McQuay MicroTech III Installation and Maintenance Manual

Installation and Maintenance Manual

IM 969

Group: Controls

Part Number: IM 969

Date: October 2009

Supercedes: New

MicroTech

®

III

Chiller Unit Controller

Modbus

®

Communication Module

Pathfinder

™

Chiller, Model AWS

NOTICE

Use this manual to physically install the MicroTech III Communication Module into the chiller unit controller and connect the chiller unit controller to your network. Use the appropriate McQuay

Engineering Data (ED), known as the Protocol Information document, to integrate the unit into your network. The Protocol Information document contains addressing details, protocol information, and a list of the data points available to the network. See the Reference Documents section of this manual for details. MicroTech II control integration literature is available from your local McQuay International sales representative and www.mcquay.com

.

Figures

Table of Contents

Figures................................................................................................................................................... 2

Revision History.................................................................................................................................... 3

Reference Documents ........................................................................................................................... 3

Limited Warranty .................................................................................................................................. 3

General Information .............................................................................................................. 4

Description ............................................................................................................................ 5

Description............................................................................................................................................ 5

Application............................................................................................................................................ 5

Component Data.................................................................................................................................... 5

Light Emitting Diodes (LEDs) .......................................................................................................... 6

Modbus Network Connector ............................................................................................................. 7

Board-To-Board Connector .............................................................................................................. 7

Installation ............................................................................................................................. 9

Contents of the Modbus Communication Module Kit........................................................................... 9

Installing a new Modbus Communication Module................................................................................ 9

Replacing an Existing Modbus Communication Module .................................................................... 10

Integration............................................................................................................................ 11

Connecting to the Network.................................................................................................................. 11

Network Topology .......................................................................................................................... 11

Configuring the Modbus Communication Module.............................................................................. 11

Modbus Addressing ........................................................................................................................ 11

Configuring the Modbus Communication Module using the Keypad/Display................................ 11

Service Information............................................................................................................. 14

Test Procedures................................................................................................................................... 14

Parts List ............................................................................................................................................. 14

Installation Kit................................................................................................................................. 14

Figure 1. Modbus Communication Module Attached to MicroTech III Chiller Unit Controller .......... 5

Figure 2. Modbus Communication Module Major Components........................................................... 6

Figure 3. Modbus Communication Module and Knockout ................................................................... 7

Figure 4. Diagram of Board-to-Board Connector ................................................................................. 8

Figure 5. Modbus Communication Module with Board-to-Board Connector Inserted ......................... 8

Figure 6. MicroTech III Chiller Unit Controller Password Menu and Main Features ........................ 12

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Revision History

IM 969 October 2009 Initial release.

Reference Documents

Number

ED 15121

IM 1002 (50Hz )

IM 997 (60Hz)

OM 998

-

Company

McQuay International

McQuay International

McQuay International

Modbus

Title Source

Protocol Information for MicroTech III Chiller

Unit Controllers, Modbus Networks

Pathfinder

™

Air Cooled Chiller Installation

Manual www.mcquay.com www.mcquay.com

Pathfinder Air Cooled Chiller Operation Manual www.mcquay.com

Modbus over Serial Line Specification &

Implementation Guide v1.0 www.Modbus.org

Limited Warranty

Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your local McQuay Representative, go to www.mcquay.com

.

Notice

Copyright © 2009 McQuay International, Minneapolis MN. All rights reserved throughout the world.

McQuay International reserves the right to change any information contained herein without prior notice. The user is responsible for determining whether this software is appropriate for his or her application.

™ ® The following are trademarks or registered trademarks of their respective companies. Modbus is a registered trademark of Schneider Electric, Inc. Windows is a registered trademark of Microsoft

Corporation. MicroTech III is a registered trademark of McQuay International.

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General Information

This manual contains the information you need to install the Modbus

®

Communication Module on a

MicroTech III Chiller Unit Controller, incorporate it into the Modbus network, and maintain it.

!

DANGER

Dangers indicate a hazardous situation that will result in death or serious injury if not avoided.

!

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

!

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

!

WARNING

Electric shock hazard. Can cause personal injury or equipment damage.

This equipment must be properly grounded. Only personnel knowledgeable in the operation of the equipment being controlled must perform connections and service to the

MicroTech III Air Handling Unit Controller.

!

CAUTION

Static sensitive components. Can cause equipment damage.

Discharge any static electrical charge by touching the bare metal inside the control panel before performing any service work. Never unplug cables, circuit board terminal blocks, or power plugs while power is applied to the panel.

NOTICE

This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with this instruction manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class

A digital device, pursuant to EN55022. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his or her own expense. McQuay International disclaims any liability resulting from any

interference or for the correction thereof.

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Description

Description

The MicroTech III

®

Modbus Communication Module incorporates a MicroTech III Chiller Unit

Controller into a Modbus local area network (LAN).

The Modbus Communication Module is a printed circuit board with a plastic enclosure that connects to the left side of the McQuay D-Net™ Module as shown in Figure 1 or directly to the unit controller.

The Modbus Communication Module provides access to the unit controller variables and parameters via Modbus.

Note:

D-Net is an optional feature that provides remote monitoring and diagnostic capability for certain models of McQuay chillers. Please refer to supporting literature, available on www.mcquay.com

, for additional details about D-Net.

Application

The Modbus Communication Module connects the unit controller to a building automation system

(BAS) on a Modbus local area network. It is the interface for the exchange of Modbus objects between the network and the unit controller. Refer to the MicroTech III Chiller Unit Controller

Operation Manual for keypad details.

Component Data

Figure 1 shows the Modbus Communication Module, located on the far left-hand side of the image below. It is connected to the AWM, which is mounted directly to the unit controller. Figure 2 shows the important features of the Modbus Communication Module.

Figure 1. Modbus Communication Module Attached to MicroTech III Chiller Unit Controller

Modbus

Communication

Module

D-Net module attached to unit controller

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Figure 2 shows the location of the major components of the Modbus Communication Module.

Figure 2. Modbus Communication Module Major Components

Network Connector

Channel 0

Light Emitting Diodes (LEDs)

The Modbus Communication Module has a BSP LED and a BUS LED to indicate communication activity and status of the Modbus Communication Module. These indicators are visible when the communication module is connected to the MicroTech III Chiller Unit Controller and the unit is powered on (see Figure 2).

BSP LED

The BSP LED indicates the communication state between the Modbus Communication Module and the MicroTech III Chiller Unit Controller. The table below describes the status of the BSP LED.

BSP LED Color Meaning

Flashing between Red & Green

Green

Board Support Package (BSP) upgrade in progress

Communication is established between the communication module and the unit controller.

Yellow The communication module is capable of communicating to the unit

Red flashing with 2Hz controller. However, communication is not established.

Red flashing with 2Hz = Software error.

1

Hardware error.

1

Red

1

In the event that this should occur, cycle power to the unit controller to attempt to clear the problem. Contact the McQuay

Controls Customer Support Group at 866-4MCQUAY (866-462-7829) for additional assistance if necessary.

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BUS LEDs

The BUS LED indicates the communication status between the Modbus Communication Module and the Modbus network. The table below describes the status of the BUS LED.

BUS LED Color

Green

Red

Orange / Yellow

Meaning

The unit controller is capable of communicating to the network.

The unit controller is not capable of communicating to the network.

Communication module is initializing.

Modbus Network Connector

An RS-485 connector connects the Modbus Communication Module to the Modbus Network and has three pins: + ,

-

, and Ref. The Modbus Communication Module has two RS-485 ports, but only the top connector (Channel 0) is used (see Figure 2).

Board-To-Board Connector

The board-to-board connector connects the MicroTech III Chiller Unit Controller to the Modbus

Communication Module (see Figures 3, 4, and 5).

Figure 3. Modbus Communication Module and Knockout

Knockout permanently removed

Board-to-board connector

Slot in module must line up with baffle in boardto-board connector

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Figure 4. Diagram of Board-to-Board Connector

Figure 5. Modbus Communication Module with Board-to-Board Connector Inserted

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Installation

The following section describes how to field install a new Modbus Communication Module or replace an existing Modbus Communication Module on the MicroTech III Chiller Unit Controller so that it can be incorporated into the Modbus network.

!

CAUTION

Electrostatic discharge hazard. Can cause equipment damage.

This equipment contains sensitive electronic components that may be damaged by electrostatic discharge from your hands. Before you handle a communications module, you need to touch a grounded object, such as the metal enclosure, in order to discharge the electrostatic potential in your body.

Contents of the Modbus Communication Module Kit

The following is the list of items included in the field-installed kit:

•

The Modbus Communication Module

•

Board-to-board connector

•

Installation Manual (IM 969)

Installing a new Modbus Communication Module

Follow these steps to install a Modbus Communication Module on the unit controller. The Modbus

Communication Module can be connected directly to the unit controller itself or to an existing module, if one is attached.

!

WARNING

Electric shock hazard. Can cause personal injury or equipment damage.

This equipment must be properly grounded. Only personnel knowledgeable in the operation of the equipment being controlled must perform connections and service to the MicroTech III Chiller Unit

Controller.

1. Remove power from the unit controller.

2. Remove the knockout on the far left end of the unit controller itself (or additional module, if present). See Figure 3.

Note: To prevent damage to the unit controller, insert a small screwdriver or other tool to the tab on the bottom of the unit controller and pull the screwdriver away from the controller.

3. Remove the knockout on the right side of the Modbus Communication Module.

4. Insert the board-to-board connector into the Modbus Communication Module (see Figures 3 and

4). Note that it only fits one way and that the baffles must line up with corresponding slots in

Modbus Communication Module and the unit controller (see Figure 4).

5. Insert the other end of the board-to-board connector to the far-left side of the unit controller or other device (i.e. module), if attached (see Figure 1).

6. Insert the network cable connector into the Modbus Communication Module (see Figure 2 for location of network connection port).

7. Power up the unit controller.

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8. The unit controller automatically resets itself approximately 30 seconds after it is powered up.

This reset is necessary so that the Modbus Communication Module is synchronized with the unit controller.

Note:

There is a limit of three devices that can be attached to the left side of the unit controller.

Replacing an Existing Modbus Communication Module

Follow these steps to remove an existing Modbus Communication Module from the unit controller and replace it with a new Modbus Communication Module.

!

WARNING

Electric shock hazard. Can cause personal injury or equipment damage.

This equipment must be properly grounded. Only personnel knowledgeable in the operation of the equipment being controlled must perform connections and service to the MicroTech III Chiller Unit

Controller.

1. Remove power from the unit controller.

2. Locate the Modbus Communication Module to the left of unit controller (see Figure 1).

3. Pull the network cable connector from the Modbus Communication Module.

4. Grasp the Modbus Communication Module and carefully pull it from unit controller (or from an adjacent module, if it is attached to one.)

5. Install the new Modbus Communication Module (see steps 2-5 from previous section).

6. Insert the network cable connector into the Modbus Communication Module (see Figure 2 for location of network connection port).

7. Power up the unit controller.

9. The unit controller automatically resets itself approximately 30 seconds after it is powered up.

This reset is necessary so that the Modbus Communication Module is synchronized with the unit controller.

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Integration

Once the Modbus Communication Module has been properly installed on the unit controller, it is then possible to integrate the unit controller into a building automation system (BAS) via the Modbus network. The configuration process is described in the following section.

Connecting to the Network

Network Topology

Standard Modbus network rules apply. The network is a daisy-chain of unit controllers including all slaves and the master. The Modbus standard recommends that the network be terminated on each end with the characteristic impedance of the network (about 120 ohms). Follow the guidelines stated in the Modbus specifications (see Reference Documents section for details.)

Configuring the Modbus Communication Module

The Modbus Communication Module can be configured using the keypad/display on the MicroTech

III Chiller Unit Controller. The unit is ready to operate after you have verified and configured the default parameter values in the unit controller for your particular network. Refer to the appropriate

MicroTech III Chiller Unit Controller Operation Manual for default values and keypad operating instructions. Refer to McQuay Protocol Document ED 15121 for descriptions of the available

Modbus variables.

Modbus Addressing

The network address for a MicroTech II Chiller Unit Controller is set in the unit controller keypad display. The Modbus network address and data transmission rate (Baud Rate) is only available in the keypad/display when the Modbus Communication Module is correctly attached to the controller. You must set the network address (or ident number), within the valid range of 1-247 and also verify the baud rate before the unit controller can properly communicate on the Modbus network (see Table 1).

Note:

Refer to the appropriate MicroTech III Chiller Unit Controller Operation Manual for details regarding the MicroTech III Chiller Unit Controller keypad/display.

Configuring the Modbus Communication Module using the Keypad/Display

1. If you have not already entered a password, select Enter Password from the Main Menu screen

(i.e. turn the circular knob on the unit controller until the cursor is in the proper location) and press Enter (i.e. press down on the knob). See Figure 6. a. If you are not at the Main Menu and need to enter a password, press the Back button from any other menu screen until you reach the Main Menu and follow step 1. See Figure 6 for the location of the Back button. b. If you have already entered a password, skip to step 3. See Figure 6 if you are not certain whether or not a password has been entered.

2. Enter Password: 6363.

3. Scroll down to View/Set Unit (i.e. turn the knob clockwise) and press Enter.

5. Scroll down to Modbus Setup and press Enter.

Note:

The Modbus Setup menu only appears if a Modbus Communication Module installed correctly (see Installation section of this document for details.) If the Modbus

Communication Module is installed correctly and this menu still does not appear, cycle power to the unit controller and repeat the procedure above.

6. Modify the parameters as necessary (see Table 1 for a complete list.)

7. Change “Apply Changes” from No to Yes.

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8. Navigate back to the Modbus Setup menu, and verify the settings of all parameters. This procedure may take a minute while the Modbus Communication Module powers up.

Verifying the Modbus Data Transmission Rate

The options for baud rate (in bps) include: 9600, 19200, 38400, and 76800. The factory default baud rate is 38400 bps. Follow the steps below to change the baud rate for desired network speed.

1. If you have not already entered a password, select Enter Password from the Main Menu screen

(i.e. turn the circular knob on the unit controller until the cursor is in the proper location) and press Enter (i.e. press down on the knob). See Figure 6. a. If you are not at the Main Menu and need to enter a password, press the Back button from any other menu screen until you reach the Main Menu and follow step 1. See Figure 6 for the location of the Back button. b. If you have already entered a password, skip to step 3. See Figure 6 if you are not certain whether or not a password has been entered.

2. Enter Password: 6363.

3. Scroll down to View/Set Unit (i.e. turn the knob clockwise) and press Enter.

4. Scroll down to Modbus Setup and press Enter.

5. Verify the Baud Rate as required by the network and change if necessary.

6. Change “Apply Changes” from No to Yes.

Figure 6. MicroTech III Chiller Unit Controller Password Menu and Main Features

If a password has been entered, a numerical value appears (in this case, 2)

Back button

Circular knob (press down to Enter value)

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Configurable Parameters

Table 1 defines the network parameters of the Modbus Communication Module that are available via the unit controller keypad/display. At a minimum, you must set the network address (ident number), and verify the correct baud rate before establishing network communication between the unit controller and the BAS. Change remaining parameters as required for your network.

Note:

To save changes to these parameters, select “Apply Changes” under Modbus Setup. For additional information on using the keypad/display, refer to the appropriate MicroTech III

Chiller Unit Controller Operation Manual.

Table 1. Network Configuration Menu

Parameter

Apply Changes

Address

1

Baud Rate

1

Value (Range)/Definition

No-Yes/ Setting this to yes will cycle power to the controller to allow the network setup changes to take place.

1-247/The Modbus Address of the communication module

9600-19200-38400-76800/ Data transfer speed (bps).

Initial Value/Note

No

1/This must be unique throughout the entire

Modbus network.

38400

Parity

Two Stop Bits

Even(0), Odd(1), None(2)/ Defines the parity that is used on the bus.

No-Yes/ This defines the number of stop bits.

None/ This must also be identical for all nodes on the bus.

Yes/ If No is set, one stop bit is used, otherwise two are used.

This value must also be coordinated with the other bus nodes.

Load Resistor

Response Dly

No-Yes/ Switches on or off the

Termination Resistor.

0-30000ms/ Response Delay. When a request is received, the response is delayed by this many milliseconds to avoid over-run of the master.

No/Set this to Yes, if this unit is the first or last slave on the segment. If an external terminating resistor is used, set this parameter to No.

0 milliseconds/Normally it is not needed to change this delay. It is just used if the

Master is too slow.

Com LED Tmout

0-3600/If the master does not poll within this time, then the BUS LED will turn red.

3Sec/ If this is set to 0, the

BUS LED is always green and cannot be used to indicate communications to the master.

Modbus BSP Basic Support Package Version

1

Parameters that require configuration for proper network communication. x.xx

Note:

If unit controller application software requires uploading in the field, the network configuration parameters revert to their default values. Please contact the Technical

Response Center at 877-349-7782 for assistance with upgrading unit controller application software.

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Service Information

Test Procedures

If you can control the unit from its keypad, but you are not able to communicate with unit via the network, follows these steps:

• Check the network wiring

• Check the network parameters and verify that they are correct and that there are no duplicate devices on the network

• Check communications

If the Modbus Communication Module still does not respond, contact the McQuay Controls

Customer Support Group at 866-4MCQUAY (866-462-7829).

Parts List

Installation Kit

Description

MicroTech III Modbus Communication Module kit (kit includes communication module with attached network connectors, board-toboard connector, and Installation Manual)

Part Number

10000109547

This document contains the most current product information as of this printing. For the most current product information, please go to

www.mcquay.com

. All McQuay equipment is sold pursuant to McQuay’s Standard Terms and Conditions of Sale and Limited Product Warranty.

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