APPLICATION MANUAL

CHILLED WATER
SYSTEM SOLUTION

ACSON Hy
dr
oT
ec
h
Hydr
droT
oTec
ech
Chilled Water System
Applica
tion Man
ual
pplication
Manual

Fir
st Edition
First
Jul
y 2005
uly

Intr
oduction
Introduction
Introduction ................................................................................................................ Introduction-1

Section 1: Netw
or
k Interf
ace Module (NIM) and Netw
ar
e2
Networ
ork
Interface
Netwar
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
anel
Control
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: Hy
dr
oIntel
Hydr
droIntel
3.1

About HydroIntel ...................................................................................................... 3-1

3.2

HydroTech System Applications .............................................................................. 3-13

3.3

Wiring for HydroTech System .................................................................................. 3-19

Appendix

Copyright c 2005 by ACSON International. All rights reserved. This publication is strictly confidential and is meant
for DISTRIBUTORS of ACSON 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 ACSON
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. ACSON International 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 HydroIntel. HydroIntel 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 HydroIntel, 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

HydroIntel
> 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

HydroIntel

Networking between HydroIntel and Mini Chiller

HydroIntel

Networking between HydroIntel 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 HydroIntel, Fan
Coil Unit (FCU) and display control panels.

Bottom Casing

Unit
Address
Dip
Sw itch

Group Address
Dip Sw itch

Top Casing
CN3
Connector

IC
CN2
Connector

CN1
Connector

Network Interface Module

This means that when FCU parameters are set using HydroIntel, 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 Installa
tion
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
ess Assignment
Addr
dress
The uniqueness of the HydroIntel 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 HydroIntel 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
Setting 00101000
Setting 00100110

represents Group Address 5

represents Group Address 20
represents Group Address 100

This Unit Address

is 0111 which
represents Unit 7

Dip switch on the

bottom represents "0"

Likewise,

Setting 0000
Setting 0101
Setting 1111

represents Unit Address 0

represents Unit Address 5
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 HydroIntel and the FCU parameter can be monitored
and set-able from the HydroIntel.
( Refer to HydroIntel Operating Manual for operation details )

13/09/2004
Status
Mode
Set Temp
Fan
Room Temp
Unit

11.00am
: ON
: Cool
: 24C
: High
: 27C
: G1U7

FCU Parameters are

easily monitored
FCU Address displayed
on the HydroIntel

HydroIntel displaying FCU parameters

MAIN MENU
Operation Menu
Settings Menu
Timer Menu
Alarm Menu

FCU Parameters are

easily set-able with the
HydroIntel

HydroIntel displaying FCU Menus

1-4

1.4 Master and Sla

ve 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
Board

Main
Board

NIM

Netware 2 Control
Panel

NIM

Netware 2 Control
Panel
Main
Board

NIM

Netware 2 Control
Panel

Main
Board

Main
Board

NIM

NIM

No IR Remote /
SLM3 / Netware 2

IR
IR Remote

Master

Slave 1

Slave 2

Master

Group 1

Slave 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 Netw

ar
e2
Netwar
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 HydroIntel has its
advantage over the Netware 2 ( Refer to Section 3 for details on the HydroIntel application )

Display Control Panel Netware 2

1.6 Netw
ar
e 2 and NIM Applica
tions
Netwar
are
pplications
Netw
ar
e 2 and NIM Applica
tion In Sc
hools
Netwar
are
pplication
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

Netw
ar
e 2 and NIM Applica
tion In Of
Netwar
are
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 Three

Zone Four

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
O
N
E

Slave Unit
Slave Unit

NIM

Slave Unit

NIM
Netware 2

Z
O
N
E

Master Unit

NIM
SLM

2
Slave Unit

NIM

Main Board / Display Control

Panel to NIM Wiring

Communication cables

1 - 10

1.7 NIM W iring

CN3 For
Communication
Cables
Connection

CN2 For Display

Control Panel Wire
Connection

CN1 For Main Control

Board Wire Connection

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

1 - 11

1.8 G-W
ay and Building Mana
gement System ( BMS )
G-Wa
Manag
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
Control
Panel
Use 5-Way
Wire to
connect to
FCU Main
Control
Board

CN3
CN2
Link to BMS
CN4
CN1
CN5

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 HydroIntel.

1 - 13

Section 2
Chiller Control Panel
2.1 About Chiller Contr
ol P
anel
Control
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 HydroIntel 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 HydroIntel front cover displays the name " HydroIntel" while Chiller Control Panel does not have
this display. Besides this, HydroIntel 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 Installa
tion
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 Sla

ve 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
anel Applica
tions
Control
Panel
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
ol P
anel Applica
tion In Pr
ocess Cooling
Control
Panel
pplication
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 setable Timer

Sun
Mon
Tue
Wed

Timer 1
ON
OFF

Timer 2
ON
OFF

0800
0800
0800
0800

1900
1900
1900
1900

1800
1800
1800
1800

2100
2100
2100
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]
The fault for
Chiller 1 is
Compressor 1
Overload

Alarm 1

Default chiller
is Chiller 1

Comp 1 overload

17/09/04

4:00am

2-6

Date and time

alarm occur

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

Communication cable

2-7

Slave Unit

Water piping

Chiller Contr
ol P
anel Applica
tion ffor
or Multiple Mini Chiller
s Used in Of
Control
Panel
pplication
Chillers
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
vance P
ar
ameter
s
Adv
Par
arameter
ameters
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
Terminal

Auxilliary
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
3. Regulator
4. Compressor
5. Defrost
6. Antifreeze
7. Alarm and Contact

Screen 4
G1 Model
G2 No. Comp
G3 On/Off In
G4 Co/Heat In
G5 Ext Alarm In
G6 Water Sys
G7 Unit No.

: Chiller
: 1 Comp
: Disable
: Disable
: Disable
: Isolated
:0

All Advance
Parameter is found
here

Model is set
according to users
requirement

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

auto

boiler

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
Chiller
Heatpump
Chiller / Boiler
Heatpump / Boiler
Chiller + Boiler
Heatpump + Boiler

Mode
Cooling Heating Boiling
o
x
x
o
o
x
o
x
o
o
o
o
o
x
Auto
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

Cooling set-point + 1/2 differential

2 Comp on

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 ONOFF 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
m

6m

1.5
m

6m

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.

Boiler
Contactor
Boiler
Terminal

Auxilliary
Heater
Terminal

Power supply
to boiler

Mini Chiller Main Control Board

3 Way Valve

N N

Mini Chiller Terminal Block

Auxilliary Heater
Relay C1

220-240VAC
C1
Auxilliary Heater

2 - 18

2.5 W iring ffor

or Chiller Netw
or
king
Networ
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
HydroIntel
3.1 About Hy
dr
oIntel
Hydr
droIntel
HydroIntel 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, HydroIntel acts as a centralized controller. It is wire-linked to all fan coil units and mini chillers.
HydroIntel has many user friendly features. Among the HydroIntel 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 HydroIntel 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

HydroIntel

3-1

The HydroIntel 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
Cool threshold
Heat threshold

: None
: 50%
: 50%

This is set-able under Priority as follows:

Priority Setting
None
FCU
Chiller

System Configuration
ON/OFF of FCU and mini chiller is independent
FCU controls mini chiller ON/OFF
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

HydroIntel 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 HydroIntel and select the desired
group address or unit address.

Unit Selection:
Select All
Select Group
Select One

Selection for FCU

HydroIntel 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 HydroIntel and select the desired unit
address.

Unit Selection:
Select All
Select One : 0

Mini Chiller Unit

Address is
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.
HydroIntel 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 HydroIntel 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 HydroIntel.

3-4

Screen 1
Unit Selection:

Select all FCU

Select All
Select Group
Select One

Selection for FCU

Screen 2
OPERATION MENU
Status
Mode
Set Temp
Fan

Screen 3

: ON
: Cool
: 25C
: High

20/09/2004
Status
Mode
Set Temp
Fan
Room Temp
Unit

Set parameters
in the Operation
Menu

11.20am
: ON
: Cool
: 25C
: High
:-: All

Parameters
setting as shown
on display
screen

HydroIntel 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.
hedule
FCU Timer Sc
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
Holiday

Select Timer
Schedules

Screen 2
SCHEDULE SETTINGS

Select Schedule

Schedule 1
Schedule 2
Schedule 3
Schedule 4
Schedule 5

Screen 3

Sun
Mon
Tue
Wed

Timer 1
ON
OFF

Timer 2
ON
OFF

0800
0800
0800
0800

1900
1900
1900
1900

1800
1800
1800
1800

2100
2100
2100
2100

Set Timer

Screen 4
OPERATION MENU
Swing

: No

Sleep
: No
Schedule : 1
Timer

: Enable

Select Schedule
to run the FCU

Enable Timer

3-6

Mini Chiller Timer Sc

hedule
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
Timer
: Disable

Screen 2

Sun
Mon
Tue
Wed

Select to set
schedule

Timer 1
ON
OFF

Timer 2
ON
OFF

0800
0800
0800
0800

1900
1900
1900
1900

1800
1800
1800
1800

2100
2100
2100
2100

Set Timer

Screen 3
TIMER MENU
Set Time
Set Date
Set Schedule
Timer
: Enable

Enable Timer

3-7

Holida
y Sc
hedule
Holiday
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
Holiday 2
Holiday 3
Holiday 4
Holiday 5

Select schedule

Set Holiday 1
Month
:1
Day
: 20
Duration : Enable

Set schedule

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 HydroIntel 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.

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

HydroIntel 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

Heating/
Cooling

Alarm

Indicator

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

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 Hy
dr
oT
ec
h System Applica
tion
Hydr
droT
oTec
ech
pplication
When HydroIntel is used together with NIM, Netware 2, FCU, Chiller Control Panel and mini chiller they form an
intelligent networking system known as HydroTech.
The advantages of HydroTech System are as follow:
1) Centralised control of all FCU and mini chillers via the HydroIntel.
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
HydroTech System gives the flexibilty to user to control and monitor the HVAC system and Applied system
together.One example is a single HydroIntel 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.
HydroTech 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.

HydroTech 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.

HydroTech System also provide the flexibility to colleges which require cooling and heating simultaneously in
various parts of the college.

3 - 13

HydroTech Application In Factory for HVAC and Process Cooling

NIM Bus

Chiller Bus

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

HydroTech Application in College

Mini Chillers

FCU

FCU
FCU

FCU

NIM Bus

Chiller Bus

HydroIntel

The above diagram is an illustration of how HydroTech 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

HydroTech 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

For cooling purpose only

NIM Bus

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

HydroTech 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

HydroIntel

Chiller Bus

Communication cable
Water Piping

Chiller for low

temperature
application
Freezer

Freezer

3 - 17

Freezer

HydroTech Application In Hotels for Cooling & Heating

Heat
reclaim
piping
Kitchen for dish
washing,
cleaning

Hot Water
Storage
Tank
Chiller
for
HVAC

Clean water supply

Heat
reclaim
piping

Hot Water
Storage
Tank

Bathroom
for
shower

Chiller
for
HVAC

Clean water supply

Chiller Bus

NIM Bus

HydroIntel

NIM
FCU for HVAC

NIM
FCU for HVAC
Netware 2

FCU for HVAC

Communication cable

NIM
Water piping

3 - 18

3.3 W iring ffor

or Hy
dr
oT
ec
h System
Hydr
droT
oTec
ech

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

HydroIntel
To FCU Main Board
To display control module
Factory Installed Cable

Networking cable

3 - 19

Appendix
Table 1-1: Bus Cables Specifications
No
1

Item
Type of cable

Cable diameter

3
4
5
6

Cable cross sectional

area
Cable material
Cable outer structure
Cable cores

7
8

Cable structure twist

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

Maximum Length ( in meter )
1000 (end to end)
1000 (end to end)
1000 (end to end)
1000 (end to end)
500 (end to end)

Connection
NIM to HydroIntel
Mini Chiller to HydroIntel
Chiller Control Panel to Mini Chiller
G-Way to BMS
HydroIntel to BMS

Appendix 1

Hy
dr
oIntel
Hydr
droIntel

Wiring for HydroTech System

Appendix 2

Address Assigment for NIM

Group
Address
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

Group
Settings
12345678 Address
00000000
64
10000000
65
01000000
66
11000000
67
00100000
68
10100000
69
01100000
70
11100000
71
00010000
72
10010000
73
01010000
74
11010000
75
00110000
76
10110000
77
01110000
78
11110000
79
00001000
80
10001000
81
01001000
82
11001000
83
00101000
84
10101000
85
01101000
86
11101000
87
00011000
88
10011000
89
01011000
90
11011000
91
00111000
92
10111000
93
01111000
94
11111000
95
00000100
96
10000100
97
01000100
98
11000100
99
00100100
100
10100100
101
01100100
102

Group
Settings
12345678 Address
00000010
128
10000010
129
01000010
130
11000010
131
00100010
132
10100010
133
01100010
134
11100010
135
00010010
136
10010010
137
01010010
138
11010010
139
00110010
140
10110010
141
01110010
142
11110010
143
00001010
144
10001010
145
01001010
146
11001010
147
00101010
148
10101010
149
01101010
150
11101010
151
00011010
152
10011010
153
01011010
154
11011010
155
00111010
156
10111010
157
01111010
158
11111010
159
00000110
160
10000110
161
01000110
162
11000110
163
00100110
164
10100110
165
01100110
166

Appendix 3

Group
Settings
12345678 Address
00000001
192
10000001
193
01000001
194
11000001
195
00100001
196
10100001
197
01100001
198
11100001
199
00010001
200
10010001
201
01010001
202
11010001
203
00110001
204
10110001
205
01110001
206
11110001
207
00001001
208
10001001
209
01001001
210
11001001
211
00101001
212
10101001
213
01101001
214
11101001
215
00011001
216
10011001
217
01011001
218
11011001
219
00111001
220
10111001
221
01111001
222
11111001
223
00000101
224
10000101
225
01000101
226
11000101
227
00100101
228
10100101
229
01100101
230

Settings
12345678
00000011
10000011
01000011
11000011
00100011
10100011
01100011
11100011
00010011
10010011
01010011
11010011
00110011
10110011
01110011
11110011
00001011
10001011
01001011
11001011
00101011
10101011
01101011
11101011
00011011
10011011
01011011
11011011
00111011
10111011
01111011
11111011
00000111
10000111
01000111
11000111
00100111
10100111
01100111

Address Assigment for NIM

Group
Address
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63

Settings
Group
12345678 Address
11100100
103
00010100
104
10010100
105
01010100
106
11010100
107
00110100
108
10110100
109
01110100
110
11110100
111
00001100
112
10001100
113
01001100
114
11001100
115
00101100
116
10101100
117
01101100
118
11101100
119
00011100
120
10011100
121
01011100
122
11011100
123
00111100
124
10111100
125
01111100
126
11111100
127

Unit
Address
0
1
2
3
4
5
6
7

Settings
1234
0000
0001
0010
0011
0100
0101
0110
0111

Settings
Group
12345678 Address
11100110
167
00010110
168
10010110
169
01010110
170
11010110
171
00110110
172
10110110
173
01110110
174
11110110
175
00001110
176
10001110
177
01001110
178
11001110
179
00101110
180
10101110
181
01101110
182
11101110
183
00011110
184
10011110
185
01011110
186
11011110
187
00111110
188
10111110
189
01111110
190
11111110
191

Unit
Address
8
9
10
11
12
13
14
15

Settings
1234
1000
1001
1010
1011
1100
1101
1110
1111

Appendix 4

Settings
Group
12345678 Address
11100101
231
00010101
232
10010101
233
01010101
234
11010101
235
00110101
236
10110101
237
01110101
238
11110101
239
00001101
240
10001101
241
01001101
242
11001101
243
00101101
244
10101101
245
01101101
246
11101101
247
00011101
248
10011101
249
01011101
250
11011101
251
00111101
252
10111101
253
01111101
254
11111101
255

Settings
12345678
11100111
00010111
10010111
01010111
11010111
00110111
10110111
01110111
11110111
00001111
10001111
01001111
11001111
00101111
10101111
01101111
11101111
00011111
10011111
01011111
11011111
00111111
10111111
01111111
RESERVED

2005 Acson International

+(603) 5510 6980

www.acson-international.com