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CHILLED WATER
SYSTEM SOLUTION
ACSON Hy
dr
oT
ec
h
Hydr
droT
oTec
ech
Chilled Water System
Applica
tion Man
ual
pplication
Manual
Fir
st Edition
First
Jul
y 2005
uly
Intr
oduction
Introduction
Introduction ................................................................................................................ Introduction-1
Section 1: Netw
or
k Interf
ace Module (NIM) and Netw
ar
e2
Networ
ork
Interface
Netwar
are
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2.2
2.3
2.4
2.5
Section 3: Hy
dr
oIntel
Hydr
droIntel
3.1
3.2
3.3
Appendix
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.
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.
Introduction
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 - 1
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
Introduction - 2
HydroIntel
HydroIntel
Introduction - 3
Section 1
Network Interface Module and Netware 2
1.1 About NIM
Network Interface Module or NIM acts as an interface to enable communcation between the HydroIntel, Fan
Coil Unit (FCU) and display control panels.
Bottom Casing
Unit
Address
Dip
Sw itch
Group Address
Dip Sw itch
Top Casing
CN3
Connector
IC
CN2
Connector
CN1
Connector
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 of
wiring).
1-1
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 Installa
tion
Installation
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.
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.
1-2
1.3 Ad
dr
ess Assignment
Addr
dress
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 numbering 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
Likewise,
Setting 10100000
Setting 00101000
Setting 00100110
Likewise,
Setting 0000
Setting 0101
Setting 1111
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 )
1-3
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
Status
Mode
Set Temp
Fan
Room Temp
Unit
11.00am
: ON
: Cool
: 24C
: High
: 27C
: G1U7
MAIN MENU
Operation Menu
Settings Menu
Timer Menu
Alarm Menu
1-4
Main
Board
Main
Board
NIM
Netware 2 Control
Panel
NIM
Netware 2 Control
Panel
Main
Board
NIM
Netware 2 Control
Panel
Main
Board
Main
Board
NIM
NIM
No IR Remote /
SLM3 / Netware 2
IR
IR Remote
Master
Slave 1
Slave 2
Master
Group 1
Slave 1
Group 2
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.
1-5
1.6 Netw
ar
e 2 and NIM Applica
tions
Netwar
are
pplications
Netw
ar
e 2 and NIM Applica
tion In Sc
hools
Netwar
are
pplication
Schools
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
1-6
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 )
1-7
Netware 2 and NIM Application For Multiple Fan Coil Units In School
Netware 2
NIM
Master Unit
NIM
Slave Unit
Slave Unit
NIM
Slave Unit
NIM
Slave Unit
NIM
Slave Unit
NIM
Slave Unit
NIM
1-8
Netw
ar
e 2 and NIM Applica
tion In Of
Netwar
are
pplication
Offfice 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 Five
Zone Three
Zone Four
Zone Two
Zone One
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.
1-9
Netware 2 and NIM Application For Multiple Fan Coil Units in Office Building
Netware 2
NIM
Master Unit
NIM
Z
O
N
E
Slave Unit
Slave Unit
NIM
Slave Unit
NIM
Netware 2
Z
O
N
E
Master Unit
NIM
SLM
2
Slave Unit
NIM
Communication cables
1 - 10
CN3 For
Communication
Cables
Connection
The other end of the communication cables are connected to punch boards to ensure wiring is fitted correctly.
1 - 11
1.8 G-W
ay and Building Mana
gement System ( BMS )
G-Wa
Manag
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 ).
To be
connected
to Display
Control
Panel
Use 5-Way
Wire to
connect to
FCU Main
Control
Board
CN3
CN2
Link to BMS
CN4
CN1
CN5
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
0010
0001
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)
1 - 12
CN3
CN4
240VAC/24VDC
CN5
240VAC/24VDC
G-Way
BMS
1 - 13
Section 2
Chiller Control Panel
2.1 About Chiller Contr
ol P
anel
Control
Panel
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 will be found on the control panel.
2-1
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. (For
wiring example refer to Wiring for Chiller Networking in this section)
2.2 Installa
tion
Installation
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.
2-2
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.
2-3
2-4
Mini Chiller
Main Control
Board
2-5
Chiller Contr
ol P
anel Applica
tion In Pr
ocess Cooling
Control
Panel
pplication
Process
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.
Sun
Mon
Tue
Wed
Timer 1
ON
OFF
Timer 2
ON
OFF
0800
0800
0800
0800
1900
1900
1900
1900
1800
1800
1800
1800
2100
2100
2100
2100
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.
Alarm Number 1
[Ch 1]
The fault for
Chiller 1 is
Compressor 1
Overload
Alarm 1
Default chiller
is Chiller 1
Comp 1 overload
17/09/04
4:00am
2-6
Chiller Control Panel Application for Multiple Mini Chillers in Process Cooling
Master Chiller
Control Panel
placed in the
Process Control
Room
Slave Unit
Master Unit
Slave Unit
Communication cable
2-7
Slave Unit
Water piping
Chiller Contr
ol P
anel Applica
tion ffor
or Multiple Mini Chiller
s Used in Of
Control
Panel
pplication
Chillers
Offfices
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
2-8
Ad
vance P
ar
ameter
s
Adv
Par
arameter
ameters
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.
Boiler
Contactor
Boiler
Terminal
Auxilliary
Heater
Terminal
Auxilliary Heater
Relay
When use boiler or auxilliary heater the model must be set. This setting is found in the following menu.
Screen 1
MAIN MENU
Operation Menu
Setting Menu
Timer Menu
Alarm Menu
Display Menu
2-9
Screen 2
SETTING MENU
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
G2 No. Comp
G3 On/Off In
G4 Co/Heat In
G5 Ext Alarm In
G6 Water Sys
G7 Unit No.
: Chiller
: 1 Comp
: Disable
: Disable
: Disable
: Isolated
:0
All Advance
Parameter is found
here
Model is set
according to users
requirement
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.
2 - 10
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 operate
based 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
differential, C is set to 0C. Mini chiller runs heating mode.
auto
boiler
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.
2 - 11
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:
Model Selection
Chiller
Heatpump
Chiller / Boiler
Heatpump / Boiler
Chiller + Boiler
Heatpump + Boiler
Mode
Cooling Heating Boiling
o
x
x
o
o
x
o
x
o
o
o
o
o
x
Auto
o
o
Auto
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 + Boiler allows boiler 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 )
2 - 12
FCU
Mini Chiller
Water Storage
Tank
Expansion
tank
FCU
Mini Chiller
Boiler
Water Storage
Tank
2 - 13
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.
One compressor system
Temperature
Comp on
Cooling set-point
Comp off
2 Comp on
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.
2 - 14
Heating set-point
Comp off
Heating set-point
2 Comp off
1 comp off
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 ONOFF cycle exceeds this time interval another compressor ON-OFF cycle can begin.
Refer to the following examples.
2 - 15
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
1m
4m
1m
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
25
10% load
15
13.5
12
10.1
1.5
m
6m
1.5
m
6m
Time
2 - 16
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 <= Start Defrost Temperature for example <= 0C it will
initiate a defrost cycle with condition the defrost interval time is met.
End Defrost Temperature, maximum duration of defrost cycle and defrost end contact open
The defrost cycle can terminate when any of the following conditions is met
1) End Defrost Temperature - The defrost sensor senses the End Defrost Temperature for example 14C and
defrost cycle is terminated
2) Maximum duration of defrost cycle - This sets the maximum allowable defrost cycle duration. Once ths
duration is elapsed for example 10 minutes the defrost cycle will
terminate.
3) Defrost end contact open - This is a dry contact ( 12VDC ) which is wired parellel with the high pressure
switch. Once the high pressure switch opens defrost end contact opens and
defrost cycle is terminated.
2 - 17
Expansion
tank
Boiler
FCU
Mini Chiller
Water Storage
Tank with
Auxilliary Heater
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.
Boiler
Contactor
Boiler
Terminal
Auxilliary
Heater
Terminal
Power supply
to boiler
3 Way Valve
N N
220-240VAC
C1
Auxilliary Heater
2 - 18
Panel ID 0
Unit ID 0
Panel ID 1
Unit ID 1
Panel ID 2
Unit ID 2
Networking cable
2 - 19
Section 3
HydroIntel
3.1 About Hy
dr
oIntel
Hydr
droIntel
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 system
4) 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
3-1
The Settings Menu allows users to determine how they would like to control the hydronic system operation.
Settings
Priority
Cool threshold
Heat threshold
: None
: 50%
: 50%
Priority Setting
None
FCU
Chiller
System Configuration
ON/OFF of FCU and mini chiller is independent
FCU controls mini chiller ON/OFF
Mini Chiller enables FCU to ON and controls FCU OFF
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 mini
chiller 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.
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.
3-2
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.
3-3
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.
Unit Selection:
Select All
Select Group
Select One
Unit Selection:
Select All
Select One : 0
3-4
Screen 1
Unit Selection:
Select All
Select Group
Select One
Screen 2
OPERATION MENU
Status
Mode
Set Temp
Fan
Screen 3
: ON
: Cool
: 25C
: High
20/09/2004
Status
Mode
Set Temp
Fan
Room Temp
Unit
Set parameters
in the Operation
Menu
11.20am
: ON
: Cool
: 25C
: High
:-: All
Parameters
setting as shown
on display
screen
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.
hedule
FCU Timer Sc
Schedule
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.
3-5
Example
College Y has fifty lecture rooms. The HVAC equipment in these lecture rooms run on a programmable timer.
Screen 1
Timer Menu
Clock Setting
Date Setting
Timer Schedules
Holiday
Select Timer
Schedules
Screen 2
SCHEDULE SETTINGS
Select Schedule
Schedule 1
Schedule 2
Schedule 3
Schedule 4
Schedule 5
Screen 3
Sun
Mon
Tue
Wed
Timer 1
ON
OFF
Timer 2
ON
OFF
0800
0800
0800
0800
1900
1900
1900
1900
1800
1800
1800
1800
2100
2100
2100
2100
Set Timer
Screen 4
OPERATION MENU
Swing
: No
Sleep
: No
Schedule : 1
Timer
: Enable
Select Schedule
to run the FCU
Enable Timer
3-6
Screen 1
TIMER MENU
Set Time
Set Date
Set Schedule
Timer
: Disable
Screen 2
Sun
Mon
Tue
Wed
Select to set
schedule
Timer 1
ON
OFF
Timer 2
ON
OFF
0800
0800
0800
0800
1900
1900
1900
1900
1800
1800
1800
1800
2100
2100
2100
2100
Set Timer
Screen 3
TIMER MENU
Set Time
Set Date
Set Schedule
Timer
: Enable
Enable Timer
3-7
Holida
y Sc
hedule
Holiday
Schedule
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.
Screen 1
Timer Menu
Clock Setting
Date Setting
Timer Schedules
Holiday
Select holiday
schedule
Screen 2
HOLIDAY SETTINGS
Holiday 1
Holiday 2
Holiday 3
Holiday 4
Holiday 5
Select schedule
Set Holiday 1
Month
:1
Day
: 20
Duration : Enable
Set schedule
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.
3-8
Advance Settings
The HydroIntel is designed with BMS ready feature. This feature allows all FCU to be integrated with BMS (
Building Management System )
Screen 1
SETTING MENU
Advance Setting
Change Password
Panel Option
Screen 2
ADVANCE SETTING
BMS
: Enable
Global ON : Enable
Enable all FCU
to ON automatically
When BMS setting is enabled, all FCU in the network system is controlled by BMS.
HydroIntel
BMS SYSTEM
BMS ALARM SWITCH
GND
+12VDC
ALARM INPUT
ONOFF INPUT
ON/OFF ALARM
OUTPUT OUTPUT
+12VDC
H/C
AUX
OUTPUT OUTPUT
ALARM INPUT
CONTACT
ON/OFF INPUT
CONTACT
ON/OFF OUTPUT CONTACT
ALARM OUTPUT CONTACT
ON/OFF INPUT CONTACT
ALARM INPUT CONTACT
Alarm
+12VDC
On/Off
+12VDC
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.
3 - 10
Indicator
Indicator
On/Off
Heating/
Cooling
Alarm
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
All the output contacts are usually linked to indicators like LED, light bulb etc.
Refer to Appendix 1 for maximum allowable cable length.
3 - 11
Example
To other FCU
Building
Management
System
Communication Cable
Punch Boards
HydroIntel
NIM
FCU
Netware 2
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.
3 - 12
3.2 Hy
dr
oT
ec
h System Applica
tion
Hydr
droT
oTec
ech
pplication
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 chiller
reclaimed 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
NIM Bus
Chiller Bus
HydroIntel
NIM
Netware 2
Mini Chiller for HVAC
Netware 2
Communication Cables
Water Piping
3 - 14
Mini Chillers
FCU
FCU
FCU
FCU
NIM Bus
Chiller Bus
HydroIntel
The above diagram is an illustration of how HydroTech System can be used to control and monitor HVAC
system 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.
3 - 15
Hot water
boiler
To other FCU
FCU for HVAC
FCU for machine cooling
Netware 2
NIM
Netware 2
NIM
NIM Bus
HydroIntel
Chiller Bus
Communication cable
Water Piping
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 fan
speed controller ) to cool machine rooms like computer rooms, generator rooms etc.
3 - 16
FCU
for HVAC
Chiller for
HVAC
Netware 2
NIM
NIM
NIM
NIM
NIM Bus
HydroIntel
Chiller Bus
Communication cable
Water Piping
Freezer
3 - 17
Freezer
Heat
reclaim
piping
Kitchen for dish
washing,
cleaning
Hot Water
Storage
Tank
Chiller
for
HVAC
Hot Water
Storage
Tank
Bathroom
for
shower
Chiller
for
HVAC
NIM Bus
HydroIntel
NIM
FCU for HVAC
NIM
FCU for HVAC
Netware 2
NIM
Water piping
3 - 18
Panel ID 1
Unit ID 1
Panel ID 0
Unit ID 0
NIM
HydroIntel
To FCU Main Board
To display control module
Factory Installed Cable
Networking cable
3 - 19
Appendix
Table 1-1: Bus Cables Specifications
No
1
Item
Type of cable
Cable diameter
3
4
5
6
7
8
Requirements
The cable shall comply at least with
IEC 189-2 or equivalent national std
unless otherwise specified below
Min: 0.8mm
Max: 1.0mm
0.5-1.0mm2
Copper and solid wires
Sheath and screened
One twisted pair with different colour
of cores
Minimum 5 twist per meter
2 core cable,minimum 50N
Connection
NIM to HydroIntel
Mini Chiller to HydroIntel
Chiller Control Panel to Mini Chiller
G-Way to BMS
HydroIntel to BMS
Appendix 1
Hy
dr
oIntel
Hydr
droIntel
Appendix 2
Group
Settings
12345678 Address
00000000
64
10000000
65
01000000
66
11000000
67
00100000
68
10100000
69
01100000
70
11100000
71
00010000
72
10010000
73
01010000
74
11010000
75
00110000
76
10110000
77
01110000
78
11110000
79
00001000
80
10001000
81
01001000
82
11001000
83
00101000
84
10101000
85
01101000
86
11101000
87
00011000
88
10011000
89
01011000
90
11011000
91
00111000
92
10111000
93
01111000
94
11111000
95
00000100
96
10000100
97
01000100
98
11000100
99
00100100
100
10100100
101
01100100
102
Group
Settings
12345678 Address
00000010
128
10000010
129
01000010
130
11000010
131
00100010
132
10100010
133
01100010
134
11100010
135
00010010
136
10010010
137
01010010
138
11010010
139
00110010
140
10110010
141
01110010
142
11110010
143
00001010
144
10001010
145
01001010
146
11001010
147
00101010
148
10101010
149
01101010
150
11101010
151
00011010
152
10011010
153
01011010
154
11011010
155
00111010
156
10111010
157
01111010
158
11111010
159
00000110
160
10000110
161
01000110
162
11000110
163
00100110
164
10100110
165
01100110
166
Appendix 3
Group
Settings
12345678 Address
00000001
192
10000001
193
01000001
194
11000001
195
00100001
196
10100001
197
01100001
198
11100001
199
00010001
200
10010001
201
01010001
202
11010001
203
00110001
204
10110001
205
01110001
206
11110001
207
00001001
208
10001001
209
01001001
210
11001001
211
00101001
212
10101001
213
01101001
214
11101001
215
00011001
216
10011001
217
01011001
218
11011001
219
00111001
220
10111001
221
01111001
222
11111001
223
00000101
224
10000101
225
01000101
226
11000101
227
00100101
228
10100101
229
01100101
230
Settings
12345678
00000011
10000011
01000011
11000011
00100011
10100011
01100011
11100011
00010011
10010011
01010011
11010011
00110011
10110011
01110011
11110011
00001011
10001011
01001011
11001011
00101011
10101011
01101011
11101011
00011011
10011011
01011011
11011011
00111011
10111011
01111011
11111011
00000111
10000111
01000111
11000111
00100111
10100111
01100111
Settings
Group
12345678 Address
11100100
103
00010100
104
10010100
105
01010100
106
11010100
107
00110100
108
10110100
109
01110100
110
11110100
111
00001100
112
10001100
113
01001100
114
11001100
115
00101100
116
10101100
117
01101100
118
11101100
119
00011100
120
10011100
121
01011100
122
11011100
123
00111100
124
10111100
125
01111100
126
11111100
127
Unit
Address
0
1
2
3
4
5
6
7
Settings
1234
0000
0001
0010
0011
0100
0101
0110
0111
Settings
Group
12345678 Address
11100110
167
00010110
168
10010110
169
01010110
170
11010110
171
00110110
172
10110110
173
01110110
174
11110110
175
00001110
176
10001110
177
01001110
178
11001110
179
00101110
180
10101110
181
01101110
182
11101110
183
00011110
184
10011110
185
01011110
186
11011110
187
00111110
188
10111110
189
01111110
190
11111110
191
Unit
Address
8
9
10
11
12
13
14
15
Settings
1234
1000
1001
1010
1011
1100
1101
1110
1111
Appendix 4
Settings
Group
12345678 Address
11100101
231
00010101
232
10010101
233
01010101
234
11010101
235
00110101
236
10110101
237
01110101
238
11110101
239
00001101
240
10001101
241
01001101
242
11001101
243
00101101
244
10101101
245
01101101
246
11101101
247
00011101
248
10011101
249
01011101
250
11011101
251
00111101
252
10111101
253
01111101
254
11111101
255
Settings
12345678
11100111
00010111
10010111
01010111
11010111
00110111
10110111
01110111
11110111
00001111
10001111
01001111
11001111
00101111
10101111
01101111
11101111
00011111
10011111
01011111
11011111
00111111
10111111
01111111
RESERVED
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