McQuay MicroTech II Installation Manual
Chiller system manager (csm)
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Summary of Contents for McQuay MicroTech II
- Page 1 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 MicroTech II Chillers Hardwired Chillers...
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Page 2: Table Of Contents
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... -
Page 3: Figures
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... -
Page 4: Tables
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;... -
Page 5: Revision History
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. -
Page 6: Introduction
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. - Page 7 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.
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Page 8: Applying The Csm
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. -
Page 9: Figure 3. Parallel Configurations
Figure 3. Parallel Configurations Chiller #1 reciprocating Chiller #2 centrifugal Chiller #3 centrifugal Chiller #12 screw Figure 4. Series/Parallel Configurations Chiller #1 Chiller #2 centrifugal centrifugal Chiller #3 Chiller #4 centrifugal centrifugal Chiller #5 Chiller #6 centrifugal centrifugal Chiller #7 Chiller #8 centrifugal centrifugal... -
Page 10: Secondary Pump/Decoupler Line Configuration
Figure 6. Common Primary Pump with Separate Isolation Valves Chiller(s) Chiller(s) 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. -
Page 11: Loop Bypass Configuration
Figure 9. Lead/Standby Secondary Pumps Uni-directional flow meter (supply to return) Decoupler line temperature a0102 Using the lead/standby secondary pumps enables the CSM or the user to select what pump is the lead pump and what pump is the standby pump. If the lead pump fails, the standby starts automatically. The auto-lead feature automatically swaps the lead and standby pumps based on run time. -
Page 12: General Description
CSM cabinet. The remote I/O modules communicate with the main processor through a L communications network. McQuay offers stand alone remote I/O modules for ORKS mounting in a field enclosure or remote I/O panels with modules mounted inside. This document describes the wiring to the remote I/O modules for application of the CSM. -
Page 13: Panel Location And Mounting
Unpack the CSM Panel Unpack the CSM and inspect the contents of the package for damaged or missing components. If damaged, notify the appropriate carrier at once and contact your local McQuay representative for immediate repair or replacement. Physical Installation... -
Page 14: Figure 12. Mounting Guide
Figure 12. Mounting Guide Ø.218" (0.55cm) .438" (1.11cm) Ø .406" (1.03cm) DETAIL KEYHOLE Upper Mounting CSM Mounting Guide 11.375" (28.89cm) Mount with this end up. Note: Electronic and printed versions of this guide may not show the mounting guide to scale. Verify all measurements before drilling. -
Page 15: Figure 13. Mounting Detail
Figure 13. Mounting Detail 8.63 (219) 1/2" CONDUIT KNOCKOUT 3.5 (89) FOR AC POWER ENTRY 1 . 2 5 (31.8) 1.030 1.130 ( 2 6 ) ( 2 9 ) 4 . 0 0 (102) KEYHOLE 0.218 DETAIL ( 5 . 5 ) 1"... -
Page 16: Removing And Replacing The Cover
Immersion Water Temperature Sensor McQuay offers the water temperature sensors for use with the CSM. McQuay Part # 049763202 is a single immersion sensor. McQuay Part # 049763203 is a pair of immersion sensors matched to ±0.1°F (±0.056°C). Matched temperature sensor pairs should be used if both supply and return chilled water temperature sensors will be installed to provide more accurate temperature differential readings. -
Page 17: Figure 14. Immersion Sensor
Figure 14. Immersion Sensor Greeenfield Connector 96.0 " ±16" Zip Cord .25 " ± .03" Dia a0046 Figure 15. Brass Thermowell IM 781-2 Page 17... -
Page 18: Outdoor Air Temperature And/Or Relative Humidity Sensor
Outdoor Air Temperature and/or Relative Humidity Sensor McQuay offers an outdoor air temperature (OAT) sensor for use with the CSM (McQuay Part # 049763302). McQuay also offers a relative humidity sensor/OAT sensor combination (McQuay Part # 112024301). The only externally visible difference is the appearance of the sensing element. -
Page 19: Field Wiring
Field Wiring Following are descriptions of the various field-wiring requirements. A typical CSM field-wiring diagram is shown in Figure 24. Wiring must comply with the National Electrical Code and all local codes and ordinances. Failures caused or contributed to by wiring not in accordance with these instructions will not be covered by warranty. Power Wiring Building power is wired directly to the transformer supplied with the CSM. -
Page 20: Ethernet Communications To The User Interface And Bacnet
Grounding—Ground Green or bare copper Grounding stud On 240 VAC models, connect 240 VAC, 50/60 Hz power to the terminals provided using the information in Table 2. Table 2. International Models - 240 VAC models building power termination Building Power Source Termination point Type of Wire Typical Color of Wire... -
Page 21: Free Topology Networks
ORKS Free Topology Networks Each Lon network node (chiller, CSM, Remote I/O Module) must be equipped an FTT-10A transceiver for network communication. For each MicroTech II chiller, an optional L Communication Module includes the required ORKS FTT-10A transceiver. This transceiver allows for (1) free topology network wiring schemes using twisted pair (shielded or unshielded) cable and (2) polarity insensitive connections at each node. -
Page 22: Free Topology Restrictions
Figure 18. Combining Network Segments with a Repeater Termination Termination Free Topology Restrictions Although free topology wiring is very flexible, there are restrictions to the number of nodes on a segment, the maximum bus length, and the wire size. The maximum number of nodes per segment is 64. The maximum total bus length depends on the wire size: Wire Size Maximum Node-to-Node Length... -
Page 23: Network Cable Termination
A stub is a piece of cable that is wired between the node and the bus (see Figure 17). Note that if the bus is wired directly to the node, there is no stub, and thus the stub length is zero. If you are wiring to a field terminal strip on a unit, be sure to account for any factory wiring between the terminal strip and the controller. -
Page 24: Onboard I/O Wiring
Table 4. Analog/Digital Inputs and Outputs Digital Input Analog Output Digital Output Analog Input Inputs and Outputs Located on Remote I/O Module CSM Feature Standard chiller sequencing control Decoupled chiller sequencing control External Demand limiting Unit leaving chilled water control Common lvg. -
Page 25: Temperature Inputs
c) UI 13 through 16 = Digital Inputs. Dry contacts, 20 Hz. max. frequency. 3V open circuit, 300-uA short-circuit current. Temperature Inputs CSM onboard universal inputs 1 to 6 are set to receive temperature data from Type 3 (10K) thermistors with a range of –10 to 135 °F (-23.3 to 57.2 °C). -
Page 26: 0-10 Vdc Inputs Or 4-20 Ma Inputs
Can cause equipment damage. If analog inputs on a MicroTech II CSM onboard I/O are connected to more than one external device, the connected analog outputs of those devices must be isolated from ground. If they are not, ground loop currents could occur which could damage the MicroTech II and connected equipment. -
Page 27: Figure 22. Analog Input 4 To 20 Ma Wiring
Figure 22. Analog Input 4 to 20 mA Wiring 4-20 mA Shield Self-powered Stud in 200' max sensor enclosure Shielded, Cable 499 Ohm (supplied with Range: 0-20 mA Controller-powered 499 Ohm sensor (supplied with Stud in 200' max Shield enclosure Shielded, Cable Range: 0-20 mA... -
Page 28: Analog Input Cable Specifications
Minimum System Setpoint (adjustable on the CSM’s User Interface). If the external reset signal equals 20 mA (10 VDC), the System Setpoint will equal the Maximum System Setpoint (adjustable on the CSM’s User Interface). For more on reset, refer to Reset in the Chilled Water Temperature Control section of OM 780-MicroTech II Chiller System Manager Operation Manual. -
Page 29: Digital Outputs
A 20-volt DC at 80-mA power source is available on the onboard I/O panel to power some of the external transmitters sending data to universal inputs 7 to 12. For example, if a McQuay relative humidity sensor is used, the power required at the relative humidity sensor can be obtained from the onboard I/O board (see Figure 24). -
Page 30: Figure 24. Csm Field Wiring Schematic
Lon Card that “nodes” (chillers and remote I/O modules) can be configured in bus, ring, star, or a combination of these three network configurations. MicroTech II MicroTech II MicroTech II 3. LonWorks cable lengths are dependent on singly or doubly terminated networks. Refer to Echelon’s... -
Page 31: Remote I/O Wiring
Remote I/O Wiring The remote I/O modules for the CSM allow for additional analog inputs, analog outputs, digital inputs, and digital outputs for Cooling Load Pump Control and Cooling Tower Control. Since both cooling load pumping and cooling tower control are optional features of the CSM, remote I/O modules will not be required on all jobs. -
Page 32: Digital Inputs
Can cause equipment damage. If analog inputs/outputs on a MicroTech II Remote I/O Module are connected to more than one external device, the connected analog outputs/inputs of those devices must be isolated from ground. If they are not, ground loop currents could occur which could damage the remote I/O module and connected equipment. -
Page 33: Digital Outputs
Can cause equipment damage. If analog outputs/inputs on a MicroTech II Remote I/O Module are connected to more than one external device, the connected analog inputs/outputs of those devices must be isolated from ground. If they are not, ground loop currents could occur which could damage the remote I/O module and connected equipment. - Page 34 Cooling Load Pump #5-#6 (Remote I/O Module C – Relay 1 and Relay 2) If the CSM will be controlling more than four cooling load pumps - Cooling Load Pump 5 Enable and Cooling Load Pump 6 Enable relay outputs are used to start and stop pumps 5 and 6. When the proper signal is sent by the CSM through the pump digital output, the pump will start.
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Page 35: Figure 25. Csm Remote I/O Modules A And B Field Wiring Schematic
Figure 25. CSM Remote I/O Modules A and B Field Wiring Schematic Remote A 24 Vac 24 Vac power Cooling Load Pumps 1 and 2 50/60 Hz Lon Network to Chillers, CSM, and/or other Remote I/O Modules Lon Port Inputs Outputs 29 (Y) 35 (Y) -
Page 36: Figure 26. Csm Remote I/O Modules C And D Field Wiring Schematic
Figure 26. CSM Remote I/O Modules C and D Field Wiring Schematic Remote C 24 Vac 24 Vac power Cooling Load Pumps 5 to 6 50/60 Hz Lon Network to Chillers, CSM, and/or other Remote I/O Modules Lon Port Inputs Outputs 29 (Y) 35 (Y) -
Page 37: Figure 27. Csm Remote I/O Modules E And F Field Wiring Schematic
Figure 27. CSM Remote I/O Modules E and F Field Wiring Schematic Remote E 24 Vac 24 Vac power Cooling Tower Outputs 1 to 4 50/60 Hz Lon Network to Chillers, CSM, and/or other Remote I/O Modules Lon Port Inputs Outputs 29 (Y) 35 (Y) -
Page 38: Figure 28. Csm Remote I/O Modules G And H Field Wiring Schematic
Figure 28. CSM Remote I/O Modules G and H Field Wiring Schematic Remote G 24 Vac 24 Vac power Cooling Tower Outputs 9 to 12 50/60 Hz Lon Network to Chillers, CSM, and/or other Remote I/O Modules Lon Port Inputs Outputs 29 (Y) 35 (Y) -
Page 39: Modems
Modems Remote connection to the CSM is available through a modem. Remote access through a modem is slower than remote access through an Internet connection. However, if Internet access is not available or cannot be provided due to security (firewall) issues or other reasons, the modem provides an alternative. Full access to the Web User Interface for monitoring and control of the CSM is provided via modem connection. -
Page 40: Using The Admin Tool To Configure The Csm/Modem
JACE NT and Web Supervisor). The Admin Tool is available at www.mcquay.com, go to Product Information > Controls > Software. Download the Admin Tool exe file to the hard drive of a Windows NT, Windows 2000 or Windows XP computer. Running this file places an Admin.exe file under the C:\niagara\McQuayAdminTool\r2.301.511_v1\nre\bindirectory. -
Page 41: Table 7. Modem Configuration Parameters (Ras.properties)
• For an internal modem COM2=MODEM • For an external modem COM2=232 Save and Close the port.properties file Click on the Modem Properties button to open the ras.properties file Edit the values per the following table Table 7. Modem Configuration Parameters (ras.properties) Parameter Valid Values Default Setting... - Page 42 external modem, the proper setting is COM2 and the physical wire connection uses COM2. BaudRate 57600 57600 57600 The initial baud rate to use between the CSM and the modem. You do not have to change this parameter. 48800 36600 19200 InitString Depends on...
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Page 43: Initial Checkout And Troubleshooting
The LED should blink about once per second. After applying power to the controller, if the heartbeat LED does not come on or comes on (steady) and stays lit longer than two minutes, contact the McQuay Controls Group at 866-4McQuay (866-462-7829). About the Battery The CSM is provided with a sealed lead acid battery, which is nearly fully charged, so the CSM has battery backup protection immediately upon installation. -
Page 44: Figure 29. Main Board Layout
Figure 29. Main Board Layout LON Port * LCD Display Ethernet Connection Ethernet LED's Heartbeat LED's Phone Connector Serial Port LED's COM3 COM4 COM1 COM2 COM5 COM6 * Not Currently Supported Page 44 IM 781-2... -
Page 45: Appendix A: Hardwired Chiller Control
Appendix A: Hardwired Chiller Control This appendix provides information about using the CSM to control chillers via hardwired binary and analog inputs and outputs. This option should be used when a serial communication option is not available since control, monitoring, and alarm indication is reduced. -
Page 46: Figure 30. Typical Hardwired Chiller Field Wiring Diagram
Figure 30. Typical Hardwired Chiller Field Wiring Diagram Remote I/O Module 24 VAC power 50/60 Hz 2 (0) Hardwired Chiller In from Lon Network of CSM, Lon Chillers Splice Splice and/or other Remote I/O Modules Lon Port 10V Sig In Common 24VAC PWR 20mA Sig Out Out to Lon Network of Lon Chillers... -
Page 47: Hardwired Chiller Remote I/O Module Analog Inputs
Remote I/O Module Special Considerations when using % RLA Signal from a McQuay MicroTech Series 200 Centrifugal Chiller McQuay MicroTech Series 200 Centrifugal chillers offer an optional analog output representing compressor % RLA. If you are using this output, follow these guidelines: Use the 0-10 VDC output option. -
Page 48: Chillers Without % Rla Output
Table 8. Signal Averaging Device Specification 2 x 0-10 VDC Signal Input 0-10 VDC (averaged) Signal Output 24 VAC Power Supply 3.4”H x 2”W x 4.8”D Dimensions (8.6 cm x 11.8 cm x 2.54 cm) Chillers Without % RLA Output If the chiller does not have a % RLA output, the compressor amp usage must be input at AI 1 and the CSM will calculate a % RLA. -
Page 49: Chiller Leaving Evaporator And Leaving Condenser Water Temperatures (Ai 3 And Ai 4)
VFD. Current transducers must be obtained locally. A 24 VDC power supply (Part #111049601) is available through McQuay Service Parts only. The input voltage to this power supply is 24 VAC and it provides a 24 VDC output at 80 mA for the loop powered current transducer. This power supply (80 mA) is capable of powering two of the above current transducers (at 30 mA max, each). -
Page 50: Hardwired Chiller Remote I/O Module Digital Inputs
System Setpoint. Many chillers (including McQuay MicroTech controlled chillers) only accept external setpoint reset in the form of a 4-20 mA signal. The 2-10 VDC signal from the remote I/O module must be changed to 4-20 mA with a signal converter. This converter is wired to the same power source that supplies 24 VAC to the module and is spliced into the signal wiring as shown in Figure 30. -
Page 51: Hardwired Chiller Load Limiting (Ao 2)
20 mA). Many chillers (including McQuay MicroTech controlled chillers) only accept external demand limiting in the form of a 4- 20 mA signal. The 2-10 VDC signal from the remote I/O module must be changed to 4-20 mA with a signal converter. -
Page 52: Table 12. Hardwired Chiller's Hardware Transformer Usage
Table 12. Hardwired Chiller’s Hardware Transformer Usage Hardware Maximum VA Description Always required for hardwired chiller. Remote I/O Module 2 (typical)* Always required for hardwired chiller. Evaporator Water Flow Switch Relay 2 (typical)* Required for water cooled chiller. Condenser Water Flow Switch Relay Required if chilled water temperature setpoint reset is desired for the controlled 0-10 VDC to 4-20 mA Converter for chiller and the chiller can not accept a 0-10 VDC signal. -
Page 53: Figure 33. Hardwired Chiller's Possible Hardware Requirements
3. Power supply must provide electrical isolation between inputs and outputs. 4. McQuay remote I/O panel provides 40VA-24VAC transformer and is available with up to four remote I/O modules. See IM 783- MicroTech II Remote I/O Panel Installation Manual for more information. Verify dimensions of the remote I/O panel for clearance and follow appropriate electrical codes. -
Page 54: Maintenance
Maintenance This section provides information on the following topics: • Cleaning • Required Battery Maintenance • Replacement Parts Cleaning If dust or metal filings are present inside the unit, clean with a vacuum or compressed air. Otherwise, no cleaning inside the unit is required. -
Page 55: Parts List
Step 7. Secure the new battery to the bottom of the unit with the bracket and tighten the lock nut. Step 8. Plug the power connector in and verify normal operation. Parts List Standard replacement parts are listed in Table 13.can be order from McQuay Parts. Table 13. Standard Replacement Parts Part Number... -
Page 56: Warranty
Replacement Parts When writing to McQuay for service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, along with an explanation of the malfunctions and a description of the replacement parts required. -
Page 57: Index
Index Admin Tool, 4, 40 , 4, 20, 21, 22, 23 ORKS Alarm Horn, 29 Loop Bypass, 11, 27, 33 Alarm LED, 29 loop differential pressure, 27 alarm output, 29 Modbus, 12 BACnet, 5, 12, 20 modem, 39 battery, 13, 19, 42, 43, 45 network segment, 22 brass well, 16 node, 21, 22, 23... - Page 58 This document contains the most current product information as of this printing. For the most up–to-date product information, please go to www.mcquay.com. © 2005 McQuay International (800) 432-1342 www. mcquay.com...
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