Installation Manual IM 783-0 MicroTech II TM Remote I/O Panel Installation Manual Group: Controls Part Number: IM 783-0 Date: February 2004 Supersedes: New 2004 McQuay International
Page 2 IM-783
Table of Contents Figures...3 Tables...3 Notice...4 Reference Documents...4 Revision History...4 Introduction... 5 Panel Location and Mounting... 6 Unpack the Remote I/O Panel...6 Physical Installation...6 Tools Required...6 Before Installation...6 Mounting...6 Removing and Replacing the Cover...9 Removing the cover of a Remote I/O Panel...9 Replacing the cover of a Remote I/O Panel...9 Field Wiring... 10 Power Wiring...10 About the Transformer...10 Making the Power Connection to the Transformer...10 Remote I/O Modules... 13 Mounting of Remote I/O Modules...13 General Control Wiring of Remote I/O Modules...13 Designation of Remote I/O Modules...13 Maintenance... 14 Cleaning...14 Parts List...14 Warranty... 15 Warranty Return Material Procedure...15 Replacement Parts...15 Figures Figure 1. Remote I/O Panel Mounting Guide...7 Figure 2. Remote I/O Mounting Detail...8 Figure 3. Remote I/O Panel General Wiring Diagram...12 Tables Table 1. Remote I/O Panel part numbers...5 Table 2. 120 VAC models building power termination...11 Table 3. International Models - 240 VAC models building power termination...11 Table 4. Standard Replacement Parts...14 IM-781 Page 3
Notice McQuay International reserves the right to change any information contained herein without prior notice. The user is responsible for determining whether this product is appropriate for his or her application. The following are trademarks or registered trademarks of their respective companies. LONWORKS from Echelon Corporation; McQuay and MicroTech II from McQuay International. Reference Documents Company Number Title Available At: McQuay International OM 780 MicroTech II Chiller System Manager Operation Manual www.mcquay.com McQuay International IM 781 MicroTech II Chiller System Manager Installation Manual www.mcquay.com All McQuay documents are available at www.mcquay.com, go to Product Information > Controls > MicroTech II > Installation and Operation. Revision History IM 783-0 February 28, 2004 First release. Page 4 IM-783
Introduction The MicroTech II TM Remote I/O Panel consists of a sheet metal enclosure housing a transformer, and remote I/O modules. These modules provide additional input/output for use with a Chiller System Manager (CSM) or a Loop Water Manager (LWM) supervisory controller. These modules communicate with the supervisory controller via a two wire LONWORKS communications network. The panel can be mounted at strategic locations around the building, near the controlled devices to avoid long runs of control wires back to the supervisory controller. A CSM or LWM can control pumps, fans, valves, boilers, etc. The supervisory controllers use remote I/O modules as an expandable platform of inputs and outputs to control different size pump stations, cooling towers, etc. For example, a large chiller plant may have more secondary pumps to control than a smaller plant and fewer remote I/O modules are required to control the smaller plant. Remote I/O modules are not application specific. All the application software resides in the supervisory controller (CSM or LWM). This means that the same remote I/O modules are used on a CSM or a LWM. Remote I/O modules may be purchased separately (McQuay part number 112024401) and mounted in the field. They can also be purchase pre-mounted in a remote I/O panel ready for wall mounting. A remote I/O panel may have from one to four remote I/O modules. The number of modules per panel is determined by job requirements. See the installation manual of the supervisory controller to determine specific uses for the modules. Each module provides the following input/outputs; 4 Universal Inputs 4 Digital Inputs 4 Relay Outputs (normally-open contacts rated for 6 Amps @ 230 Volts) 2 Analog Outputs (0-10 Volts DC) Remote I/O panels come with either 120Volt or a 240 Volt power supplies. See the part number designation table below: Table 1. Remote I/O Panel part numbers Number of Modules per Panel 120 Volt 240 Volt 1 112028701 112029401 2 112029101 112029501 3 112029201 112029601 4 112029301 112029701! WARNING Electric shock hazard. Can cause personal injury or equipment damage. This equipment must be properly grounded to the MicroTech II control panel. Connections and service must be performed by trained personnel with experience with the equipment being controlled. Static sensitive components. Can cause equipment damage.! CAUTION 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. IM-783 Page 5
Panel Location and Mounting Unpack the Remote I/O Panel Unpack the remote I/O panel and inspect the contents of the package for damaged or missing components. If damaged, notify the appropriate carrier at once and contact your local McQuay representative for immediate repair or replacement. Physical Installation Tools Required The following tools and supplies may be required for installation: Small flat-blade screwdriver: used for terminal connections Phillips screwdriver: used to secure the door Before Installation To avoid the possibility of condensation resulting from shipping at low temperatures, keep the Remote I/O Panel at room temperature for at least 24 hours before applying power. Avoid mounting this panel in areas with high electromagnetic interference (EMI). Mounting Mount the Remote I/O Panel in a location that allows clearance for wiring, servicing, and module removal. For mounting details and drill hole locations, refer to the Mounting Guide and Mounting Details, Figure 1 and Figure 2. Mount the Remote I/O Panel within the maximum node-to-node distance to another node of your LONWORKS network. See IM 781 for detail on LONWORKS network wiring and maximum node-to-node distance charts. On a typical network this means the panel must be mounted within 820 ft (250 m) of the nearest LONWORKS device (other devices can be the CSM or LWM, a chiller, another remote I/O module, etc). This typical node-to-node distance can be increased to a maximum of 8855-ft (2700 m) by using thicker cable (up to 16 AWG) and doubly terminated networks. This product is intended for indoor use only. The unit should not be exposed to ambient conditions outside of the range of 0 to 50 C (32 to 122 F) and relative humidity outside the range 5% to 90%, non-condensing (pollution degree 1). If the controller is mounted inside an enclosure, that enclosure must be designed to keep the unit within its required operating range considering 40-watts heat dissipation. This is especially important if the panel is mounted inside an enclosure with other heat dissipating equipment. For proper mounting clearances see Figure 2. Minimum clearance from the wall on which the unit is mounted is 0.2 inches (provided by the dimpled mounting feet). Ensure that this space is not compromised and that airflow is not blocked behind the unit. DO NOT mount the unit: In an area where excessive moisture, corrosive fumes, or explosive vapors may be present. Where vibration or shock is likely to occur. In a location subject to electrical noise. This includes large electrical contactors, electrical machinery, variable frequency drives, welding equipment, spark igniters, and other equipment of this nature. The unit is designed to be wall mounted with the transformer situated towards the top of the unit. For proper airflow at temperature extremes, do not mount the unit oriented in any other way. Page 6 IM-783
Figure 1. Remote I/O Panel Mounting Guide Ø.218" (0.55cm).438" (1.11cm) Ø.406" (1.03cm) DETAIL KEYHOLE Upper Mounting Remote I/O Panel Mounting Guide 11.375" (28.89cm) Mount with this end up. Note: Drawing not to scale. Verify all measurements before drilling. Lower mounting holes are 0.221" (0.56cm) dia. Clearance for a #10 screw. 9.50" (24.13cm) IM-783 Page 7
Figure 2. Remote I/O Mounting Detail 8.63 (219) 1/2" CONDUIT KNOCKOUT FOR AC POWER ENTRY 3.5 (89) 1.25 (31.8) 1.030 (26) 1.130 (29) 4.00 (102) 0.218 (5.5) KEYHOLE DETAIL 1" CONDUIT KNOCKOUTS 0.438 (11) 15.5 (394) 9.50 (241) 3.00 (76) 0.406 (10.3) 3.05 (77) 3/4" CONDUIT KNOCKOUTS 20.8 (528) 16.846 (428) 11.375 (289) 3/4" CONDUIT KNOCKOUTS (5 TOTAL THIS SIDE) 3/4" CONDUIT KNOCKOUTS 0.218 (5.5) MINIMUM CLEARANCE AREA 1" CONDUIT KNOCKOUTS 2.00 (51) 1.00 (25.4) 17.5 (444) NOTES: 1. ALLOW MINIMUM OF 1 " CLEARANCE AROUND ALL SIDES OF UNIT FOR COOLING. 2. ALLOW MINIMUM OF 24" IN FRONT OF UNIT FOR DOOR OPENING. 3. MOUNT ONLY IN POSITION SHOWN (TRANSFORMER AT TOP). 4. DO NOT BLOCK AIR FLOW BEHIND UNIT. 5. DIMENSIONS ARE IN INCHES (MM). Page 8 IM-783
Removing and Replacing the Cover The remote I/O panel cover is removable and provides a security screw that secures the cover in place. Note: The security screw that ships with the remote I/O panel is a standard #10-32 machine screw, pan head, ½-inch Phillips. You can replace this screw with a tamper-proof screw to provide a more secure installation. In addition, you can secure the unit with a padlock through the security tab that protrudes through the cover. Removing the cover of a Remote I/O Panel Step 1. Loosen the security screw and open the cover. Step 2. On the inside of the door, loosen and remove the nut and locking washer that secures the green grounding strap to the cover. Step 3. Pull the grounding strap off the screw post. Step 4. Replace the locking washer, then the nut on the screw post, and tighten. Step 5. Close the door about half way. Step 6. Slide the cover toward the top of the unit until the tops of the hinge tabs on the cover hit the top of the hinge slots on the left wall of the metal enclosure. Step 7. Slide the hinge tabs out of the slots. Replacing the cover of a Remote I/O Panel Step 1. Align the hinge tabs on the cover with the hinge slots on the left wall of the metal casing. Step 2. Slide the hinge tabs into the slots and slide the door toward the bottom of the unit, until the bottom of the hinge tabs hit the bottom of the slots. Step 3. Loosen and remove the nut and locking washer on the grounding strap post on the door. Step 4. Slide the ground strap onto the screw post and replace the locking washer, then the nut, and tighten. Step 5. Close the door and tighten the security screw. IM-783 Page 9
Field Wiring Following are descriptions of the various field-wiring requirements. Wiring must comply with the National Electrical Code and all local codes and ordinances. Failures caused, or contributed to, by wiring not in accordance with these instructions will not be covered by warranty. Power Wiring Building power is wired to the transformer supplied with the remote I/O panel. Wire the transformer to an external switch or breaker, as there is no disconnect switch in the unit. Some local codes require the switch to be in sight of the unit. The switch must be capable of 120VAC or 240VAC service (depending on model) to switch the transformer primary. About the Transformer The Remote I/O Panel ships with a 120VAC or 208/240VAC (depending on model), 40 VA, 50/60 Hz transformer. The transformer provides 24-volt power to the remote I/O modules. The panel ships with from one to four remote I/O modules. Each module requires 10 VA of power. Do not power other devices from this transformer. The following things should be noted about the remote I/O panel transformer:! WARNING Improper wiring can cause severe personal injury or death. All connections must be made in accordance with national and local electrical codes. Use copper conductors only. The transformer must be dedicated to running the devices in the remote I/O panel. Do not power other devices from the transformer. Do not use any other power source or otherwise defeat the isolation provided by the integral transformer. A two-wire power source, including a 24V transformer, can cause permanent damage or greatly shorten the life of the unit.! CAUTION Verify that neither wire of the transformer's secondary winding is connected to earth ground or building neutral. Ground loops on the analog inputs and outputs could result and damage the modules or connected equipment. Making the Power Connection to the Transformer The following procedure is provided for supplying high voltage power to the remote I/O panel: 1. Remove the ½ knockout provided above the transformer. 2. Run the electrical supply wires through the knockout hole. 3. Using the provided two-position terminal block, connect high voltage power to the transformer primary lead wires. Page 10 IM-783
4. Connect a ground wire to the grounding lug provided.! CAUTION Do not bundle LONWORKS communication wiring with high-voltage supply or high-voltage control wiring. Communication problems over the LONWORKS network can occur. On 120 VAC models, connect 120 VAC, 50/60 Hz power to the two position terminal block provided using the information in Table 2. Table 2. 120 VAC models building power termination Building Power Source Termination point Type of Wire Typical Color of Wire Ungrounded Hot Black Either empty terminus of the terminal block Grounded Neutral White Other empty terminus of the terminal block Grounding Ground Green or bare copper Grounding stud On 240 VAC models, connect 208/240 VAC, 50/60 Hz power to the two-position terminal block provided using the information in Table 3. The transformer s primary wiring is factory wired to the terminal block for 240 VAC power. If your power supply is closer to 208 VAC, switch the primary wiring from 240 VAC to 208 VAC by replacing the orange wire in the terminal block with the red wire from the transformer. The remote I/O modules require 24 VAC ± 20%. Table 3. International Models - 240 VAC models building power termination Building Power Source Termination point Type of Wire Typical Color of Wire Ungrounded Hot Brown Either empty terminus of the terminal block Grounded Neutral Blue Other empty terminus of the terminal block Grounding Ground Green or bare copper Grounding stud When power is supplied to the Remote I/O Modules, a green LED located on the lower left hand side on the top of the module, comes on. IM-783 Page 11
Figure 3. Remote I/O Panel General Wiring Diagram Power Supply 120 VAC or 208/240 VAC (depending on model) If the module s relay outputs will be controlling high voltage (230 Volt maximum) devices, bring high voltage control wires to modules 3 and 4 through the top of the panel. Transformer Primary Ground 24 VAC High Voltage Terminals-Orange High Voltage Terminals-Orange 4 th Remote I/O Module 3 rd Remote I/O Module Low Voltage Terminals-Brown 1 2 23 22 Low Voltage Terminals-Brown 1 2 23 22 Blue Yellow Blue Yellow Bring low voltage control wires and LonWorks network cable in through the sides of the panel. Yellow Blue 22 23 2 1 Low Voltage Terminals-Brown Yellow Blue 22 23 2 1 Low Voltage Terminals-Brown Bring low voltage control wires and LonWorks network cable in through the sides of the panel. 2 nd Remote I/O Module 1 st Remote I/O Module High Voltage Terminals-Orange High Voltage Terminals-Orange Legend If the module s relay outputs will be controlling high voltage (230 Volt maximum) devices, bring high voltage control wires to modules 1 and 2 through the bottom of the panel. Notes Factory wiring Field wiring Field wiring terminal 1. Depending on the model ordered, the panel will contain from 1 to 4 modules. Additional modules may be purchased separately and added to a panel in the field. 2. See the supervisory controller installation manual (e.g. IM-781 for the Chiller System Manager) for wiring diagrams of the control wiring. Page 12 IM-783
Remote I/O Modules Mounting of Remote I/O Modules Each remote I/O module mounts on a DIN rail. The modules are snapped in place on the rail. To remove a module from a rail, slip a flat-head screwdriver into the stirrup located on the base of the module (center tab under the brown terminals). Gently pull the stirrup away from the housing while lifting up on the module. General Control Wiring of Remote I/O Modules The remote I/O panel comes with the 24 VAC power wires supplied from the transformer to the modules. All control wiring is field supplied in accordance with the supervisory controllers (CSM or LWM) Installation Manual with which the panel will be used. All wiring must comply with applicable electrical codes and ordinances. Note: Terminals on the remote I/O module accept wire from 20 AWG (0.5 mm 2 ) to 14 AWG (2.5 mm 2 ). Each remote I/O module is equipped with four 230 VAC, digital outputs (i.e. relays). Two are normally open (N.O.) and two are changeover (C.O.) relays. All four normally open contacts are rated for 6 amps continuous current while the normally closed contacts of the two C.O. relays are rated for 1 amp continuous current. These high-voltage relay terminals are the orange touchless terminals on the module (separated from the brown low-voltage terminals). The modules are mounted so that the orange high-voltage terminals are directed toward the top and bottom of the remote I/O panel to keep high-voltage wiring separated from low-voltage wiring (see Figure 3). If you are wiring to remote I/O modules mounted in the remote I/O panel and high-voltage devices are being switched, run the wiring from these devices into the top or bottom of the panel. Connect these wires directly into the touchless orange relay terminals on the high voltage side of the module. Wire the low-voltage and communication wiring into the sides of the panel and connect these wires directly into the brown terminals on the low-voltage side of the modules. If these relays are used for control of high-voltage devices, the wiring must be run separately from any low-voltage wiring. Do not mix relay control of high voltage and low voltage devices on the same module.! WARNING Electric shock hazard. Can cause personal injury or equipment damage. If the remote I/O module relay outputs will be switching high voltage devices, high voltage wiring must be run separately from low voltage wiring. Do not mix low-voltage and high-voltage wires on the relay side (orange terminals) of a remote I/O module. Note: Local wiring guidelines may take precedence over recommendations provided in these instructions. Designation of Remote I/O Modules When you receive remote I/O modules in a remote I/O panel, they are not yet assigned a designation (meaning it is not yet assigned to be Remote A, or Remote B, etc.). The module only becomes REMOTE I/O MODULE A (or B, or C, etc.) after it has been commissioned into the supervisory controllers LONWORKS communications network. This assignment is accomplished at the Device Addressing screen of the supervisory controllers user interface by selecting the SERVICE PIN field associated with a remote I/O device (e.g. REMOTE I/O A). While the service pin timer is counting down, press the Service Pin button on the module you want to designate as REMOTE I/O MODULE A. After you have assigned a module, it should be labeled REMOTE A for future reference. Labels are included with the Remote I/O Panel for this purpose. IM-783 Page 13
Maintenance This section provides information on the following topics: Cleaning Replacement Parts Cleaning If dust or metal filings are present inside the unit, clean with vacuum or compressed air. Otherwise, no cleaning inside the unit is required. Optionally, if the outside of the metal enclosure becomes dirty, you can wipe it with a damp cloth and mild detergent. Parts List Standard replacement parts are listed in Table 4 and can be ordered from stock without restriction. Standard replacement parts cannot be returned for credit and should be disposed of in an appropriate manner. Table 4. Standard Replacement Parts Part Number Description 063042601 Remote I/O Panel Transformer, 120V-40VA 063042401 Remote I/O Panel Transformer, 208/240V-40VA 112024401 Remote I/O Module Page 14 IM-783
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. Warranty Return Material Procedure Defective material may not be returned without permission of authorized factory service personnel of McQuay International in Minneapolis, Minnesota, phone number (763) 553-5330. A "Return Goods" tag must be included with the returned material. Enter the required information to expedite handling and prompt issuance of credits. All parts must be returned to the appropriate McQuay facility, designated on the "Return Goods" tag. Transportation charges must be prepaid. The return of the part does not constitute an order for replacement. Therefore, a purchase order must be entered through the nearest McQuay representative. The order should include part number, model number, and serial number of the unit involved. Credit will be issued on customer's purchase order following an inspection of the return part and upon determination that the failure is due to faulty material or workmanship during the warranty period. Replacement Parts When writing to McQuay for service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, along with an explanation of the malfunctions and a description of the replacement parts required. IM-783 Page 15
This document contains the most current product information as of this printing. For the most up to-date product information, please go to www.mcquay.com. www. mcquay.com (800) 432-1342