mini chiller switches to boiler mode the water entering temperature is 30C. The boiler will operate. The

boiler stops operation when water entering temperature reaches 40C.

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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:

Cooling Heating Boiling

o x x

o o x

o x o

o o o

o x Auto

o o Auto

Model Selection Mode

Chiller

Heatpump

Chiller / Boiler

Heatpump / Boiler

Chiller + Boiler

Heatpump + Boiler

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 + Boilera llows bo il er 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 )

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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 15C when mini chiller is running cooling mode or 50C when mini

chiller is running heating mode. This could cause compressor high pressure.

An example of 2 pipe system

Mini Chiller

Boiler

FCU

Water Storage

Tank

Expansion

tank

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 ).

An example of 4 pipe system

Mini ChillerFCU

Water Storage

Tank

Boiler

Expansion

tank

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.

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Regulator Parameter

Cooling Set-point

When a cooling set point is set say 12C, the compressor cuts off when the water entering sensor senses the

water temperature to be 12C.

Cooling differential

When the cooling differential is set to say 1.5C, the compressor that has cut off at 12C as mentioned above

will cut in at ( 12+1.5 = 13.5C ). This is for the one compressor system. As for the dual compressor system it is

slightly different.

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 12C and the cooling differential is set to 3C, one compressor cuts off at (

12.0 + 1.5 =13.5C ) while the second compressor cuts off at 12.0C. When the water entering sensor senses

the water temperature at 13.5C, one compressor will cut in. The other compressor will cut in at 15C

Heating Set Point

When a heating set point is set say 40C, the compressor cuts off when the water entering sensor senses the

water temperature to be 40C

Heating differential

When the heating differential is set to say 1.5C, the compressor that has cut off at 40C as mentioned above

will cut in at ( 40-1.5 = 38.5C ). This is for the one compressor system.

One compressor system

Temperature

Cooling set-point + differential Comp on

Cooling set-point

Comp off

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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 40C and the heating differential is set to 3C, one compressor cuts off at

( 40.0 - 1.5 =38.5C ) while the second compressor cuts off at 40.0C. When the water entering sensor senses

the water temperature at 38.5C, one compressor will cut in. The other compressor will cut in at 37.0C

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.

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Examples

A dual compressor system runs cooling mode. When the compressors start the water temperature is 25C. 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

15

13.5

12

1 m 4m 1 m 4m

Time

The system runs with 90% load. During startup, both compressors run until 13.5C 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 15C. Both compressors run until water temperature

reaches 13.5C 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 13.5C where

one compressor cuts off. As the load is small water temperature continues to go down to 12C. Then the

second compressors cuts off. Water temperature goes up to 13.5C 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 10C. It will take 6 minutes to rise to 13.5C before the second compressor cuts in.

Again the compressor ON/OFF cycle has exceeded the minimum time interval of 5 minutes.

Temperature

2510% load

15

13.5

12

10.1

1.5 6m 1.5 6m

m m

Time

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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


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Wiring for boiler and auxiliary heater

Mini Chiller

Boiler

FCU

Water Storage

Tank with

Auxilliary Heater

Expansion

tank

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.

Mini Chiller Main Control Board

Mini Chiller Terminal Block

Auxilliary

Heater

Terminal

Boiler

Contactor

Boiler

Terminal

N N

Auxilliary Heater

Relay C1

3 Way Valve

Power supply

to boiler

R S T N

C1

Auxilliary Heater

220-240VAC

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2.52.52.52.52.5 WWWWWiring firing firing firing firing for Chiller Networ Chiller Networ Chiller Networ Chiller Networ Chiller Networororororkingkingkingkingking

Mini Chiller Main Board

Unit ID 0

4 pole terminal block for networking cable


Unit ID 1


Unit ID 2

Factory Installed Cable Networking cable

Panel ID 2


Slave Chiller Control Panel


Panel ID 0

Panel ID 1

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3.13.13.13.13.1 About HyAbout HyAbout HyAbout HyAbout HydrdrdrdrdroInteloInteloInteloInteloIntel

HydroIntel 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, HydroIntel acts as a centralized controller. It is wire-linked to all fan coil units and mini chillers.

HydroIntel has many user friendly features. Among the HydroIntel 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 system4) Unique Address Assignment to each unit in the networking system

The advantages of HydroIntel 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

HydroIntel

Section 3HydroIntel

3 - 1


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The HydroIntel menu consists of Fan Coil Unit, Chilleror Settings.

The Settings Menu allows users to determine how they would like to control the hydronic system operation.

This is set-able under Priority as follows:

FCU controls mini chiller ON/OFFFCU

Chiller Mini Chiller enables FCU to ON and controls FCU OFF

System ConfigurationPriority Setting

ON/OFF of FCU and mini chiller is independentNone

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 minichiller 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.

Fan Coil UnitChiller

Settings

Priority : None

Cool threshold : 50%

Heat threshold : 50%

Settings

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.

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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.

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HydroIntel 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 HydroIntel and select the desired

group address or unit address.

HydroIntel 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 HydroIntel and select the desired unit

address.

Example

In Hotel X ,rooms are grouped according to floors. The hotel has ten floors and each floor has ten rooms.

HydroIntel 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 HydroIntel 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 25C and run the fan at high speed.He can easily do this within a short time via the HydroIntel.

Unit Selection:

Select All

Select Group

Select One

Selection for FCU

Unit Selection:

Select All

Select One : 0

Selection for Mini Chiller

Mini Chiller Unit

Address is

selected here

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Screen 1

Unit Selection:

Select All Select all FCU

Select Group

Select One

Selection for FCU

Screen 2

Status : ON

Mode : Cool Set parameters

Set Temp : 25C in the Operation

Fan : High Menu

OPERATION MENU

Screen 3 20/09/2004 11.20am

Status : ONMode : Cool Parameters

Set Temp : 25C setting as shown

Fan : High on display

Room Temp : - - screen

Unit : All

HydroIntel 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.

FCUFCUFCUFCUFCU Timer ScTimer ScTimer ScTimer ScTimer Schedulehedulehedulehedulehedule

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.

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Example

College Y has fifty lecture rooms. The HVAC equipment in these lecture rooms run on a programmable timer.

Screen 1

Clock Setting

Date Setting

Timer Schedules Select Timer

Holiday Schedules

Screen 2

Select Schedule

Screen 3 Timer 1 Timer 2

ON OFF ON OFF

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100 Set Timer

Tue 0800 1800 1900 2100

Wed 0800 1800 1900 2100

Screen 4

Swing : No

Sleep : No

Schedule : 1 Select Schedule

Timer : Enable to run the FCU

Enable Timer

Schedule 5

OPERATION MENU

Schedule 1

Schedule 2

Schedule 3

Schedule 4

Timer Menu

SCHEDULE SETTINGS

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Mini ChillerMini ChillerMini ChillerMini ChillerMini Chiller Timer ScTimer ScTimer ScTimer ScTimer Schedulehedulehedulehedulehedule

Mini Chiller programmable timer schedule has two ON/OFF timer each day. This is a 7 day timer schedule.

Screen 1

Set Time

Set Date

Set Schedule Select to set

Timer : Disable schedule

Screen 2 Timer 1 Timer 2

ON OFF ON OFF

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100 Set Timer

Tue 0800 1800 1900 2100

Wed 0800 1800 1900 2100

Screen 3

Set Time

Set Date

Set Schedule

Timer : Enable

Enable Timer

TIMER MENU

TIMER MENU

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HolidaHolidaHolidaHolidaHoliday Scy Scy Scy Scy Schedulehedulehedulehedulehedule

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.

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.

Screen 1

Clock Setting

Date Setting

Timer Schedules

Holiday Select holiday

schedule

Screen 2

Select schedule

Set Holiday 1

Month : 1

Day : 20 Set schedule

Durat ion : Enable

Holiday 3

Holiday 4

Timer Menu

HOLIDAY SETTINGS

Holiday 5

Holiday 1

Holiday 2

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Advance SettingsAdvance SettingsAdvance SettingsAdvance SettingsAdvance Settings

The HydroIntel is designed with BMS ready feature. This feature allows all FCU to be integrated with BMS (

Building Management System )

When BMS setting is enabled, all FCU in the network system is controlled by BMS.

Screen 1

Advance Setting

Change Password

Panel Option

Screen 2

BMS : Enable

Global ON : Enable

Enable all FCU

to ON automatically

SETTING MENU

ADVANCE SETTING

HydroIntel with Building Management System

+12VDC

GND

GND

+12VDC

BMS SYSTEM

ALARM INPUTCONTACT

ON/OFF OUTPUT CONTACT

ALARM OUTPUT CONTACT

ON/OFF INPUT CONTACT

ALARM INPUT CONTACT

HydroIntel

ON/OFF INPUTCONTACT

BMS ALARM SWITCH

BMS ON/OFF SWITCHALARM INPUT

ONOFF INPUT

ON/OFFOUTPUT

ALARMOUTPUT

H/COUTPUT

AUXOUTPUT

3 - 9


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Input Contact (Connect to BMS)Input Contact (Connect to BMS)Input Contact (Connect to BMS)Input Contact (Connect to BMS)Input Contact (Connect to BMS)

Alarm

On/Off

+12VDC

+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.

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Output contact (Connect to BMS)Output contact (Connect to BMS)Output contact (Connect to BMS)Output contact (Connect to BMS)Output contact (Connect to BMS)

Heating/

Cooling

On/OffAlarm

Indicator

Indicator

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.

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Example

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.

To other FCU

NIM

Netware 2

HydroIntel

FCU

Building

Management

System

Communication Cable

Punch Boards

3 - 12


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3.2 Hy3.2 Hy3.2 Hy3.2 Hy3.2 HydrdrdrdrdroToToToToTececececech Systemh Systemh Systemh Systemh System AAAAApplicapplicapplicapplicapplicationtiontiontiontion

When HydroIntel is used together with NIM, Netware 2, FCU, Chiller Control Panel and mini chiller they form an

intelligent networking system known as HydroTech.

The advantages of HydroTech System are as follow:1) Centralised control of all FCU and mini chillers via the HydroIntel.

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

HydroTech System gives the flexibilty to user to control and monitor the HVAC system and Applied system

together.One example is a single HydroIntel 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.

HydroTech System can also be used to control and monitor the HVAC system in a hotel. The mini chillerreclaimed heat can be used to heat up water for shower, dish washing, cleaning etc.

HydroTech 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.

HydroTech System also provide the flexibility to colleges which require cooling and heating simultaneously in

various parts of the college.

3 - 13


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HydroTech Application In Factory for HVAC and Process Cool ing

3 - 14

Netware 2

Ducted FCU to Office 1

Netware 2 Mini Chiller for HVAC

Communication Cables

Water Piping

Ducted FCU to Office 2

Mini Chiller for Process CoolingMachine

Mini Chiller for HVAC

NIM

HydroIntel

NIM Bus Chiller Bus


53/62

HydroTech Application in College

The above diagram is an illustration of how HydroTech System can be used to control and monitor HVACsystem 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.

HydroIntel

Mini Chillers

FCU

FCU

FCU

FCU

NIM BusChiller Bus

3 - 15


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HydroTech Application for Cooling and Heating with 4 pipe system

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 fanspeed controller ) to cool machine rooms like computer rooms, generator rooms etc.

To other FCU

FCU for HVAC

FCU for machine cooling

Netware 2 NIM Netware 2 NIM

For cooling and heating

For cooling purpose only

HydroIntel

Communication cable

Water Piping

NIM Bus

Hot water

boiler

Chiller Bus

3 - 16


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HydroTech Application In Supermarket for Cooling and Heating purpose

FCU

for HVAC

Chiller for

HVAC

Netware 2

NIM NIM NIM NIM

HydroIntel

Communication cable

Water Piping

Chiller for low

temperature

application

Hot water boiler

Freezer Freezer Freezer

Chiller Bus

NIM Bus

3 - 17


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HydroTech Application In Hotels for Cooling & Heating

Chiller

for Clean water supply

HVAC

Chiller

for Clean water supply

HVAC

HydroIntel

NIM

FCU for HVAC

NIM

FCU for HVAC

Netware 2

FCU for HVAC NIM

Communication cable Water piping

Hot Water

Storage

Tank

Heat

reclaim

pipingKitchen for dish

washing,

cleaning

Hot WaterStorage

Tank

Heat

reclaimpiping Bathroomfor

shower

NIM BusChiller Bus

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3.33.33.33.33.3 WWWWWiring firing firing firing firing for Hyor Hyor Hyor Hyor HydrdrdrdrdroToToToToTececececech Systemh Systemh Systemh Systemh System


Unit ID 1

4 pole terminal block for networking cable


Unit ID 0

HydroIntel

To FCU Main Board

To display control module

Factory Installed Cable Networking cable

Panel ID 0

NIM


Panel ID 1


3 - 19


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Table 1-1: Bus Cables Specifications

No Item Requirements

1 Type of cable The cable shall comply at least with

IEC 189-2 or equivalent national std

unless otherwise specified below

2 Cable diameter Min: 0.8mm

Max: 1.0mm

3 Cable cross sectional 0.5-1.0mm2

area4 Cable material Copper and solid wires

5 Cable outer structure Sheath and screened

6 Cable cores One twisted pair with different colour

of cores

7 Cable structure twist Minimum 5 twist per meter

8 Tensile strength 2 core cable,minimum 50N

Table1-2: Recommended Communication Cable Length

Connection

NIM to HydroIntel

Mini Chiller to HydroIntel

Chiller Control Panel to Mini Chiller

G-Way to BMS

HydroIntel to BMS

1000 (end to end)

500 (end to end)

Maximum Length ( in meter )

1000 (end to end)

1000 (end to end)

1000 (end to end)

Appendix 1

Appendix


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Wiring for HydroTech System

Appendix 2

HyHyHyHyHydrdrdrdrdroInteloInteloInteloInteloIntel


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Address Assigment for NIM

Settings Settings Settings Settings

12345678 12345678 12345678 12345678

0 00000000 64 00000010 128 00000001 192 00000011

1 10000000 65 10000010 129 10000001 193 10000011

2 01000000 66 01000010 130 01000001 194 01000011

3 11000000 67 11000010 131 11000001 195 11000011

4 00100000 68 00100010 132 00100001 196 00100011

5 10100000 69 10100010 133 10100001 197 10100011

6 01100000 70 01100010 134 01100001 198 01100011

7 11100000 71 11100010 135 11100001 199 11100011

8 00010000 72 00010010 136 00010001 200 00010011

9 10010000 73 10010010 137 10010001 201 10010011

10 01010000 74 01010010 138 01010001 202 01010011

11 11010000 75 11010010 139 11010001 203 11010011

12 00110000 76 00110010 140 00110001 204 00110011

13 10110000 77 10110010 141 10110001 205 10110011

14 01110000 78 01110010 142 01110001 206 01110011

15 11110000 79 11110010 143 11110001 207 11110011

16 00001000 80 00001010 144 00001001 208 00001011

17 10001000 81 10001010 145 10001001 209 10001011

18 01001000 82 01001010 146 01001001 210 01001011

19 11001000 83 11001010 147 11001001 211 11001011

20 00101000 84 00101010 148 00101001 212 00101011

21 10101000 85 10101010 149 10101001 213 10101011

22 01101000 86 01101010 150 01101001 214 01101011

23 11101000 87 11101010 151 11101001 215 11101011

24 00011000 88 00011010 152 00011001 216 00011011

25 10011000 89 10011010 153 10011001 217 10011011

26 01011000 90 01011010 154 01011001 218 01011011

27 11011000 91 11011010 155 11011001 219 11011011

28 00111000 92 00111010 156 00111001 220 00111011

29 10111000 93 10111010 157 10111001 221 10111011

30 01111000 94 01111010 158 01111001 222 01111011

31 11111000 95 11111010 159 11111001 223 11111011

32 00000100 96 00000110 160 00000101 224 00000111

33 10000100 97 10000110 161 10000101 225 10000111

34 01000100 98 01000110 162 01000101 226 01000111

35 11000100 99 11000110 163 11000101 227 11000111

36 00100100 100 00100110 164 00100101 228 00100111

37 10100100 101 10100110 165 10100101 229 10100111

38 01100100 102 01100110 166 01100101 230 01100111

Group

Address

Group

Address

Group

Address

Group

Address

Appendix 3


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Address Assigment for NIM

Settings Settings Settings Settings

12345678 12345678 12345678 1234567839 11100100 103 11100110 167 11100101 231 11100111

40 00010100 104 00010110 168 00010101 232 00010111

41 10010100 105 10010110 169 10010101 233 10010111

42 01010100 106 01010110 170 01010101 234 01010111

43 11010100 107 11010110 171 11010101 235 11010111

44 00110100 108 00110110 172 00110101 236 00110111

45 10110100 109 10110110 173 10110101 237 10110111

46 01110100 110 01110110 174 01110101 238 01110111

47 11110100 111 11110110 175 11110101 239 11110111

48 00001100 112 00001110 176 00001101 240 0000111149 10001100 113 10001110 177 10001101 241 10001111

50 01001100 114 01001110 178 01001101 242 01001111

51 11001100 115 11001110 179 11001101 243 11001111

52 00101100 116 00101110 180 00101101 244 00101111

53 10101100 117 10101110 181 10101101 245 10101111

54 01101100 118 01101110 182 01101101 246 01101111

55 11101100 119 11101110 183 11101101 247 11101111

56 00011100 120 00011110 184 00011101 248 00011111

57 10011100 121 10011110 185 10011101 249 10011111

58 01011100 122 01011110 186 01011101 250 01011111

59 11011100 123 11011110 187 11011101 251 11011111

60 00111100 124 00111110 188 00111101 252 00111111

61 10111100 125 10111110 189 10111101 253 10111111

62 01111100 126 01111110 190 01111101 254 01111111

63 11111100 127 11111110 191 11111101 255 RESERVED

Group

Address

Group

Address

Group

Address

Group

Address

Unit Settings Unit Settings

Address 1234 Address 1234

0 0000 8 10001 0001 9 1001

2 0010 10 1010

3 0011 11 1011

4 0100 12 1100

5 0101 13 1101

6 0110 14 1110

7 0111 15 1111

Appendix 4


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Acson Hydrotech Chilled Water System Solution Application Manual

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