McQua

McQuay y Smar
Smartt Mana
Managger
Chilled Water System
Applica tion Man
pplication ual
Manual

Fir st Edition
First
Jul
ulyy 2005
Intr oduction
Introduction

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

Section 1: Networ
Networ k Interf
ork ace Module (NIM) and Netw
Interface ar
Netwar e2
are

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

1.2 Installation ................................................................................................................ 1-2
1.3 Address Assignment ................................................................................................ 1-3
1.4 Master and Slave FCU ............................................................................................. 1-5
1.5 About Netware 2 ...................................................................................................... 1-6
1.6 Netware 2 and NIM Application ................................................................................ 1-6
1.7 NIM Wiring ............................................................................................................... 1-11
1.8 G-Way and Building Management System(BMS) ................................................... 1-12

Section 2: Chiller Contr ol P

Control anel
Panel

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

2.2 Installation ................................................................................................................ 2-2
2.3 Master and Slave Mini Chiller .................................................................................. 2-5
2.4 Chiller Control Panel Applications ............................................................................ 2-5
2.5 Wiring for Chiller Networking ................................................................................... 2-19

Section 3: Smar
Smartt Mana
Managger

3.1 About Smart Manager .............................................................................................. 3-1

3.2 Smart Manager Chilled Water System Applications ................................................ 3-13
3.3 Wiring for Smart Manager Chilled Water System .................................................... 3-19

Appendix

Copyright c 2005 by McQuay International. All rights reserved. This publication is strictly confidential and is meant
for DISTRIBUTORS of McQuay 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
McQuay 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. McQuay 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 Smart Manager. Smart Manager 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 Smart Manager, 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
 Smart Manager
> User friendly
> Easy Installation
> Networking capability up to 120 fan coil
units and 50 mini chillers
> Energy saving
> Programmable Timer,Integration with BMS
alarm alert and many more

Netware 2
> User friendly
> Easy Installation
> Networking capability
> Energy saving
> Programmable Timer
> System fault code display

NIM
> Compact
> Easy Installation
> Energy saving

Chiller Control Panel

> User friendly
> Easy Installation
> Networking capability up to 50 mini chillers
> Energy saving
> Programmable Timer
> Alarm alert

Introduction - 2
 Smart Manager
HydroIntel

Networking between Smart Manager and Mini Chiller

HydroIntel
Smart Manager

Networking between Smart Manager and Fan Coil Unit

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 Smart Manager,
Fan Coil Unit (FCU) and display control panels.

Bottom Casing Top Casing

Group Address CN3

Unit Dip Sw itch Connector
Address
Dip
Sw itch

IC

CN2 CN1
Connector Connector

Network Interface Module

This means that when FCU parameters are set using Smart Manager, 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 Installation
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.

Completed NIM Installation

The following precaution must be taken when selecting the location to install NIM

a) Do not expose to direct sunlight

b) Do not expose to electromagnetic waves
c) Do not expose to heat source

Whenever possible, it is recommended to install NIM next to the FCU.

1-2
1.3 Ad dr
Addr ess Assignment
dress

The uniqueness of the Smart Manager 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 Smart Manager 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

This Group Address

is 10000000 which
represents Group 1

Dip switch on top

represents "1"

Likewise, Setting 10100000 represents Group Address 5

Setting 00101000 represents Group Address 20
Setting 00100110 represents Group Address 100

This Unit Address

is 0111 which
represents Unit 7

Dip switch on the

bottom represents "0"

Likewise, Setting 0000 represents Unit Address 0

Setting 0101 represents Unit Address 5
Setting 1111 represents Unit Address 15

Refer to Appendix 3 and Appendix 4 for dedicated address which are assigned to each FCU.

Group Address that can be assigned are 0 to 254. Group Address 255 is reserved for PC Operation only ( this
application is not covered in this manual ). Unit Address that can be assigned are 0 to 15. Unit address "0" is
reserved for Master Unit only.
( For more details refer to Master and Slave FCU in this section )

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 Smart Manager and the FCU parameter can be monitored
and set-able from the Smart Manager.
( Refer to Smart Manager Operating Manual for operation details )

13/09/2004 11.00am
FCU Parameters are
Status : ON
easily monitored
Mode : Cool
Set Temp : 24C
Fan : High FCU Address displayed
Room Temp : 27C on the Smart Manager
Unit : G1U7

Smart Manager displaying FCU parameters

MAIN MENU

Operation Menu FCU Parameters are

Settings Menu easily set-able with the
Smart Manager
Timer Menu
Alarm Menu

Smart Manager displaying FCU Menus

1-4
1.4 Master and Slave FCU
Slav

Master Unit is a FCU with a unique address "0" assigned to it. Slave Unit is a FCU within the same network
group as the Master Unit that has any address from 1 to 15 assigned to it.
Master Unit is used to control all other Slave Units which are assigned to the same network group with it.
Master Unit must be linked to Netware 2 for this purpose.

Main Main
NIM NIM
Board Board

Netware 2 Control Netware 2 Control

Panel Panel

Main Main Main

NIM NIM NIM
Board Board Board

. No IR Remote /
Netware 2 Control
IR SLM3 / Netware 2
Panel
IR Remote

Master Slave 1 Slave 2 Master Slave 1

Group 1 Group 2

Typical Bus Structure For NIM Network

These Slave Units will receive data from the Master Unit and change their parameters to follow exactly the
parameters change of the Master Unit.

This means that when the Master Unit is turn ON all Slave Units would turn ON too. When the Master Unit runs
Cool Mode all Slave Units would run Cool Mode too. When the Master Unit is turn OFF all Slave Units are turn
OFF too. When Master Unit room temperature is set to 24C all Slave Units room temperature are set to 24C.

Note that a Group can only have one Master Unit and up to fifteen Slave Units.

This type of Master and Slave Networking System is suitable for use in places with multiple FCU such as office
building, cinemas ,schools and lecture theatres.

1-5
1.5 About Netwar
Netwar e2
are

Netware 2 is a wired LCD remote control panel used to control and monitor individual fan coil unit. When linked
to NIM, Netware 2 can be used to control all other FCU in the same networking group.

The advantages of Netware 2 are

1) Ability to ON / OFF up to fifteen fan coil units simultaneously under the same network group
2) Ability to control all fan coil units to run with the same parameters.
3) Ability to run or stop all fan coil units based on a 7 day programmable timer
4) Ability to display fault code when problem occur and in which fan coil unit

However the disadvantages of Netware 2 ( as master display control panel ) are it is not able to set different
parameters for each fan coil unit and is limited to display fault code only. This is where the Smart Manager has
its advantage over the Netware 2 ( Refer to Section 3 for details on the Smart Manager application )

Display Control Panel Netware 2

1.6 Netwar
Netwar
aree 2 and NIM Applications
pplications

Netwar
Netwar e 2 and NIM Applica
are tion In Sc
pplication hools
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
Main Board / Display Control
Panel to NIM Wiring

Communication cables
Slave Unit
NIM

Slave Unit
NIM

Slave Unit

NIM

Slave Unit

NIM

Slave Unit

NIM

1-8
Netwar
Netwar e 2 and NIM Applica
are tion In Of
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 Four Zone Three

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 Slave Unit
O
Slave Unit
N
E NIM

Slave Unit
NIM

Netware 2

Z
O Master Unit
N NIM
E
SLM

Slave Unit
NIM
Main Board / Display Control Communication cables
Panel to NIM Wiring

1 - 10
1.7 NIM W iring

CN3 For
Communication
Cables
Connection

CN2 For Display CN1 For Main Control

Control Panel Wire Board Wire Connection
Connection

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

1 - 11
1.8 G-Way and Building Mana
G-Wa Managgement System ( BMS )

G-Way has almost the same outlook as NIM but it has a different function compared to NIM. It is designed to
link FCU to BMS. When FCU is used with G-Way and BMS it can be remotely ON/OFF and monitored for alarm
and operation status ( ON/OFF ).

To be
connected
to Display CN3
Control
Panel CN2

Use 5-Way Link to BMS

Wire to CN4
connect to CN1
FCU Main
Control CN5
Board

Dip Switch

G-Way has a Dip Switch ( DSW2 ) to enable user to set the type of operation they prefer.

DSW2 Setting Type of Operation

0000 Control and Monitoring ( External Switch Closes to
ON FCU , Opens To OFF FCU )
0010 Control and Monitoring ( External Switch Opens to
ON FCU , Closes To OFF FCU )
0001 For Monitoring Only. No ON/OFF via BMS

The ON on top of the dip switches represents "1". This means that when we turn the dip switch to the top the
setting changes to 1 and if the dip switch is at the bottom the setting is 0.

When DSW2 is set to 0000 or 0010, FCU can only be ON/OFF via BMS. No display control panel/handset will
be able to ON/OFF the FCU. However when FCU is ON, FCU parameters are set-able using display control
panel/handset.

When DSW2 is set to 0001, FCU can be ON/OFF using display control panel/handset and BMS cannot ON/
OFF the unit. However all three settings allow for monitoring of the alarm or operation status of the FCU (ON/
OFF)

1 - 12
 CN3

ON/OFF Dry Contact Input

FCU ON/OFF Indicator

CN4 240VAC/24VDC

Dry Contact Output 1

Alarm Indicator

CN5 240VAC/24VDC

Dry Contact Output 2

G-Way BMS

Refer to Appendix 1 for recommended cables length.

G-Way is suitable for use in office building, supermarkets and hotels where FCU can be turn ON/OFF and
alarm can be easily monitored via BMS.

However each G-Way module can only be linked to one fan coil unit. This module is not designed for networking
purpose and it cannot be linked to the Smart Manager.

1 - 13
Section 2
Chiller Control Panel
2.1 About Chiller Contr ol P
Control anel
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 Smart Manager 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 Smart Manager front cover displays the name "Smart Manager" while Chiller Control Panel does
not have this display. Besides this, Smart Manager 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
 For field wiring, connect
communication cables
here

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 Installation
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
2.3 Master and Slave Mini Chiller
Slav

Master Unit is a mini chiller unit with a unique address "0" assigned to it. Slave Unit is a mini chiller unit within
the same network group as the Master Unit with any address from 1 to 50 assigned to it. Master Unit is used to
control and monitor all the Slave Units which are assigned to the same network group with it. Master Unit is
linked to Master Chiller Control Panel for this purpose.

The Chiller Control Panel has a Panel ID which is set-able. The default Panel ID from factory is "0". With the "0"
Panel ID the Chiller Control Panel acts as a Master Panel. It can be used to view and set parameters of the
Master mini chiller unit with which it is attached to as well as to view and set parameters of other mini chillers
within the same network group.

Ensure that all mini chillers' addresses in the network system is assigned correctly. Each mini chiller must be
given a unique address and no two or more mini chiller can share the same address. If a sharing occur the
Master Chiller Control Panel will not be able to identify that particular address which is shared.

For details on networking and address assignment refer to Mini Chiller Technical Manual

Mini Chiller
Main Control
Board

Typical Bus Structure for Mini Chiller Network

2.4 Chiller Contr ol P

Control anel Applica
Panel tions
pplications

The advantages of the Chiller Control Panel are

1) Remote monitoring via a centralised control room
2) Alarm alert ( with buzzer ) and display of specific mini chiller fault help to ease troubleshooting.
3) 7day programmable timer ( 2 timer each day ) to ON/OFF each mini chiller
4) Economical and low operating cost.
5) No complicated wiring helps in easing installation
6) Specific temperature setting for each mini chiller
7) One Chiller Control Panel acting as a Master Panel can support up to 50 units of mini chiller

This type of Master and Slave System is suitable for use in multiple mini chillers system such as factory process
cooling, lecture theatres, hotels and office buildings.

2-5
Chiller Contr
Controlol Panel Applica
Panel tion In Pr
pplication ocess Cooling
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.

An example of this application is in Factory XYZ.

Ten units of mini chiller are installed in this factory for process cooling. Each mini chiller has a Chiller Control
Panel. The mini chiller operating parameters are set during commisioning. All Chiller Control Panel are linked
for networking purpose.

One of the Chiller Control Panel acts as a Master Chiller Control Panel. This Master Panel is rewired to be
located in the process control room.

The Master Panel is used to ON/OFF all mini chillers used in the plant. This is done by pre-setting the
programmable timer for each mini chiller.

Two set-
able Timer
Timer 1 Timer 2
ON OFF ON OFF

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100
Tue 0800 1800 1900 2100
Wed 0800 1800 1900 2100

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] Default chiller
The fault for Alarm 1 is Chiller 1
Chiller 1 is
Compressor 1 Comp 1 overload
Overload

17/09/04 4:00am
Date and time
alarm occur

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 Slave Unit

Communication cable Water piping

2-7
Chiller Contr ol P
Control anel Applica
Panel tion ffor
pplication or Multiple Mini Chiller
Chillerss Used in Of
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.

Master Chiller Control Panel

placed in the HVAC centralised
control room

Communication cable

2-8
Ad
Advvance Par
Par ameter
arameter
ameterss

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 Auxilliary
Terminal Heater
Terminal

Auxilliary Heater
Relay

Mini Chiller Main Control Board

N N

Mini Chiller Terminal Block

Field Wiring for boiler ( for Cooling & Heatpump )

Field Wiring for auxilliary heater ( for Heatpump model only )

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
All Advance
3. Regulator
Parameter is found
4. Compressor here
5. Defrost
6. Antifreeze
7. Alarm and Contact

Screen 4 Model is set

G1 Model : Chiller according to users
requirement
G2 No. Comp : 1 Comp
G3 On/Off In : Disable
G4 Co/Heat In : Disable
G5 Ext Alarm In : Disable
G6 Water Sys : Isolated
G7 Unit No. :0

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

When the water entering temperature reaches 35C, ( A-B ) the boiler will operate. When the water entering
temperature reaches 40C, ( A-C ) , the boiler will stop operation.

When mini chiller switches to boiler mode the water entering temperature is 30C. The boiler will operate. The
boiler stops operation when water entering temperature reaches 40C.

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 Mode

Cooling Heating Boiling
Chiller o x x
Heatpump o o x
Chiller / Boiler o x o
Heatpump / Boiler o o o
Chiller + Boiler o x Auto
Heatpump + Boiler 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
Piping System Configuration

The piping system can be 2 pipe system or 4 pipe system. 2 pipe system is more economical compared to 4
pipe system. In 2 pipe system chilled water and hot water are mixed together. In 4 pipe system chilled water
and hot water are in different pipe lines.

However when use two pipe system, one design consideration is to ensure that that temperature of water
entering the mini chiller does not exceed 15C when mini chiller is running cooling mode or 50C when mini
chiller is running heating mode. This could cause compressor high pressure.

Expansion
tank

Boiler

FCU
Mini Chiller

Water Storage
Tank

An example of 2 pipe system

This type of 2 pipe system is suitable for use when boiler is not running during cooling mode and temperature
of water entering mini chiller does not exceed the limit as above. This is done by setting the cooling set-point
and heating set-point below these limit. ( Refer to Regulator Parameter in this section ). For this type of 2 pipe
system the recommended model selection would be Chiller/Boiler, Heatpump and Heatpump/Boiler ( For wiring
examples refer to Wiring for boiler and auxilliary heater in this section ).

Expansion
tank

FCU
Mini Chiller Boiler

Water Storage
Tank

An example of 4 pipe system

This type of piping system is suitable for use for all types of model. The FCU consists of one cooling coil and
one heating coil. Ensure temperature of water entering mini chiller does not exceed the above limit.

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

Cooling set-point + differential Comp on

Cooling set-point
Comp off

Two compressor system

Temperature

Cooling set-point + differential 2 Comp on

Cooling set-point + 1/2 differential 1 Comp on

1 Comp off

Cooling set-point
2 Comp off

When the cooling set-point is set to 12C and the cooling differential is set to 3C, one compressor cuts off at (
12.0 + 1.5 =13.5C ) while the second compressor cuts off at 12.0C. When the water entering sensor senses
the water temperature at 13.5C, one compressor will cut in. The other compressor will cut in at 15C

Heating Set Point

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

Heating differential

When the heating differential is set to say 1.5C, the compressor that has cut off at 40C as mentioned above
will cut in at ( 40-1.5 = 38.5C ). This is for the one compressor system.

2 - 14
 One compressor system

Temperature

Heating set-point Comp off

Heating set-point - differential

Comp on

Two compressor system

Temperature

Heating set-point 2 Comp off

Heating set-point - 1/2 differential 1 comp off

Comp on

Heating set-point - differential

2 comp on

When the heating set-point is set to 40C and the heating differential is set to 3C, one compressor cuts off at
( 40.0 - 1.5 =38.5C ) while the second compressor cuts off at 40.0C. When the water entering sensor senses
the water temperature at 38.5C, one compressor will cut in. The other compressor will cut in at 37.0C

Compressor Parameter

Compressor minimum run time

The compressor must run for a minimum of this set time after it has start to run. This applies to compressor
cycle on when water temperature is met.

Compressor minimum stop time

The compressor must stop for a minimum of this set time after it has stop. This applies to compressor cycle off
when water temperature is met.

Time interval between two starts

The compressor ON-OFF cycle must at a minimum equal this set time. In other word if the compressor ON-
OFF cycle exceeds this time interval another compressor ON-OFF cycle can begin.

Refer to the following examples.

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 6m 1.5 6m
m m

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
Wiring for boiler and auxiliary heater

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.

R S T N

Boiler
Contactor
Boiler Auxilliary
Terminal Heater
Terminal

Power supply
to boiler

Mini Chiller Main Control Board 3 Way Valve

N N
Mini Chiller Terminal Block
Auxilliary Heater 220-240VAC
C1
Relay C1

Auxilliary Heater

2 - 18
2.5 W iring ffor
or Chiller Networ
Networ king
orking

Master Chiller Control Panel Mini Chiller Main Board

Panel ID 0 Unit ID 0

4 pole terminal block for networking cable

Slave Chiller Control Panel Mini Chiller Main Board

Panel ID 1 Unit ID 1

Slave Chiller Control Panel Mini Chiller Main Board

Panel ID 2 Unit ID 2

Factory Installed Cable Networking cable

2 - 19
Section 3
Smart Manager
3.1 About Smar
Smartt Mana
Managger

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

Smart Manager has many user friendly features. Among the Smart Manager 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 Smart Manager 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

Smart Manager

3-1
The Smart Manager menu consists of Fan Coil Unit, Chiller or Settings.

Fan Coil Unit

Chiller
Settings

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

Settings

Priority : None
Cool threshold : 50%
Heat threshold : 50%

This is set-able under Priority as follows:

Priority Setting System Configuration

None ON/OFF of FCU and mini chiller is independent
FCU FCU controls mini chiller ON/OFF
Chiller 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
Smart Manager 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 Smart Manager and select the
desired group address or unit address.

Unit Selection:

Select All
Select Group
Select One

Selection for FCU

Smart Manager can control and monitor individually or collectively all the mini chillers in the network system. To
choose either one of this option, go to Unit Selection screen on the Smart Manager and select the desired unit
address.

Unit Selection:

Select All
Mini Chiller Unit
Address is
Select One : 0 selected here

Selection for Mini Chiller

Example

In Hotel X ,rooms are grouped according to floors. The hotel has ten floors and each floor has ten rooms. Smart
Manager is used to control all the FCU ( 100 units ) and mini chillers ( 10 units ) used as HVAC equipment in the
hotel.

The hotel manager uses the Smart Manager to ON / OFF the FCU as well as to set FCU parameters such as
room temperatures and fan speed.

He wishes to ON all the FCU ( 100 units ) and set all the FCU to operate at 25C and run the fan at high speed.
He can easily do this within a short time via the Smart Manager.

3-4
 Screen 1
Unit Selection:

Select All Select all FCU

Select Group
Select One

Selection for FCU

Screen 2
OPERATION MENU

Status : ON
Mode : Cool Set parameters
Set Temp : 25C in the Operation
Fan : High Menu

Screen 3 20/09/2004 11.20am

Status : ON
Mode : Cool Parameters
Set Temp : 25C setting as shown
Fan : High on display
Room Temp :-- screen
Unit : All

Smart Manager 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.

FCU Timer Schedule

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 Select Timer
Holiday Schedules

Screen 2
SCHEDULE SETTINGS

Schedule 1 Select Schedule

Schedule 2
Schedule 3
Schedule 4
Schedule 5

Screen 3 Timer 1 Timer 2

ON OFF ON OFF

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100 Set Timer
Tue 0800 1800 1900 2100
Wed 0800 1800 1900 2100

Screen 4
OPERATION MENU

Swing : No
Sleep : No
Schedule : 1 Select Schedule
Timer : Enable to run the FCU

Enable Timer

3-6
Mini Chiller Timer Schedule
Schedule

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

Screen 1
TIMER MENU

Set Time
Set Date
Set Schedule Select to set
Timer : Disable schedule

Screen 2 Timer 1 Timer 2

ON OFF ON OFF

Sun 0800 1800 1900 2100

Mon 0800 1800 1900 2100 Set Timer
Tue 0800 1800 1900 2100
Wed 0800 1800 1900 2100

Screen 3
TIMER MENU

Set Time
Set Date
Set Schedule
Timer : Enable

Enable Timer

3-7
Holida
Holidayy Schedule
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 Select schedule

Holiday 2
Holiday 3
Holiday 4
Holiday 5

Set Holiday 1

Month :1
Day : 20 Set schedule
Duration : Enable

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 Smart Manager 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.

Smart Manager
HydroIntel BMS SYSTEM
BMS ALARM SWITCH
GND

+12VDC
ALARM INPUT
ONOFF INPUT BMS ON/OFF SWITCH
GND
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

Smart Manager with Building Management System

3-9
Input Contact (Connect to BMS)

Alarm
+12VDC

On/Off
+12VDC

When BMS is set to Enable:

If On/Off input contact is closed. (+12VDC is supplied to the dry contact)
All FCU is not able to be turned On.
All the FCU will be turned Off if the FCU is currently In running status.
On/Off output contact will be opened

If On/Off input contact is opened (No +12VDC is supplied)

All FCUs remain current state (FCU can be turned On or Off individually)
If Global On is set Enable, all the FCU will be turned On automatically
On/Off output contact will be closed

If Alarm input contact is closed. (+12VDC is supplied to the dry contact)

All the FCU will be turned Off
Alarm output contact will be closed

If Alarm input contact is opened. (No +12VDC is supplied)

All the FCU remain as the current state.
Alarm output contact will be opened.

Note 1: The +12 VDC is from other peripheral device as long as the +12VDC and GND
must come from the same source.

Note 2: Global On.

With BMS is set to Enable
(a) Global ON is set Disable
When On/Off input contact is opened, all the FCU can be turned On individually.

(b) Global ON is set Enable

When On/Off input contact is opened, all the FCU will be turned On automatically.

3 - 10
Output contact (Connect to BMS)

Indicator Indicator

On/Off
Alarm

Heating/ Indicator
Cooling

The output contact is controlled by relay with the load rating of 30VDC,1A or 125VAC,0.5A

1)On/Off contact
(a) On/Off contact will be opened
when On/Off Input contact is closed.
when All the FCUs are Off.

(b) On/Off contact will be closed.

when On/Off Input contact is opened.
when at least one FCU is On.

2) Heating / Cooling Contact

(a) H/C contact will be opened
when FCU running Cooling

(b) H/C contact will be closed

when FCU running Heating

Basically, the contact Open or Close depend on the heat and cool threshold Triggering

3) Alarm Output Contact

(a) Alarm Contact will be opened
when Alarm input contact is opened.

(b) Alarm Contact will be closed

when Alarm input contact is closed.

All the output contacts are usually linked to indicators like LED, light bulb etc.
Refer to Appendix 1 for maximum allowable cable length.

3 - 11
Example

To other FCU
Building
Management
System

Communication Cable
Punch Boards Smart Manager
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 Smar
Smartt Mana
Managger Chilled Water System Application
pplication

When Smart Manager is used together with NIM, Netware 2, FCU, Chiller Control Panel and mini chiller they
form an intelligent networking system known as Smart Manager Chilled Water System.

The advantages of Smart Manager Chilled Water System are as follow:

1) Centralised control of all FCU and mini chillers via the Smart Manager.
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

Smart Manager Chilled Water System gives the flexibilty to user to control and monitor the HVAC system and
Applied system together.One example is a single Smart Manager 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.
Smart Manager 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.

Smart Manager Chilled Water 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.

Smart Manager Chilled Water System also provide the flexibility to colleges which require cooling and heating
simultaneously in various parts of the college.

3 - 13
 Smart Manager Chilled Water System Application
In Factory for HVAC and Process Cooling

NIM Bus Chiller Bus

Smart Manager
HydroIntel

NIM

Netware 2
Mini Chiller for HVAC

Ducted FCU to Office 1

Netware 2 Mini Chiller for HVAC

Communication Cables
Water Piping
Ducted FCU to Office 2

Machine Mini Chiller for Process Cooling

3 - 14
 Smart Manager Chilled Water System Application in College

Mini Chillers

FCU

FCU

FCU

FCU

Chiller Bus NIM Bus

Smart Manager
HydroIntel

The above diagram is an illustration of how Smart Manager Chilled Water 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
 Smart Manager Chilled Water System Application
for Cooling and Heating with 4 pipe system

Hot water
boiler
To other FCU
FCU for HVAC

FCU for machine cooling

Netware 2 NIM Netware 2 NIM

For cooling and heating

NIM Bus
For cooling purpose only

Smart Manager
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
 Smart Manager Chilled Water System Application
In Supermarket for Cooling and Heating purpose

Hot water boiler

FCU
for HVAC

Chiller for
HVAC

Netware 2
NIM NIM NIM NIM

NIM Bus

Smart Manager
HydroIntel

Chiller Bus

Communication cable
Water Piping

Chiller for low

temperature
application
Freezer Freezer Freezer

3 - 17
 Smart Manager Chilled Water System Application
In Hotels for Cooling & Heating

Heat
reclaim
piping
Hot Water Kitchen for dish
Storage washing,
Tank cleaning
Chiller
for Clean water supply
HVAC
Heat
reclaim
piping Hot Water Bathroom
Storage for
Tank shower

Chiller
for Clean water supply
HVAC
Chiller Bus NIM Bus

Smart Manager
HydroIntel

NIM
FCU for HVAC

NIM
FCU for HVAC

Netware 2

FCU for HVAC NIM

Communication cable Water piping

3 - 18
3.3 W iring ffor
or Smar
Smartt Mana
Managger Chilled Water System

Slave Chiller Control Panel Mini Chiller Main Board

Panel ID 1 Unit ID 1

4 pole terminal block for networking cable

Master Chiller Control Panel Mini Chiller Main Board

Panel ID 0 Unit ID 0

NIM

Smart Manager
HydroIntel

To FCU Main Board

To display control module

Factory Installed Cable Networking cable

3 - 19
Appendix

Table 1-1: Bus Cables Specifications

No Item
1 Type of cable
2 Cable diameter
3 Cable cross sectional
area
4 Cable material
5 Cable outer structure
6 Cable cores
7 Cable structure twist
8 Tensile strength
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

Table1-2: Recommended Communication Cable Length

Connection Maximum Length ( in meter )

NIM to Smart Manager 1000 (end to end)
Mini Chiller to Smart Manager 1000 (end to end)
Chiller Control Panel to Mini Chiller 1000 (end to end)
G-Way to BMS 1000 (end to end)
Smart Manager to BMS 500 (end to end)

Appendix 1
Wiring for Smart Manager Chilled Water System

Appendix 2
 Address Assigment for NIM

Group Settings Group Settings Group Settings Group Settings

Address 12345678 Address 12345678 Address 12345678 Address 12345678
0 00000000 64 00000010 128 00000001 192 00000011
1 10000000 65 10000010 129 10000001 193 10000011
2 01000000 66 01000010 130 01000001 194 01000011
3 11000000 67 11000010 131 11000001 195 11000011
4 00100000 68 00100010 132 00100001 196 00100011
5 10100000 69 10100010 133 10100001 197 10100011
6 01100000 70 01100010 134 01100001 198 01100011
7 11100000 71 11100010 135 11100001 199 11100011
8 00010000 72 00010010 136 00010001 200 00010011
9 10010000 73 10010010 137 10010001 201 10010011
10 01010000 74 01010010 138 01010001 202 01010011
11 11010000 75 11010010 139 11010001 203 11010011
12 00110000 76 00110010 140 00110001 204 00110011
13 10110000 77 10110010 141 10110001 205 10110011
14 01110000 78 01110010 142 01110001 206 01110011
15 11110000 79 11110010 143 11110001 207 11110011
16 00001000 80 00001010 144 00001001 208 00001011
17 10001000 81 10001010 145 10001001 209 10001011
18 01001000 82 01001010 146 01001001 210 01001011
19 11001000 83 11001010 147 11001001 211 11001011
20 00101000 84 00101010 148 00101001 212 00101011
21 10101000 85 10101010 149 10101001 213 10101011
22 01101000 86 01101010 150 01101001 214 01101011
23 11101000 87 11101010 151 11101001 215 11101011
24 00011000 88 00011010 152 00011001 216 00011011
25 10011000 89 10011010 153 10011001 217 10011011
26 01011000 90 01011010 154 01011001 218 01011011
27 11011000 91 11011010 155 11011001 219 11011011
28 00111000 92 00111010 156 00111001 220 00111011
29 10111000 93 10111010 157 10111001 221 10111011
30 01111000 94 01111010 158 01111001 222 01111011
31 11111000 95 11111010 159 11111001 223 11111011
32 00000100 96 00000110 160 00000101 224 00000111
33 10000100 97 10000110 161 10000101 225 10000111
34 01000100 98 01000110 162 01000101 226 01000111
35 11000100 99 11000110 163 11000101 227 11000111
36 00100100 100 00100110 164 00100101 228 00100111
37 10100100 101 10100110 165 10100101 229 10100111
38 01100100 102 01100110 166 01100101 230 01100111

Appendix 3
 Address Assigment for NIM

Group Settings Group Settings Group Settings Group Settings

Address 12345678 Address 12345678 Address 12345678 Address 12345678
39 11100100 103 11100110 167 11100101 231 11100111
40 00010100 104 00010110 168 00010101 232 00010111
41 10010100 105 10010110 169 10010101 233 10010111
42 01010100 106 01010110 170 01010101 234 01010111
43 11010100 107 11010110 171 11010101 235 11010111
44 00110100 108 00110110 172 00110101 236 00110111
45 10110100 109 10110110 173 10110101 237 10110111
46 01110100 110 01110110 174 01110101 238 01110111
47 11110100 111 11110110 175 11110101 239 11110111
48 00001100 112 00001110 176 00001101 240 00001111
49 10001100 113 10001110 177 10001101 241 10001111
50 01001100 114 01001110 178 01001101 242 01001111
51 11001100 115 11001110 179 11001101 243 11001111
52 00101100 116 00101110 180 00101101 244 00101111
53 10101100 117 10101110 181 10101101 245 10101111
54 01101100 118 01101110 182 01101101 246 01101111
55 11101100 119 11101110 183 11101101 247 11101111
56 00011100 120 00011110 184 00011101 248 00011111
57 10011100 121 10011110 185 10011101 249 10011111
58 01011100 122 01011110 186 01011101 250 01011111
59 11011100 123 11011110 187 11011101 251 11011111
60 00111100 124 00111110 188 00111101 252 00111111
61 10111100 125 10111110 189 10111101 253 10111111
62 01111100 126 01111110 190 01111101 254 01111111
63 11111100 127 11111110 191 11111101 255 RESERVED

Unit Settings Unit Settings

Address 1234 Address 1234
0 0000 8 1000
1 0001 9 1001
2 0010 10 1010
3 0011 11 1011
4 0100 12 1100
5 0101 13 1101
6 0110 14 1110
7 0111 15 1111

Appendix 4
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