MISSION CRITICAL Air Conditioning Systems M52 Microprocessor User’s Guide ClimateWorx International Inc. M52UMCT2014.
M52 Microprocessor User's Guide 2 M52UMCT2014.
M52 Microprocessor User's Guide Table of Contents Sequence of Operation ...................................................................................................................................................... 6 Phase Loss (OPTION):.................................................................................................. 6 Analogue and digital outputs for functions ................................................................... 6 DX Demand (Cooling) ................................
M52 Microprocessor User's Guide Alarms ..............................................................................................................................................................................20 Review Active Alarm Queue ........................................................................................20 Acknowledging Alarm..................................................................................................21 Clear Alarm Message .......................................
M52 Microprocessor User's Guide High Temperature Alarm ............................................................................................ 50 Low Temperature Alarm.............................................................................................. 50 High Humidity Alarm .................................................................................................. 51 Low Humidity Alarm ...................................................................................................
M52 Microprocessor User's Guide Sequence of Operation The following is an outline of the operation of the unit. Not all units have all options. 1. Unit powered 2. ClimateWorx Banner appears and controller beeps three times. 3. Microprocessor initializes Co-Work and runs self check. 4. Random start timer activates 5. Restart delay counts down Phase Loss (OPTION): On loss or cross of a phase of supply power the unit will shut down or display Phase Loss alarm.
M52 Microprocessor User's Guide N/C auxiliary contact on compressor contactor opens and de-energizes crankcase heater. N/O auxiliary contact on compressor contactor starts remote condenser. (Air-cooled units only) Low-pressure switch remains closed after Pos. start time expires and compressor remains on. • • • Compressor stops when: • • • • • Loss of demand Compressor contactor opens Low pressure condition Compressor stops when LP SW. opens. (Automatic reset) compressor contactor opens.
M52 Microprocessor User's Guide The Dehum. Solenoid closes off refrigerant flow to part of the evaporator coil. This causes a drop in suction pressure and a lower coil surface temperature over a portion of the coil. The coil begins to remove more moisture as a result. The air is partially reheated, as the air through the inactive part of the evaporator is unconditioned.
M52 Microprocessor User's Guide glycol valve begins to open when the difference between the return air temperature (Temp 1) and the (EGT) entering glycol temperature (temp 2) is greater than 3°C, (6°F). The unit will operate in Free Cooling as long as the cooling demand remains in the 0-50% range. Once the cooling demand reaches 51-99% range the unit will operate with one circuit in Free Cooling and the opposite circuit in DX Cooling.
M52 Microprocessor User's Guide Loss of demand Loss of air flow Boiler Dirty Alarm intervention. PID The M52 microprocessor uses PID control logic to maintain the set point conditions. The following parameters are adjustable so the controller can be fine-tuned to specific site conditions. Dead band, temp. humid. dead band Cool prop. band Heating prop. band Humidifying prop. band Dehum. prop. band Integral time temp Integral time hum.
M52 Microprocessor User's Guide Note: On/Off mode: When operating in a Co-Work network all On/Off mode options are synchronized. Therefore, turning off a unit, either by the touch screen when in Local, by the remote on/off at terminals 15 and 16 when in Remote, or through the schedule when in Timer mode will turn off all units in that network. To turn off an individual unit either as a stand-alone or in a Co-Work network see the Test Mode section or simply open the disconnect switch. M52UMCT2014.
M52 Microprocessor User's Guide Powering Up / Powering Down The first powering up must be performed by CLIMATEWORX authorized personnel only. Failure to do so may damage the unit and void the warranty. The main power switch (rotary disconnect) is located on the front of the unit. Series 6, 8 and 9 only. Immediately after turning on the main power switch, the control system will perform the following power up sequence: 1.
M52 Microprocessor User's Guide The Control Panel The control panel is formed by a graphic LCD display and an overlay touch screen keypad. The layout of the screen consists of three distinctive regions - the Banner line, the Active tab display area and the Tab bar. The tabs are set-up like the tabs in a 3-ring binder. Each section contains different information. Banner line The Banner line shows the system type and the current date and time. Date is in DD/MM/YYYY format and time in 24-hour HH:mm format.
M52 Microprocessor User's Guide Operating Status Network address Unit fan on/off icon Main or return air temperature Main or return air humidity Co-Work address icon Alarm icon On/Off mode icon Process status display Main Return Air Temperature & Humidity Readout The main temperature & humidity readout shows the values of the return air being sensed by the system. Temperature readout can be displayed in either °C or °F depending on the setting “Temperature display”.
M52 Microprocessor User's Guide Alarm Icon The alarm icon shows up if there is any active alarm in the system. You can review the details of the alarm in the {Alarm} tab. Unit fan On/Off Icon The unit fan on/off icons show up when the unit fan is running. This icon changes from continuously on to blinking when the unit is under fan purge shutdown. On/Off Mode Icon The On/Off mode icons keep you aware of the current On/Off mode selection.
M52 Microprocessor User's Guide Co-Work™ Address Icon This shows the Co-Work™ operation mode and network address. Duty Master (e.g. Address 1) Standby Master (e.g. Address 1) Every master unit in the Co-Work™ network must have a unique address which can be set through the DIP switches on the main board and I/O expansion board.
M52 Microprocessor User's Guide Security To prevent unauthorized interference with the system operation and settings, the M52 Microprocessors have three levels of security that can be assigned to different personnel having different responsibilities. Settings can only be altered after entering the four-digit password for the corresponding security level.
M52 Microprocessor User's Guide Security level selector Password enter keys Log-out Security Exiting the security can be achieved by pressing the Log-out key in the log-out / change password screen. Cancel key Log-out key The system will also automatically re-lock security approximately 1 minutes after the last key is released. Change Password After logging-in to security, you can press the active tab again to invoke the log-out / change password screen.
M52 Microprocessor User's Guide Password enter keys M52UMCT2014.
M52 Microprocessor User's Guide Alarms Review Active Alarm Queue Active alarms and their date & time of occurrence can be reviewed under the alarm tab. The active alarms are displayed chronologically with the latest alarm at the top. Unit no. Scroll bar 20 Alarm description Occurrence date Occurrence time Change page M52UMCT2014.
M52 Microprocessor User's Guide Acknowledging Alarm In case of an alarm condition occurrence and provided the alarm is enabled and configured for audible warning, (See Alarm Configuration), a pop-up message will display on the screen like the following: Acknowledge alarm key You are requested to press the alarm activated “tick” or “check” mark, [Alarm acknowledge] alarm key in order to mute the audible warning and de-activate the common alarm output. The alarm will not return again.
M52 Microprocessor User's Guide Alarm Configuration The alarm configuration screen is under the active alarm queue screen inside the {Alarm} tab. You can switch to alarm configuration screen by pressing the [Change page] key in the alarm queue screen. Alarm description Scroll bar Configuration keys Configuration icon Change page Every alarm has a number of configuration options. You can customize the way alarms are reported and what automatic actions will be performed. 22 M52UMCT2014.
M52 Microprocessor User's Guide Enable option key - alarm will only be monitored if this option is selected. Unit shutdown option key - if this option is selected, unit will be automatically shutdown under alarm condition. Standby enable option key - if this options is selected, standby enable output will be activated under alarm condition. Common alarm option key- if this options is selected, common alarm output will be activated under alarm condition.
M52 Microprocessor User's Guide Alarm Response Summary The following table summarizes the default configuration for all the alarms and their corresponding system action: Alarm Message Fan overload (DP float S11 only) Default Configuration Mandatory System Action Immediate unit shutdown Low airflow Boiler dirty Humidifier shutdown Heater overheat Heater shutdown Filter dirty Immediate unit shutdown 1 Fire Flood High humidity High humidity 2 High temperature High temperature 2 High voltage Low Humidi
M52 Microprocessor User's Guide Historical Event Log For fault analysis, the system maintains the latest 50 historical events logged in the memory. The logs are ranked chronologically with the latest event at the top. Scroll bar Event type icon Event description Unit no. Log date Log time The following type of events will be logged: Power failure / Power restore / Unit start / Unit stop Alarm raised Alarm acknowledged Alarm cleared M52UMCT2014.
M52 Microprocessor User's Guide Timer On/Off Schedule Review Timer On/Off Schedule The weekly on/off program provides 4 changeover events per day and 7 days per week automatic on/off/relax control for the system.
M52 Microprocessor User's Guide Programming the Timer On/Off Schedule If security access is granted, you can alter the Timer On/Off Schedule settings from the following screen: Set clock key Increment / Decrement value keys Cursor Cursor movement keys Set Clock You can press the set clock key on the Timer On/Off Schedule screen to adjust the date and time display. Cursor Increment / Decrement value keys M52UMCT2014.
M52 Microprocessor User's Guide Temperature and Humidity Log Graph The historical temperature and humidity variation can be reviewed under the Graph tab. The log graph stores the latest 24-hour main temperature and humidity data. Data are logged in 15 minutes interval.
M52 Microprocessor User's Guide Settings System settings can be reviewed and altered in the {Setting} tab. Settings are divided into three groups. You can switch the display by pressing the [Change page] keys. Scroll bar Setting description Setting value Change page Programming Settings You can alter any keycode setting only if you have gained access to the appropriate security level. After gaining the programming right, you can change the settings by using the [Increment] and [Decrement] keys.
M52 Microprocessor User's Guide Settings Summary Version 473 (All units except Chilled Water) The following tables summarize the settings in each page: Page 1 : Configuration 1 Description No. of duty unit Temp. setpoint Temp. Hi limit Temp. Low limit Humid. setpoint Humid. Hi limit Humid. Lo limit Range 1-8 15-30 15-37 10-30 30-80 50-90 20-50 Page 2 : Configuration 2 Description Software ver.
M52 Microprocessor User's Guide Page 4 : Description Temp. dead band Relaxband Temp Temp.2 Hi limit Temp.2 Lo limit Hum. dead band Relaxband Humid Hum.2 Hi limit Hum. 2 Lo limit Volt. Hi limit Volt. Lo limit Prop.band Cool Prop.band Heat Prop.band Humid Prop.band Dehum Temp. I-time Humid. I-time Humid. Control Setback Humid.
M52 Microprocessor User's Guide Page 2: Configuration 2 Parameter Definition Software ver. Network address Baud rate On/Off mode Version of software operating on the microprocessor Controller address to identify the unit in a SatchNet network/BMS Network Restart mode Auto changeover Restart delay Warm-up period Fan purge delay Comp. elapse Pos.start delay SatchNet network communication speed Sets unit to turn “ON” and “OFF” by local keypad, remote signal or timer schedule.
M52 Microprocessor User's Guide Page 4: Control Parameter Parameter Definition Temp. dead band Tolerance for return air, + or – ½ deadband. Range of temperature where temperature control operation does not change Used in the timer schedule allows an alternate deadband setting Maximum allowable spare temperature before activating alarm 1 Minimum allowable spare temperature before activating alarm 1 Tolerance for return air, + or – ½ deadband.
M52 Microprocessor User's Guide Page 2 : Configuration 2 Description Software ver. Network address Baud rate On/Off mode Restart mode Auto changeover Restart delay Warm-up period Fan purge delay Comp. elapse Pos.start delay Humid. Ser. delay IR auto flush Sensor mode Temp. units Sensor display Language Common Alr. Mode Page 3 : Description C. water circuit 1 C. water circuit 2 C. water 1 temperature C. water 2 temperature C. water 1 temperature* C. water 2 temperature* Primary circuit Changeover delay C.W.
M52 Microprocessor User's Guide Page 4 : Description Temperature 1A Temperature 2 Humidity 1A Humidity 2 Voltage Fan runtime (1-8) Comp.1 runtime (1-8) Heater runtime (1-8) SCR Heat. runtime Humid. Runtime (1-8) Dehum. Runtime (1-8) Readings Range 0-50.0 0-50.0 0-99.9 0-99.
M52 Microprocessor User's Guide Settings Summary Glossary Version 491B2 (Chilled Water units only) The following provides a definition of the parameters used in the Settings section: Page 1: Parameter No Duty Units Temp. setpoint Temp. Hi limit Temp. Lo limit Humid. setpoint Humid. Hi limit Humid. Lo limit No of Standby Page 2: Configuration 1 Definition Units required to run together in a Co-Work network to satisfy the load. Controls space temperature base on return air temperature.
M52 Microprocessor User's Guide Page 3 Readings Parameter C. water circuit 1 C. water circuit 2 C. water 1 temperature C. water 2 temperature C. water 1 temperature* C.
M52 Microprocessor User's Guide Page 5: Parameter Temp. dead band Relaxband Temp Temp.2 Hi limit Temp.2 Lo limit Hum. dead band Relaxband Humid Hum.2 Hi limit Hum. 2 Lo limit Volt. Hi limit Volt. Lo limit Prop.band Cool Prop.band Heat Prop.band humid Prop.band Dehum Temp. I-time Humid. I-time Temp. D-time Humid. D-time Humid. Control Dual-cooling Free-cooling 38 Control Parameter Definition Tolerance for return air, + or – ½ deadband.
M52 Microprocessor User's Guide Test Mode The {Testmode} tab contains an assortment of utilities designed to simplify field testing and troubleshooting.
M52 Microprocessor User's Guide In the Microprocessor board diagnostic page, each input or output on the Microprocessor board are represented by a symbol on the display.
M52 Microprocessor User's Guide Digital I/O Board Diagnostic The digital I/O board diagnostic page under the {Testmode} tab is as follows: Selected slave board State selector Selected I/O Available slave boards Description line Switched inputs Switched outputs Change page Under the digital I/O board diagnostic page, you can: - Select any of the linked digital I/O board to review. - Review the status of the switched inputs on the selected digital I/O board.
M52 Microprocessor User's Guide Card icon State selector Sensor Calibration The sensor calibration page under the {Testmode} tab is as follows: Temperature input readings Set 0°C Humidity input readings Supply voltage percentage Load default value Change page Under the sensor calibration page, you can: 42 - Review the current temperature inputs, adjust the 0°C reference and restore temperature input offsets to default value.
M52 Microprocessor User's Guide Sensor Calibration Sequence Temperature 1. 2. 3. Power off unit and set the jumper on the temperature and humidity sensor board to “Zero” position. The pin 1 and 2 of the sensor board should read approximately 1000 ohms which corresponds to 0°C for the Hycal PT100 sensor. Switch unit on and after one minute login security level 1. Go to the sensor page under the [Test mode] tab and press the “Def.” And then “Set 0” key next to the temp1 reading.
M52 Microprocessor User's Guide Under this page, you can: 1 44 - Set alarm configurations to default configurations (See Alarm Response Summary)1. - Set timer on/off schedule to default configurations (See Timer On/Off Schedule). - Set system configuration and control settings to default configurations (See Setting Summary) - Clear log data in historical event log. - Clear log data in temperature and humidity log graph.
M52 Microprocessor User's Guide Co-Work™ Co-Work™ is a six function networking feature that is built into every M52 controller. Through the use of a six wire telephone cable you can link up to 8 compressor circuits on one local area network. What this does is it makes all units in the network operate as one system which improves the system performance, reliability and manageability. Refer to page 59 for the wiring details. Co-Work™ performs the following six functions: Two Levels of Duty Sharing.
M52 Microprocessor User's Guide Control Value Averaging Co-Work™ exchanges sensor reading of temperature and humidity of network units and operates from the average reading. This prevents units from fighting each other when multiple units control one space. Settings Menu, Sensor mode: Additional flexibility in configuring a ‘n+1’ Co-Work network has been added. In certain cases it could be desirable to ignore the sensor data from standby units.
M52 Microprocessor User's Guide Decide how many units are required to maintain the room load. This is the number of duty units. Log on to any unit in the network using the Level 1 password. Select the Setting page. Enter the number of duty units on page one of the settings tab. Log off of the system (page 12) The Co-Work network is now set up. Each unit has a unique address that identifies each printed circuit board in the network. See page 14 & 16 for the PC board address code.
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M52 Microprocessor User's Guide Fault Finding In some cases, determining the cause of a fault requires a fair amount of technical knowledge and skill. The following fault finding charts are given as a guide for the service personnel to locate the common faults which may be encountered in the unit. High Temperature Alarm High temperature alarm Main temperature higher than "Temp. Hi Limit" setting Main temperature too high ? no Wrong setting in "Temp. Hi Limit" Set "Temp.
M52 Microprocessor User's Guide High Humidity Alarm High humidity alarm Main humidity higher than "Humid. Hi Limit" setting Main humidity too high ? no Wrong setting in "Humid. Hi Limit" Set "Humid. Hi Limit" 5-10%rh higher than "Humid. setpoint" yes Abnormal site condition Check opened doors/windows or abnormal site condition Inoperative dehumidifying system Check dehumidifying system operation Low Humidity Alarm Low humidity alarm Main humidity lower than "Humid.
M52 Microprocessor User's Guide High Voltage Alarm High voltage alarm Supply voltage higher than the setting "Volt. Hi limit" Supply voltage too high ? no Wrong setting in "Volt. Hi limit" Set "Volt. Hi limit" to 105115% Poor power condition Add voltage stabilizer yes Low Voltage Alarm Low voltage alarm Supply voltage lower than the setting "Volt. lo limit" Supply voltage too low ? no Wrong setting in "Volt. lo limit" Set "Volt.
M52 Microprocessor User's Guide Low Airflow Alarm Low airflow alarm Airflow differential pressure switch intervention No air flow ? no Open panles in air compartment Close all panels in the air handling compartment Blocked air path Clear obstruction in air path yes Fan motor running ? no yes Broken belts Replace defective belts Overcurrent protective device tripped Check control circuit Defective fan motor Check fan motor Filter Dirty Alarm Filter dirty alarm Filter differential pressure
M52 Microprocessor User's Guide Fan Overload Alarm Heater Overheat Alarm Heater overheat alarm Safety overheat thermostat intervention Dirty air filter Too low airflow 54 Replace filter and re-calibrate the filter differential pressure switch Check possible obstructions in air path M52UMCT2014.
M52 Microprocessor User's Guide Boiler Dirty Alarm Boiler dirty alarm Electrode boiler humidifier control board intervention Water level at top of the cylinder ? no Water forning at top of the cylinder due to over concentration Check inoperative drain valve or blocked strainer yes Low concentration of current carrying minerals in cylinder Dissolve half a teaspoon of salt in a cup of water and fill into the new cylinder yes Initial startup with a new cylinder ? no Cylinder is fully calcified M52U
M52 Microprocessor User's Guide High Pressure Alarm High pressure alarm Compressor high pressure cutout switch intervention Too high discharge pressure ? no Wrong high pressure cutout switch calibration Re-calibration the high pressure cutout switch yes Air cooled system ? yes Condenser fans not running Dirty condenser Check condenser control circuit and indoor unit interlock wirings Clean condenser Too low airflow Clear air intake and discharge obstructions Too high air temperature Check p
M52 Microprocessor User's Guide Low Pressure or Short Cycling Alarm Low pressure/short cycling alarm Compressor low pressure cutout switch intervention Too low suction pressure ? no Wrong low pressure cutout switch calibration Re-calibration the low pressure cutout switch yes Too low condensing pressure Check condenser control circuit Low refrigerant charge Check possible leak, repair and recharge Clogged filter - drier Replace filter drier Failure liquid line solenoid valve Replace defective
M52 Microprocessor User's Guide Appendix A: Electrical Schematic Diagrams 58 Drawing Title Drawing no. Page No. Electrical Schematic - IIC Interconnection Link M52ES01E 59 Electrical Schematic - RS485 Serial Communication Link M52ES02E 60 M52UMCT2014.
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60 1 U1 1 J13 1 J12 1 J11 R(-) Grd T/R(+) T/R(-) Not used Not used Not used 1 2 3 4 5 6 Not used T(+) T(-) Grd R(+) Half duplex M52ES02E 1 J01 BL1 Full duplex J21 and J22 (RS485) J14 J51 U3 JP1 JP2 JP11 U5 U14 J21 J22 J31 J32 J02 PIN No.
M52 Microprocessor User's Guide Notes: M52UMCT2014.
