United CoolAir MARVEL MINI Installation, Operation And Maintenance Manual Download Page 6

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Installation, Operation and Maintenance Manual

Marvel Mini

Subject to change without notice.

120.9-IM (1218)

HARDWARE AND ARCHITECTURAL LAYOUT

FORM: MARPREM

3/28/17

ARDWARE AND

RCHITECTURAL

AYOUT

FIGURE 1 – HARDWARE / ARCHITECTURE LAYOUT

Building

Management

System

Terminal /

Wall Mount

Control

Networking Cable

RS485

Interface

RS485

Interface

Interface Wiring

Marvel Premium

Mini Main Board 1

BMS - Interface

Marvel Premium

Mini Main Board 2

FIGURE 1 – HARDWARE / ARCHITECTURE LAYOUT

Summary of Contents for MARVEL MINI

Page 1: ...MARVEL MINI HVAC MICROPROCESSOR CONTROLLER Installation Operation and Maintenance Manual Effective December 2018 Interactive PDF Building Management System ...

Page 2: ...ERMINATIONS 13 Static Pressure Transducer Duct Mount 13 MARVEL MULTIAPP CONTROLLER SEQUENCE OF OPERATION 21 STANDARD SYSTEM SAFETIES 29 OPTIONAL SYSTEM SAFETIES 31 Marvel Terminal Keypad and Display Operation 32 Controller Operation 32 Changing Set Points Parameters And Values 33 SYSTEM ENABLES 39 SET POINTS 40 ALARM SET POINTS 44 Run Hours 46 Clock Settings 47 Schedule 47 Set Back 49 CHANGE PASSW...

Page 3: ...tworking building management and supervisory system setups Customers have the option of either a built in or wall mount display and keypad or even both of these if desired The Marvel Mini system also contains common required standard sensors as well as optional sensors that must be field installed and wired to the factory provided field interface terminal blocks in the air handlers electrical cont...

Page 4: ...pressor 1 could be configured on any of the Digital Outputs NO1 through NO18 example of large controller maximum number of Digital Outputs These Universal Functions for each of the four I O Groups are ANALOG UNIVERSAL INPUTS Return Temperature Compressor 1 Liquid Temperature Compressor Liquid Pressure Space Temperature Compressor 1 Suction Temperature Space Humidity Outdoor Air Temperature Water T...

Page 5: ...ications via ECM motors Hot Gas Reheat either by Stage or Modulating Compressor safeties for high and low pressure are wired independently for true notification of which failure High or Low Pressure An Air Switch has been incorporated to turn off cooling heating dehumidification and humidification in the event of a loss of air flow due to a broken v belt or other means On a heater high limit failu...

Page 6: ...TECTURAL LAYOUT HARDWARE AND ARCHITECTURAL LAYOUT FIGURE 1 HARDWARE ARCHITECTURE LAYOUT Building Management System Terminal Wall Mount Control Networking Cable RS485 Interface RS485 Interface Interface Wiring Marvel Premium Mini Main Board 1 BMS Interface Marvel Premium Mini Main Board 2 FIGURE 1 HARDWARE ARCHITECTURE LAYOUT ...

Page 7: ...2 Universal Inputs used for sensor readings Each channel can handle any of the Analog Universal Input functions J3 Used for connecting the Remote Display Wall Terminal J4 Fieldbus Device Connections J6 BMS Interface RS 485 or Ethernet based on model ordered J7 No Function for the Marvel Mini controller J8 Digital Inputs used for safety and alarm devices and Analog Outputs used for optional modulat...

Page 8: ...d in the building s space that is being conditioned The Terminal can be mounted up to 1000 feet from the equipment See Figure 3 Terminal below for reference The Terminal is made up of the following components A External buttons Prg Esc and or adjustment buttons with integral LED indicators B Submenus include System ON OFF System Status System Enables Set Points Alarm Set Points Run Hours Day Min M...

Page 9: ...MS To reset the alarm simply press the button again to reset the alarm PROGRAM BUTTON The Prg button is used to enter into menus and sub menus On controllers with built in displays the is the program button ESCAPE BUTTON The Esc button is used to return to the main system status from a menu or sub menu or escape to the previous menu from a sub menu On controllers with built in displays the is the ...

Page 10: ... the Night Set Back Function is enabled the type of control Temp Humidity Setback is enabled and Set Points for Temperature and Humidity Setback Control shall appear as well as the day of the week to enable Night Set Back and time of day for occupied and unoccupied period 6 SYSTEM ENABLES menu This sub menu allows for re enabling of system functions System ON OFF Humidification Dehumidification Co...

Page 11: ...to Figure 6 Terminal Dimensions for dimensional data Dimensions shown are in inches FIGURE 6 TERMINAL DIMENSIONS Marvel Display Terminal Wall Mounting Refer to Figure 7 Wall Mounting for instructions to mount the Terminal to a wall FIGURE 7 WALL MOUNTING Components of the Wall Controller A Faceplate B Wall Controller C Mounting Plate ...

Page 12: ...lled on metal or wood studded framing Route the field provided connecting cable to the box 1 Remove the Faceplate A from the Wall Controller 2 Using a small straight screw driver remove the two screws which secure the Wall Controller B to the Mounting Plate C 3 Route the connector cable through the back of the Mounting Plate C then screw the mounting plate to the electrical box 4 Plug the field pr...

Page 13: ...nation point is located within the unit s electrical control panel All units must have a hard wired ground from a source Earth Ground IMPORTANT Metal Conduit is not an acceptable source of ground as there may be air gaps between connection points SENSOR FIELD MOUNTING WIRING All sensors and optional components that must be field installed and wired to the electrical control panel must be wired as ...

Page 14: ...arvel Controller s Technician s Menu Sensor Setup area for setting up the range of the sensor Duct Mount Supply Air Temperature Sensor The duct mount supply air temperature sensor s shown in Figure 9 Supply Air Sensor must be field installed in the supply air ducting The location of the sensor must be relatively close to the duct pressure transducer and must not impede with airflow to the inlet of...

Page 15: ...al Humidity The return air temperature sensor shown in Figure 11 Return Air Sensor must be field installed in the return air ducting close to the unit The return air sensor must be located relatively close to the Filter Rack of the unit IMPORTANT If the unit has optional humidity control please observe when making electrical connections Mounting 1 Cut out the mounting template provided with the se...

Page 16: ...her NTC terminal inside the temperature sensor to TB RATS NTC 4 Connect the drain wire to ground at the unit s electrical control panel end only c pCOmini Use the accessory cable P N S90CONN0S0 connected as shown in the figure The maximum distance allowed between controller and terminal is 10 m FIGURE 11 5 CONNECTING THE TERMINAL Optional Humidity Control If the sensor for Return Air has the optio...

Page 17: ...imately 3 8 to 1 2 in diameter for the cable as required 5 Place the cable through the back of the sensor 6 Using the screws provided screw the sensor to the wall Wiring Figure 13 Room Temperature Humidity Sensor Wiring shows the electrical connections for the sensor Using a minimum 18 20 AWG 300 volt rated two conductor shielded cable with drain wire make the following electrical connections NOTE...

Page 18: ... of outdoor air when occupied in this case the sensor could be located between the outdoor air louver and the unit IMPORTANT If the unit has humidity control for airside economizer polarity must be observed when making electrical connections 1 Cut out the mounting template provided with the sensor 2 Select the location to mount the sensor and drill a hole through the supply air duct at least in di...

Page 19: ...the outdoor temperature humidity sensor to TB OTHS NTC 3 Connect the other NTC terminal inside the outdoor temperature humidity sensor to TB OTHS NTC 4 Connect the drain wire to ground at the unit s electrical control panel end only 5 Connect from the terminal marked G inside the outdoor temperature humidity sensor to terminal TB OTHS G inside the unit s electrical box 6 Connect from the terminal ...

Page 20: ...Water Pump s Contactor Starter and wire nut or splice cap this wire with one of the two wires going to the Remote Water Pump interlock wiring 2 Connect the other wire of the Remote Water Pump interlock wiring to the location of the wire removed from the Contactor Starter Coil 3 At the unit connect one of the wires to TB WP 1 4 Connect the other wire to TB WP 2 Optional Airside Economizer Damper Co...

Page 21: ...ided to Terminals TB RMTO 1 and TB RMTO 2 This closure should be provided by a dry contact closure switch installed at a remote location Install two conductors minimum 18 AWG 300 volt rated from the Remote ON OFF Switch location to the unit s terminal blocks TB RMTO Connect the wires as follows Wiring 1 Connect one wire at the Remote ON OFF switch to one termination pole of the switch 2 Connect th...

Page 22: ...FD causing the blower to speed up or slow down If the Duct Pressure is within the Duct Pressure Dead Band Set Point range Duct Pressure Set Point and Duct Pressure Dead Band Set Point 0 15 iwc there is no output adjustment the VFD so the blower speed will remain constant On units with Electronically Commutated Blower Motors the output adjustment is the same only without the VFD interface since Ele...

Page 23: ...ter piping shall be piped internally so that mechanical cooling will be able to assist the waterside economizer operation The controller shall be enabled for the mechanical cooling assist option The Compressors will be staged when the Waterside Economizer Demand is equal to 100 for greater than the Economizer Assist field adjustable time delay The amount of compressors shall be limited based on th...

Page 24: ...mand rises above 66 3 and stops at 0 3 These Start and Hysteresis Set points are adjustable but it is not recommended unless consulting with United CoolAir s support team first Important Heating Start and End points also allow for a buffer around the Temperature Set Point to help prevent overshoot Heating Mode by Supply Air Temperature Heating by Supply Air Temperature is based on the Heating Dema...

Page 25: ... the Supplemental Heaters are Staged or Modulated to maintain the demand for Heating As the Temperature of the Outdoor Air or Water rises above the Low Temperature Lockout Set Point plus the Low Temperature Lockout Band Set Point the Supplemental Heaters are staged off or modulated down to allow the Heat Pump Mode to restart Defrost Cycle Heat Pump systems have a defrost cycle that performs defros...

Page 26: ...ation the heating demand will become 100 The compressor s will continue operating and reheat will stage on off or modulate to satisfy the optional reheat function The reheat type could be Hot Gas Reheat Electric Reheat or a Hot Water or Steam Coil Humidification option Each system with the Humidification option will have a Modulating Humidifier controlled through the controller via Modbus Communic...

Page 27: ...ate to provide cooling If Compressor 1 cannot meet the demand for cooling and the Cooling Demand remains equal to 100 for greater than 10 minutes Compressor 2 shall be cycled on to provide Cooling Assistance The Cooling Demand is calculated by the Space or Supply Temperature based on system setup for control method by supply or return temperature Space or Supply Temperature Set Point and Space or ...

Page 28: ...nts are adjusted through the Set Points menu Warm Up should be scheduled to operate during the Unoccupied Mode just before the start of the occupied day Morning Warm Up shall start the heating cycle and heat until either the Return Air Temperature rises above the Morning Warm Up Set point or the Morning Warm Up Time period expires Once this occurs the start of the occupied day becomes active Morni...

Page 29: ...han the Freeze Limit Set Point output to the control valve will be 100 demand so that flow will remain at 100 to prevent the system from freezing Remote Start Stop Remote Start Stop is a standard feature with all units The Remote Start Stop feature allows customers to tie in a field provided external Voltage Free Dry Contact Switch to Remotely Start and Stop the unit based on their own time of day...

Page 30: ...essor contactor and the other relay contact sends the alarm signal back to the controller to let the control know that Compressor 1 High Pressure switch tripped The high pressure switch will take the compressor offline as it is wired to the relay that controls the contactor for the compressor but it will also allow the relay to provide the alarm signal Once the High Pressure Trip occurs the compre...

Page 31: ... when the water level is too high in the unit s drain pan indicating that the condensate drain may be blocked If there is a blockage in the condensate line the rising water level in the condensate drain pan will open the drain pan switch creating an alarm at the controller The drain pan overflow switch shuts down cooling preventing the condensate from overflowing the drain pan The alarm will notif...

Page 32: ...arvel Terminal Keypad and Display Operation This section is provided as a guide to explain the functions of each of the display screens associated with the operation of the unit Upon application of power there will be two screens called splash screens identifying United CoolAir with a Logo not pictured then transferring it to the name of the controller being developed by United CoolAir Corporation...

Page 33: ...stored into memory If there are no alarm logs present the system will not enter the Alarm Logger Press the Esc button to return to the main status loop NO ALARMS Press ENTER to enter ALARM LOGS Alarm Logger Record 01 15 35 04 05 17 Comp 2 Low Pressure Changing Set Points Parameters And Values Set points Parameters and changeable values are known as Fields Press the enter button to move the cursor ...

Page 34: ...per delay take precedence so once the system is on the start delay must time out and then the damper output is energized Once the output for the damper is on for the length of the damper delay then the blower output is energized Once the blower is on for the length of the mode start delay then the mode of operation cooling heating humidification or dehumidification will start if required U01 Air E...

Page 35: ...before it can turn off Typically if something like this occurs where a compressor turns on and then immediately there is no longer a demand for that particular compressor to run it indicates that the Proportional Band of the Set Point should be adjusted to prevent short cycling of the compressor s Any alarms that occur within compressor circuits will bypass the minimum on time s for the particular...

Page 36: ...ng the override time until the Unoccupied Override Duration time has Elapsed So the Elapsed time is the amount of time that has passed with the unit operating in the Unoccupied Override period The Override On Off Reset is the setting is the enable point to start or stop the Override time Once the Override Duration has Elapsed the Override On returns to Off automatically Should the occupant s wish ...

Page 37: ...n Enter Selected Menu Esc to Previous The System Enables is used to Enable or Disable Compressors Heaters Humidification andDehumidification It is also used to re enable compressors after a Compressor Safety high pressure low pressure digital compressor module alarm has disabled a compressor Main Menu 04 Set Points Scroll Up Down Enter Selected Menu Esc to Previous The Set Points sub menu is used ...

Page 38: ...and highest and lowest humidity for Return Space Humidity if humidity sensor is installed over a 24 hour period Main Menu 08 Clock Settings Scroll Up Down Enter Selected Menu Esc to Previous The Clock Settings sub menu allows the customer to adjust time zone time of day day of the week and date Main Menu 09 Schedule Scroll Up Down Enter Selected Menu Esc to Previous The Schedule sub menus allows c...

Page 39: ...chnician Menu sub menu allows Technicians to access the following sub menus Fan Settings System Units Unit of Measure Network sets up network units Manual Control Sensor Setup Digital Inputs Economizer Blower VFDs Change Passwords and Information The Technician Menu password is 9995 Once the password is installed the sub menu will remain actively open until a button has not been pressed for five 5...

Page 40: ...at Set Point as well as if a humidity sensor is installed there will be a Dehumidify Set Point and a Humidify Set Point only if the Humidifier option is installed Explanation of Set Point Screens Set Point Set Point is the desired setting that the customer would like the unit function to maintain for specific comfort level Prop Band Prop Band is the proportional band setting that over the range of...

Page 41: ...d set point change Press the up or down buttons to change the present value of the set point to the newly desired set point Press the enter button to save the change into memory U01 Return Cooling Set Points Setpoint 73 0 F Prop Band 5 0 F Dead Band 1 0 F U01 Return Heating Set Points Setpoint 68 0 F Prop Band 2 0 F Dead Band 0 0 F U01 Return Dehumidify Set Points Setpoint 50 0 Prop Band 4 0 Dead ...

Page 42: ...ed on being above or below the Return Air Temperature Set Point The system then controlled the amount of stages for cooling or heating by the Supply Cooling and Heating Set Points This is no longer the case as now the system will work as follows Should the Heating Set Point remain less than the Cooling Set point Heating will heat the supply air temperature back to set point and allow the individua...

Page 43: ...ion See Airside Economizer sequence for full explanation of operation For Water Economizer the Water Temperature entering the unit must be less than the Return Air Temperature minus the Differential Set Point If the entering water temperature is greater than the Return Air Temperature minus the differential the system will only use the Mechanical Cooling Compressors to satisfy the cooling demand U...

Page 44: ...m Up Set Point is met The Morning Cool Down screen is the Set Point screen for the compressors to control to during Morning Cool Down Mode Morning Cool Down will terminate after the Cool Down duration has expired or the Cool Down Set Point is met The Prop Band setting for each is the same as others If the Return Temperature is less than the Warm Up Set Point minus the Prop Band the system will be ...

Page 45: ...tpoint 60 0 F Low Setpoint 20 0 F Enable High Yes Enable Low No Alarm Delay 060sec Depending on the setup Return Humidity or Space Humidity there are specific High and Low Alarm Set Points both having enable points for high and low alarm The Enable High and or Enable Low must be set to Yes in order to the High and or Low Alarm to trigger when the humidity rises above or falls below the Alarm Set P...

Page 46: ... above shows Total Run Hours for specific components installed The Run Hours section tracks total Life Hours of the unit Supply Blower total run hours and total run hours of compressors and heaters Should a component be replaced for example Compressor 2 was just replaced The total run hours for Compressor 2 is capable of being reset to 000000 hours To reset the Run Hours of a component press the e...

Page 47: ...o move the cursor to the time zone field Select the appropriate time zoned using the up or down button to change the value and then press the enter button move the cursor to the Update Timezone Selecting Yes and pressing the enter button again will save the change into memory Schedule U01 Schedule Enables Mon Yes Tue Yes Wed Yes Thu Yes Fri Yes Sat Yes Sun Yes In order to add an Occupancy Schedule...

Page 48: ... Setback OFF 20 00 The Set Back ON is the Start time for the unit to be in the Set Back Mode The Set Back OFF is the stop time for Set Back Mode The unit will either go back into Occupied Mode or into Unoccupied Mode depending on how the Schedule is set up The Set Back Set Points for Cooling Heating Humidification and Dehumidification all appear under the Set Back Menu Morning Warm Up U01 Warm Up ...

Page 49: ... appear to allow set up of the Set Back feature to allow each Mode of Operation to work in the Set Back Mode U01 Enable Set Back Control Cooling Yes Heating Yes Dehumidify Yes Humidify Yes Enable each of the Modes of Operation that should operate during the Set Back Mode The enable points and set points follow the same principle Cooling will automatically appear Heating will only appear if heaters...

Page 50: ... that should operate during the Unoccupied Control Mode The enable points and set points follow the same principle Cooling will automatically appear Heating will only appear if heaters are enabled within the Factory Menu Dehumidification will appear when either the Return Humidity or Space Humidity Sensor is enabled and Humidification will only appear when either the Return Humidity or Space Humid...

Page 51: ...he Main Menu that allows Technicians to access the system for minor adjustments of settings and parameters of the system and view functions of specific components to troubleshoot diagnose problems with components Technician Menu 01 Fan Settings Scroll Up Down Enter Selected Menu Esc to Previous The Fan Settings sub menu allows technicians to adjust Time Delays with Fans and Blowers as well as Damp...

Page 52: ...ased consult factory first sensor in the event that the customer has a failed sensor and a critical application that the unit needs to be running that same day and they cannot wait for a factory supplied original sensor It also allows adjustment of Minimum and Maximum output settings for the Modulating Analog Output devices connected to the controller Technician Menu 06 Digital Inputs Scroll Up Do...

Page 53: ...t 015sec Damper Delay 060sec U01 Blower Delays Blower Start 015sec Blower Min ON 030sec Blower Min OFF 030sec Airflow Check 060sec The Damper Delays and Blower Delays allow adjustment of system delays The Unit Start delay is the length of time between the Unit ON OFF switch and when the Damper starts The Damper Delay is the length of time that the damper output must be on before the Supply Air Blo...

Page 54: ... to make sure a unit that is presently operating goes into stand by mode and brings the next unit required out of stand by to the on position Shift Delay is the amount of time between the time a unit presently operating shuts down and goes into stand by mode and the start of the next unit from the stand by mode to the on position U01 Network Setup Continuous Units U01 Yes U05 No U02 Yes U06 No U03...

Page 55: ...r the unit with alarms to the standby mode and bring the next unit in line within the network out of stand by to the on position SENSOR SETUP U01 Return Temp Actual 073 00 F Offset 000 00 F Custom Yes Type 0 10vdc Minimum 050 00 F Maximum 150 00 F U01 Supply Temp Actual 073 00 F Offset 000 00 F Custom No The screens above are two variations of setups The Offset is that calibration adjustment for t...

Page 56: ... air volume duct pressure control The Minimum Output voltage to the Electronically Commutated Motor is 3 0 volts dc This means the blower will always be 30 of the maximum when the blower is on Airside Economizer is enabled on Analog Output 2 The minimum output is adjusted to 2 0 volts dc This is simply because the type of damper actuators installed is a 2 0 to 10 0 vdc type MANUAL CONTROL U01 Manu...

Page 57: ...member to set the Alarm back to the op position ECONOMIZER U01 Economizer Setup Type Air Mod Water Valve Assist Enable Damper Minimum 000 Damper Maximum 100 U01 Economizer Assist Delay 15min Start 100 End 50 Comps 3 Comps Total comps allowed to assist The above screens for Economizer Setup and Economizer Assist allow for setup of the Economizer package The parameter for Type of Economizer can be s...

Page 58: ...ANGE PASSWORDS The Enable Password screens allow for enabling of the Basic and or Technician Passwords The passwords can be a value between 0 and 9999 Please record the passwords if installed U01 Enable Passwords Basic User Disable Technician Enable U01 Enable Passwords Basic User 0000 Technician 9995 SYSTEM INFORMATION U01 Information United CoolAir Marvel Premium Controller Version 1 1 00 1 Op S...

Page 59: ...ital inputs with a dc voltage source a 24 V AC DC common must be wired to the actual digital input and must also be the same as the connection to the G0 terminal which is normally referenced to ground The 24 VDC would then be wired directly to the IDCx or common for the digital input Refer to Figure 16 Digital Input Termination References for further details FIGURE 16 DIGITAL INPUT TERMINATION REF...

Page 60: ...ts The Analog Outputs on a Marvel controller are capable of providing modulating output voltage of 0 10 VDC to control any of the following Analog Outputs listed on page 4 The analogs outputs must be powered externally using 24 VAC The neutral side of the 24 VAC power supply is connected to terminal VG0 The 24VAC hot side is connected to terminal VG1 Analog Output 1 through Analog Output 6 Y1 thro...

Page 61: ...nit 2 to Unit 3 iii Unit 3 to Unit 4 and so on b Network wiring must be 4 Conductor Minimum 20 AWG shielded cable FIGURE 20 SYSTEM NETWORKING 2 Should there be a need to re order the number of unit identification Figure 21 Adjusting pLAN Addresses below displays the location and momentary push button access for renumber the plan networking addresses a Simply insert a very small screw drive in thro...

Page 62: ...ion Press the enter button until the next screen appears and then once this screen appears press the enter button again till the Priv Shared Screen as shown appears Terminal config Press ENTER To Continue 6 Trm1 must be a value of 32 to match the value previously set If it is not a 32 use the up or down buttons to change the value to a 32 then press the enter button to save it into memory Next use...

Page 63: ...Installation Operation and Maintenance Manual Marvel Mini 63 Subject to change without notice 120 9 IM 1218 NOTES ...

Page 64: ... the compressor labor not included Maintenance items such as filters and belts are excluded under this limited warranty FACTORY TESTED All units are functionally run tested before shipment to ensure a trouble free start up and unit commissioning Industry proven components are used throughout to enhance system reliability and peace of mind VertiCool Classic Vertical 3 30 Ton VertiCool Aurora Vertic...

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