ClimateCraft MatrixMonitor V2 Installation, Operation And Maintenance Manual

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Installation, Operation and

Maintenance Manual

MatrixMonitor™ V2

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

for fan arrays.

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Summary of Contents for ClimateCraft MatrixMonitor V2

Page 1 Installation, Operation and Maintenance Manual MatrixMonitor™ V2 This is the installation, maintenance and operation manual for the ClimateCraft® MatrixMonitor™ airflow monitoring system for fan arrays. ...
Page 2: Table Of Contents
Contents Introduction ..............................3 MatrixMonitor™ Components ........................3 Control Unit ............................... 3 Embedded Control System ........................3 Power Supply ............................4 Key Pad Display ............................4 Piezometric Pressure Port ......................... 5 Fan Sensor ..............................5 Fan Array Pressure Rise Sensor ......................... 7 User Interface ...............................
Page 3 Replace or Install a Wiring Connector for an FSB ................... 64 Replacement parts list ..........................66 System Specifications ..........................67 Sample Wiring Diagram ..........................68 Modbus® Register List ..........................69 ClimateCraft® Service ..........................75 MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 2...
Page 4: Introduction
Introduction The ClimateCraft® MatrixMonitor™ is a digital instrument that monitors the operation of ClimateCraft® FanMatrix™ fan arrays. A fan array will have two or more fans operating in parallel to provide airflow in an air handling system. MatrixMonitor™ solves the problems of monitoring the airflow of multiple fans by combining the individual fan airflow readings into a combined reading for the array.
Page 5: Power Supply
The control unit firmware is written to flash memory on the Rabbit RCM3000 module. It is self- contained, universal and upgradeable on site. MatrixMonitor™ can be used on any ClimateCraft® FanMatrix™ fan array using standard firmware. The unit is configured for a specific unit by selecting data from set up menus accessed by the key pad display.
Page 6: Piezometric Pressure Port
or more fans go into surge. The second yellow LED (right) is turned on if the MatrixMonitor™ determines that there is a problem in reading any of the transducers. If a transducer has gone bad or a signal has reached the maximum making it impossible to calculate the actual flow or pressure this LED will be lit. It will also light when the grease monitor trips or the fan vibration limits are exceeded.
Page 7 ports are accessible for connecting to the piezometric port. The FSB acts as the box cover. When it is removed the switches and connections are accessible. The fan sensors are mounted on the entering air side of the fan back panel. There is one fan sensor for every fan in the array.
Page 8: Fan Array Pressure Rise Sensor
a strain relief cover attached to keep incidental wire movement from pulling on the connection pins which insures a good electrical connection between the cable conductors and the connector. There is a dual DIP switch mounted on the component side of the FSB assembly. This switch is to activate the line termination resistors.
Page 9: User Interface
ClimateCraft® fan array. When the unit powers up a sign on message appears. The sign on message will display the ClimateCraft® logo and the message string “ ClimateCraft ” will scroll horizontally across MatrixMonitor V2.nn...
Page 10 The main menu is the highest menu in the structure and is your starting point for navigating through the display and set up screens. The main menu of the MatrixMonitor™ is as follows: Menu Lines Displayed ……………….. Screen Type (Screen Function) <<<...
Page 11 Submenu screens are used for set up functions to simplify the collection of data. They allow branching to setup screens for entering individual data items required to properly set up the MatrixMonitor™ for the array(s) used with it. The submenu screens function in the same way as the main menu screen. In order to exit a submenu screen and return to the main menu the last menu item in each submenu ”.
Page 12: Set Up Procedure
When MatrixMonitor™ is factory installed the configuration is done at ClimateCraft® before the unit is shipped. The only thing that might be required to do on the job site would be to set the local time and to set the scaling factors for the analog output signals if they are used by the building management system (BMS).
Page 13: Set The Array Data
Set the Array Data The array data setup is accomplished through by using the “ ” and “ ” Array 1 Options Array 2 Options submenus. If the unit has just one array only “ ” need to be set. All of the setup Array 1 Options information for array 1 must be entered for the MatrixMonitor™...
Page 14: Select The Fan Model
”. Press the  (enter) key and the From the “ ” submenu highlight “ Array 1 Options 2. Number of Fans fan quantity setup screen will appear. The first line on the screen will display the array name if it has been set.
Page 15: Select The Wheel Width
The number will scroll to display all of the nominal fan diameters currently available on ClimateCraft® fan arrays. It will wrap around these values. When the model displayed on line 2 is correct, press the  (enter) key to confirm the selection and return to the submenu.
Page 16: Set The Array Name
The bottom two lines are the navigation aids. Use the + and - keys to select the wheel width. When you press the keys the number displayed after the = will change reflecting the current selection of nominal fan wheel width. The number will scroll between 50 and 100 in increments of 5 and will wrap around these values.
Page 17: Set The Sensor Position
In most cases 0 to 14 inches WC is sufficient for fan operating conditions used FanMatrix™ fans. ClimateCraft® fans have the pressure tap installed at the minimum diameter, or throat, of the inlet cone so that the maximum pressure signal is available. If a fan is expected to have abnormally high flow, the piezometric pressure depression may be higher than 14 inches WC and outside of the range of the sensor.
Page 18: Set The Optional Dampers
”. Press the  From the “ ” submenu, scroll down to highlight “ Array 1 Options 5. Sensor Position (enter) key and the sensor position setup screen will appear. The first line on the screen will display the array name. It should have been set in a previous step. The second line on the screen will read “ Sensor ”.
Page 19: Set The Fan Status
Set the Fan Status The fan status flag is used by MatrixMonitor™ to correctly calculate the array airflow in the event that it detects a fan is not operating and to properly set the fan failure alarm. The control unit monitors the piezometric port pressure of each fan.
Page 20: Set Up Array 2
array so that the status of each fan can be set individually. The description after the colon (:) is the current selection. The default value is “ ”. It can be switched between “ ”, “ ” and “ ” Blanked Off The bottom two lines are the navigation aids.
Page 21: Set The Control Data
You will get a similar message any display screens that are to display data about Array 2 fans. The “ ” screen is also different when the number of fans for Array 2 is not 0. (See “Display Display Airflow Information”...
Page 22: Scale The Flow Signal
………………… Setup (selects the BMS communication protocol) 4. BMS Protocol ………………… Setup (selects the baud rate for the BMS RS485 comm line) 5. BMS Baud Rate ………………… Setup (selects the parity for the BMS RS485 comm line) 6. BMS Parity …………………...
Page 23: Select The Flow Units
”. Press the  From the “ ” submenu scroll down to highlight “ Control Set Up 2. Scale Pressure Signal (enter) key to display the pressure signal set up screen. The first line will read “ ”. Select Max Pressure The second line will read “...
Page 24: Set The Baud Rate For The Rs485 Communication Line
will read “ ”. The text after the = sign is the BMS protocol used. The last two lines are Type = None navigation aids. ” and press the  (enter) key to confirm the Use the + and - keys to select “ ”...
Page 25: Set The Device Id For Bms Communication
”. Press the  (enter) key From the “ ” submenu scroll down to highlight “ Control Set Up 6. BMS Parity to display the BMS parity set up screen. The first line will read “ ”. The second line Select BAS Serial: will read “...
Page 26: Grease Life Timer
monitored by this unit. The number can be adjusted from 0.100 ips to 0.300 ips in increments of 0.010 ips. The software will wrap around the limits. A “+” key press when the limit = 0.300 ips will result in a limit of 0.100 ips.
Page 27 If you press the “+” key, the grease life timer for array 1 will start and the following screen will appear confirming this: Supply : Has been reset or enabled. Press any key to continue. . . When you press any key you will get: Supply Life 100 Last Grease: 10/28/12...
Page 28 Press the  (enter) key and the grease life system for array one will be operational and you can now start the grease life timer for array two. If the grease life timer for array two has not been started the screen will look like this: Return Life 100 Monitor Not Enabled...
Page 29 Resetting one array systems is slightly different than 2 array systems. To reset the grease life timers follow this procedure: One array systems: ( if you have a two array system skip this section and go to the section for “Two array systems” directly below) From the “...
Page 30 On a typical system with two fan arrays measured by one MatrixMonitor™ both arrays seldom required service at the same time. The maintenance staff will adopt one of two policies to deal with this situation. The first and most common strategy is to grease all of the fans in the unit when any of the fan arrays requires it.
Page 31 Supply Life 100 Last Grease: 10/28/12 + Resets Grease Life Enter to Continue The date on the second line will be todays date. If it is not, the real time clock is not set properly. That must be done before you can use the grease life timer. Leave the reset screen by pressing the ...
Page 32: Set The Real Time Clock
Press the  (enter) key to return to the “ ” sub menu and the grease life Control Set Up timer for array 1 will be reset. Return to Main Menu ”. Press the  From the “ ” submenu, scroll down to highlight “ Control Setup 10.
Page 33 this to the actual year press the + key until the current year is displayed on the second line. It will increment by 1 year for every key press and auto scroll if the key is held for more than 1 second. If you overshoot the year you can use the –...
Page 34: Display Information
The number after the colon is the minute. To change this to the actual minute press the + key until the current minute is displayed on the first line. It will increment by 1 minute for every key press and auto scroll if the key is held for more than 1 second.
Page 35: Display Individual Fan Details
numbers. This is an option selectable under the “ ” submenu. The second line is a status Control Setup information line. It will display the fan array pressure rise in units of inches Water Column, the air temperature entering the fan array in :F, and the calculated speed of the fans in RPM. If the yellow “Read Error”...
Page 36 Array2 : Not Set Up! Go back to Main Menu for Array2 Options Any key to continue Pressing any key will return you to the main menu if you see this screen. This section will describe information available and the navigation details for menu option “ ”.
Page 37 …………………. The piezometric pressure port reading reported from the FSB 13,300 CFM Max Flow for this fan is greater than 14 inches WC. This is the full scale reading for the pressure transducer and the actual flow of the selected fan is greater than the displayed flow. The yellow “Read Error”...
Page 38 If the fan status for the selected fan has been set to “Off” or Blanked Off” in the “Set the Fan Status” setup procedure one of the following messages will appear on the second line in place of the fan flow information.
Page 39: Display Time/Date
Display Time/Date This displays the current time and date on the graphic display screen. Use this to check that the real time clock is set so the lubrication system will function properly. ” and press the  From the “ ”, scroll down to menu option “...
Page 40: Vibration Data
The second line shows the communication quality for a specific sensor. In the example above the communication quality for the array 1 pressure rise sensor is displayed. The bottom two lines are navigation aids. The ˄ and ˅ keys allow you to scroll through all of the FSB devices installed on the network.
Page 41 data displayed on line 2. The 10 highest vibration levels are determined for each fan and can be displayed on line 2. The vibration levels are indexed from highest to lowest so the vibration for index 1 is the highest vibration level in units of inches/second currently measured for that fan. The second line displays the actual vibration measurement in units of inches/second and the corresponding frequency of that vibration in hertz.
Page 42: Motherboard Data
Motherboard Data This screen displays the environmental conditions of the control unit. The information displayed is the temperature of the control enclosure, the barometric pressure, and the DC voltage and current supplied to the FSB communication network. From the “ ”, scroll down to highlight menu Main Menu ”...
Page 43: Software Version
This displays the ClimateCraft® logo and the software version number. From the “ ” scroll down and highlight menu option “ Main Menu ”. This will bring up a screen that displays the ClimateCraft logo About graphic and a scrolling message that reads: “ ClimateCraft ”.
Page 44: Vibration Monitoring
Vibration Monitoring The fan sensors used with MatrixMonitor™ have a tri-axial accelerometer on the printed circuit board that contains the pressure transducer. The accelerometer reads the acceleration of all three axis 3000 times a second with 10 bit accuracy. The fan sensor assemblies (FSBs) are mounted on the backplane of every fan where they can sense vibration in the fan assembly.
Page 45: Lubrication Monitoring
Lubrication Monitoring MatrixMonitor™ is equipped with a lubrication monitoring system to control the motor bearing lubrication cycle and reduce the cost associated with this maintenance. The running speed of each fan array is continuously calculated. The fan speed is calculated from the airflow and pressure rise data measured for the array knowing the performance of the fans installed in the array.
Page 46 left of the grease life for planning purposes. This prediction of the “hours left” until the next grease requirement is very useful to help schedule this necessary maintenance. This data is available from the display screens or through the Modbus interface. See the “Lubrication Status”...
Page 47: Throat And Cone Tap Flow Range
The grease life timer does not start automatically when MatrixMonitor™ is set up and running. It must be activated by the user. This is a function that is not activated by ClimateCraft when it does the set up for units configured by the factory.
Page 48: Interface To Building Management System
When the individual fan airflow will exceed the maximum airflow for the throat tap in the table, ClimateCraft will locate the tap in the cone. If the fan array is designed to give N-1 redundancy, the maximum design airflow will occur when one fan is off line.
Page 49: Modbus® Communications
pressure rise. The physical connections to the analog output signals are on the motherboard through TS8. There are 5 positions on TS8, one for each signal and one for a common ground. There are three SPDT output relays on MatrixMonitor™. These relays signal operation, alarms, and warnings.
Page 50 The cable and connections to MatrixMonitor must conform to the EIA/TIA 485 standards for 2 wire multipoint connections. ClimateCraft recommends Belden 9842 dual, shielded, twisted wire cable for the connection. One pair should be used to connect the digital communication lines (A and B) while both wires of the other pair are used to connect the ground connection back to the Reference or Signal Ground terminal on the Building Management System (BMS) controller.
Page 51 Communications with the Building Management System In order to communicate with the BMS, Modbus® must be enabled and the communication line transmission parameters must be set up. These are all set up key pad display user interface. The set up procedures are accessed for the “Control Setup” submenus. See the section titled “Set the Control Data”...
Page 52 The Modbus message is formatted in the following sequence: 1. Slave Address – 1 byte ; 1 to 247 2. Function Code – 1 byte ; 03h or 06h 3. Data – Variable depending on function and data 4. CRC Error Check – 2 Bytes This format is the same for commands from the master and responses from the salves.
Page 53 Eight bytes of data are sent to the MatrixMonitor™ to make this read register request. The MatrixMonitor™ will respond to the read register request with the following message: Decimal Byte Modbus Message Value Order Message Item Byte No. Data Slave Address Function Code Data Quantity High...
Page 54 Eight bytes of data are sent to the MatrixMonitor™ to make this read register request. The MatrixMonitor™ will respond to the read register request with the following message: Decimal Byte Modbus Message Value Order Message Item Byte No. Data Slave Address Function Code High Register Address...
Page 55: Trouble Shooting Guide
Trouble Shooting Guide Problem Possible Cause Corrective Action When power is available to the Loss of power supplied to Check AC input power to Power control unit the keypad display MatrixMonitor™ DC power supply with voltmeter. Restore will always be active, there are supply.
Page 56 Shutting one or more fans off experiencing surge. and installing blank off plates will usually solve the problem. Contact ClimateCraft® for help in resolving persistent surge issues. There are one or more green The four green LEDs light up in...
Page 57 Problem Possible Cause Corrective Action The yellow Read Error LED The grease timer for the array Perform the grease maintenance (furthest to the right) on the has timed out and it is time to in accordance with your safety keypad display is lit and the grease the motor bearings for standards and reset the grease information line on the Display...
Page 58 Warning Message Possible Cause Corrective Action Bad Airflow Reading The pressure returned by the Check the tubing connection FSB to the control unit is from the FSB to the piezometric inappropriate. tap. Repair if possible. Replace the FSB. High Vibration The vibration readings from the Determine and correct the FSB exceed the limits set up by...
Page 59: Repair And Replacement
Repair and Replacement Remove the Swing out Graphic Panel The mother board which houses the embedded RCM3000 processor board and the keypad display panel are mounted on the swing out graphic panel. These parts can be accessed by loosening the two captive screws on the right side of the panel (opposite the hinges) and swinging the panel open.
Page 60: Power Supply
screw from each hinge. The screw to be removed is the inside screw closest to the hinge. There is a lock washer between the machine screw head and the panel. There is a machine nut held in place by a hexagonal cavity on the back of the plastic hinge body. Carefully tap on the hinges to remove these nuts as they will easily fall out once the screw is removed.
Page 61: Mother Board
#4 machine screws that hold the mother board to the swing out graphic panel while it is in place on an air handling unit. ClimateCraft® recommends you first remove the graphic panel from the NEMA 4 enclosure per the instructions listed above.
Page 62: Clock Battery
4. If you are replacing the mother board you will have to remove the embedded processor and install it on the new mother board before you install it. See the section below that details that replacement. The replacement mother board will have a full complement of removable terminal strips shipped with it.
Page 63: Embedded Processor Board
ClimateCraft recommends removing the swing out graphic panel first per the instructions listed above before attempting to replace the embedded processor board.
Page 64: Fan Sensor
removal of the swing out graphic panel before you attempt to remove the motherboard and replace the keypad display unit. Remove the mother board using the procedure outlined above. To remove the keypad display unit after the mother board has been removed: 1.
Page 65: Array Pressure Rise Sensor
FSB from the cable is made with a feed trough style insulation displacement style 4 pin receptacles (ClimateCraft® P/N PELE-115-001). The insulation displacement technology allows the cable to run unbroken from the control unit to the last FSB on the network. This reduces communication problems caused by loose or poor connections.
Page 66 Use a punch down tool specifically designed for the connector used. ClimateCraft® recommends a model D814 by Fluke using the number 66 punch down tip. The conductors must be punched into the connector in the...
Page 67: Replacement Parts List
Replacement parts list Item Part Number Description of Part Location of Part PELE-103-003 NEMA 4 ABS control enclosure Control unit PELE-114-001 12VDC power supply Control unit PELE-080-001 Grounding Strip Control Unit PELE-111-001 Motherboard Control Unit PELE-113-001 Rabbit RCM3000 embedded Processor Control Unit PELE-113-002 Rabbit Keypad Display Unit...
Page 68: System Specifications
System Specifications Environmental  Temperature: - 20:F to 145:F non condensing  Barometric Pressure: 300 to 1100 mBar  NEMA 4/4X high impact polycarbonate enclosure with hinged clear cover and SS latch Electrical  100 watt power supply  Input voltage: 88VAC to 264VAC ...
Page 69: Sample Wiring Diagram
Sample Wiring Diagram MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 68...
Page 70: Modbus® Register List
Modbus® Register List Software Version 2.04 Released to Production Rev 7 12/2/2012 Abs. Modbus® Address Register Operation Data Description Units/Notes 40001 Read Only Array 1 Airflow cfm/100 or scfm/100 see Register 40015 40002 Read Only Array 1 Pressure Rise inch WC x 10 sensor addr = 00 40003 Read Only...
Page 71 Abs. Modbus® Address Register Operation Data Description Units/Notes 40025 Number of fans in Array 1 1 to 49 40026 Array 1 Fan Model -----Register Value with: ------ Throat Port Cone Port Model No. Connected Connected MTX12 1000 MTX15 1001 MTX16 1002 MTX18 1003...
Page 72 Abs. Modbus® Address Register Operation Data Description Units/Notes 40030 Pressure Signal Limit Min = 1 In WC The pressure at which the Max = 20 In WC analog pressure output voltage (registers 40019 and 40020) correspond to the maximum output voltage of 10.0 VDC. Can be any number between 1 and 20.
Page 73 Abs. Modbus® Address Register Operation Data Description Units/Notes 40150 Array 1 Fan 1 Status Status Codes 40151 Array 1 Fan 2 Status [Low Byte] Bit 0: 1=Fan Failed Bit 1: 1= Fan In Surge Bit 2: 1=Vibration Warning Bit 3: 1=Fan is Backflowing Bit 4: 1=Sensor Board not responding Bit 5: Not Used...
Page 74 Notes: MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 73...
Page 75 Notes: MatrixMonitor™ IOM - Rev 4 - 4/11/2013 Page 74...
Page 76: Climatecraft® Service
ClimateCraft’s fan array products allow for fans to be turned off for safety, repair, and maintenance purposes. ClimateCraft’s fan array products are not designed to turn individual fans on and off for the purpose of improving fan array efficiency, and ClimateCraft® does not endorse turning individual fans on and off for the purpose of improving fan array efficiency.