Marvair Product Bulletin - Airxcel | AC, Heating & Appliances · PDF file · 2017-09-266" CL-SDCARD-ATT Release 1.5 August 22, 2017 " Verify RBS Temp High...

1

CL-SDCARD-ATT Release 1.5 August 22, 2017

Marvair® Product Bulletin

Number Date

16-004 8/22/2017

TO AT&T Cellular Technicians & HVAC Field Service Providers

SUBJECT CoolLinks™ Thermal Management Program Update

This bulletin describes the process to re-configure the Marvair® ASDCA ComPac II HVAC units and to update the Marvair® CoolLinks™ controller software to support the AT&T CEMPO Thermal Management Program Updates. This program is intended to increase the overall energy efficiency of environmental system within shelters and to improve the cooling and humidity control with variable heat loads. Update Instructions:

Three specific actions are required to complete the AT&T CEMPO Thermal Management Program Update. Note that ALL three actions MUST be completed to fully realize the benefits of this program and that failure to apply any of these changes will significantly compromise the energy efficiency enhancements:

1. Adjust HVAC Unit Fan Purge Thumbwheel Switch 2. Verify RBS Temp High and RBS Temp Low Alarms

3. Download Marvair® CoolLinks™ Software Tools & Materials:

• 5/16” nut driver and 3/16” flathead tip screwdriver • Punch down tool • SD memory card CL AT&T SW 1.2.1.8* • SD memory card CL AT&T SW 2.1.0.3* • SD memory card CL AT&T SW 3.1.0.3* • SD memory card CL AT&T SW 1.2.1.8cb* • SD memory card CL AT&T SW 2.1.0.3cb* • SD memory card CL AT&T SW 3.1.0.3cb*

* See download section to update controller with the Software Update Tool rather than SD memory cards.

2


Pre-Requisites:

It is essential that the service technician have a working knowledge of shelter HVAC wall-mount units and, in particular, the Marvair ASDCA ComPac II units. In addition, the technician should be familiar with the operation of the Marvair CoolLinks controller in order adjust the cooling set point, identify HVAC alarms, and reset HVAC Lockout faults. No special tools are required other than typical hand tools identified above.

Important Safety Information Removal of the electrical box cover as indicated in this bulletin exposes the field technician to 240 VAC and 48 VDC power sources. Only qualified, experienced service technicians should perform this work. Please observe and comply with ALL applicable electrical and building codes and ordinances. Above all, use common sense and BE SAFETY CONSCIOUS. Ensure that you are familiar with the AT&T “Ask Yourself Handbook”, APEx doc ATT-002-200-715, and can answer Yes to the 10 questions below. 1.2. “Ask Yourself” Principles and Philosophy “Ask Yourself” principles are presented in the form of questions. Listed in the table below are the ten “Ask Yourself” questions that you should be able to confidently answer “yes” to before you undertake any task related to the network. If you are unable to answer “yes” to any of the ten questions, please stop and resolve the issues before resuming your work. Protecting the network is everyone’s responsibility. THE TEN “ASK YOURSELF” PRINCIPLES:

1. Do I have the proper access and appropriate login credentials for the work I am about to do? 2. Do I know why I'm doing this work? 3. Have I identified and notified all key stakeholders who will be directly and possibly indirectly affected by this work? 4. Can I prevent or control service interruption or defect introduction? 5. Is this the right time to do this work? 6. Am I trained and qualified to do this work? 7. Is all relevant documentation for this work complete, current and error-free? 8. Do I have everything I need to quickly and safely restore service if something goes wrong? 9. Have I walked through the entire process or procedure I am about to follow? 10. Have I verified/validated that I have completed all the steps in the process or procedure, obtained proper closure and notified appropriate technology centers, as applicable?

3


Adjust HVAC Unit Fan Purge Thumbwheel Switch Each of the HVAC units must be re-configured to stop the evaporator blower at the end of the cooling or heating cycle. This is a simple case of adjusting the Fan Purge Seconds thumbwheel switch on the HVAC control board inside the HVAC unit to its minimum setting. Outside the Shelter:

• On one of the HVAC units, turn the breaker cover bale screw 90 degrees and lift the breaker cover. Turn off the two 240 VAC circuit breakers and one 48 VDC circuit breaker. If this unit is actively cooling, the CoolLinks™ controller will automatically switch to the other HVAC unit when the breakers are turned off.

• Remove the six screws on the lower cover with the 5/16” nut driver then remove the cover. Place the cover against the side of the shelter to avoid any damage.

• Next, remove the two screws holding the electrical box cover in place and CAREFULLY remove the cover. Place the cover with the lower cover. The HVAC control board is now accessible as shown in fig. 1.

Fig. 1: HVAC Control Board Inside ComPac II Unit

• Locate the Fan Purge Seconds thumbwheel switch on the HVAC control board as shown in fig. 2. Rotate this thumbwheel to the right (clockwise) until the wheel will no longer turn. The wheel can either be turned by the thumb and forefinger or with the 3/16” flathead tip screwdriver. The small arrow on the top of the wheel should now be pointing to the value “10” on the printed circuit board (figure shows thumbwheel set to “90” seconds).

HVAC Control Board

Circuit Breakers

4


Fig. 2: Fan Purge Seconds Thumbwheel

• Reinstall the electrical box cover and the lower cover.

• Turn on the 48 VDC circuit breaker and the two 240 VAC circuit breakers.

• Turn the bale screw 90 degrees on the breaker cover to lock the cover in place.

• Repeat the process for the other HVAC unit.

Fan Purge

5


Identify Marvair® CoolLinks™ Controller The next steps require identification of the controller type and three versions are available dependent on the hardware and equipment configuration. The different configurations can be identified as follows:

• No vertical relays, (fig. 3a or fig. 3b): Original Controller • Vertical relays, EOL/NSB (fig. 4a, 4b): EOL/NSB Controller • Vertical relays, EOL/NSB 2016 (fig. 4a, 4c): EOL/NSB 2016 Controller

Fig. 3a: Original Fig. 3b: Original

Fig.4a: EOL/NSB

Fig.4b: EOL/NSB Fig. 4c: EOL/NSB 2016

6


Verify RBS Temp High and RBS Temp Low Alarms The devices that report RBS Temp High and RBS Temp Low alarms to the shelter alarm block must be adjusted to be consistent with the cooling and heating set points of the new controller software. Any re-configuration is dependent on the type of controller and the work required varies from a simple case of adjusting the setting on an alarm thermostat to punching down new connections on the controller 66 block. Original Controller (fig. 3a or 3b):

• The RBS Temp High and RBS Temp Low alarms originate from two independent Dayton thermostats installed inside the shelter similar to the unit shown in fig. 5 below. The alarm set point is indicated on the scale on the front of the thermostat. Turn the adjustment knob clockwise to increase the set point or counter-clockwise to decrease the set point.

• For the RBS Temp High thermostat, turn the adjustment knob to 98°F.

• For the RBS Temp Low thermostat, turn the adjustment knob to 35°F.

Fig. 5: Shelter RBS High or Low Temp Alarm Thermostat EOL Controller (fig. 4a):

• The RBS Temp High and RBS Temp Low alarms may either originate from two independent Dayton thermostats similar to the original controller (fig. 5), or from the punch down block on the CoolLinks™ controller (fig. 6).

• If the RBS Temp High and RBS Temp Low alarms are connected to the CoolLinks™ controller punch down block then no further action is necessary. The RBS Temp High alarm will automatically trigger from the controller at 98°F and the RBS Temp Low alarm at 45°F.

• If the RBS Temp High and RBS Temp Low alarms originate from the Dayton thermostats, the alarm connections should be migrated to the CoolLinks™ controller punch down block and the thermostats removed from service by disconnecting their alarm wires at the external alarm 66 block.

Alarm Set Point

7


Fig. 6: CoolLinks™ EOL Controller Punch Down Block

NSB Controller (fig. 4a):

• The RBS Temp High and RBS Temp Low alarms may either originate from two independent Dayton thermostats similar to the original controller (fig. 5), or from the terminal block inside the CoolLinks™ controller (fig. 7).

• If the RBS Temp High and RBS Temp Low alarms are wired to the CoolLinks™ controller then no further action is necessary. The RBS Temp High alarm will automatically trigger from the controller at 98°F and the RBS Temp Low alarm at 45°F.

• If the RBS Temp High and RBS Temp Low alarms originate from the Dayton thermostats, turn the adjustment knob to 98°F on the RBS Temp High thermostat and 35°F on the RBS Temp Low thermostat. If the controller is identical to those shown in Figures 4a, 4b or 4c the alarms should be migrated to the CoolLinks controller and the Dayton alarm wires disconnected at the external alarm 66 block.

Alarm Connections

8


Fig. 7: CoolLinks™ NSB Controller Alarm Connections

Alarm Connections

9


Downloading Marvair® CoolLinks™ Software

The controller software can be updated with an SD memory card or through the use of the CoolLinks™ Software Update Tool. This section describes the process to update the controller software with an SD memory card. Detailed instructions for the download, installation, and operation of the Software Update Tool and the associated controller program files can be found on the CEMPO National SharePoint Site at CoolLinks Download Tool Installation Instructions 12082016 Choose the SD memory card that matches the hardware configuration of the controller:

• Original Controller (fig. 3a or fig. 3b) SW 1.2.1.8 or 1.2.1.8cb software release 1.2.1.8 • EOL/NSB (fig. 4a, 4b) SW 2.1.0.3 or 2.1.0.3cb software release 2.1.0.3 • EOL/NSB 2016 (fig. 4a, 4c) SW 3.1.0.3 or 3.1.0.3cb software release 3.1.0.3

There are two versions of the software for each hardware configuration, one without continuous blower and one with continuous blower (“cb”) operation on the lead HVAC unit. In sites with significant heat loads, with radios inside the shelter, or with any localized sources of heat, install the software with continuous blower (“cb”) operation to ensure an even temperature profile within the shelter. In newer, smaller, lower heat load sites, install the software without continuous blower operation to prevent potential moisture issues. In the DC Plant, turn the breaker to the CoolLinks controller to the OFF position to remove power from the PLC. Open the top cover on the CPU (SIMATIC S7-1200), choose the appropriate SD memory card and insert as shown. Push down until it snaps into place. You will hear a click and the top of the SD card will be flush with the top of the card slot.

Fig. 8: Load SD Memory Card

10


In the DC Plant, turn the breaker to the CoolLinks controller to the ON position to restore power to the PLC. Watch the LEDs on the PLC. The RUN/STOP LED flashes green/yellow while the program is loading. The operation should take about 15 seconds and is complete when the RUN/STOP LED is solid yellow, the ERROR LED is off, and the MAINT LED is flashing yellow.

Fig. 9: Download Complete

In the DC Plant, turn the breaker to the CoolLinks controller to the OFF position to remove power from the PLC. Push down then remove the SD memory card. After removing the SD memory card, turn the breaker to the CoolLinks controller to the ON position to restore power to the PLC. Operation is complete when the RUN/STOP LED is solid green and the ERROR and MAINT LEDs are both off.

Fig. 10: Software Update Complete

11


After the controller restarts, verify the successful upgrade of the CoolLinks software from the operator screen. To do so, wait until the operator screen displays the main system status screen then press the Reset Lock Out push button to display the current software version in the Indoor Air Temperature field. The field will appear as one of the following dependent on the software downloaded to the controller:

Fig. 11a: Original Controller Fig. 11b: EOL/NSB Controller

Fig.11c: EOL/NSB 2016 Controller

The field value 218°F corresponds to software version 1.2.1.8 (original controller configuration) and the field value 103°F corresponds to software version 2.1.0.3 (EOL/NSB controller). For the EOL/NSB 2016 or later controllers, the software version is displayed in the title bar on the upper left-hand corner of the screen (version 3.1.0.3). Note: if after completing the CoolLinks upgrade the shelter smoke detector is activated due to the higher temperature in the building, it must be determined if the detector is in a location that may be a “hot spot” due to restricted airflow and/or nearby equipment that is generating excessive heat. If so, the smoke detector may need to be relocated to a more suitable location within the shelter.

12


Firmware Release History:

Revision Date Description

3.0.2 10-‐14-‐2013 Initial Release

3.0.3 02-‐03-‐2014 SNMP Port Update (Olympus Compatibility)

Software Release History (Original Controller):


1.2.1.0 10-‐14-‐2013 Initial Release

1.2.1.1 11-‐19-‐2013 Coastal Unit Operation

1.2.1.2 02-‐03-‐2014 SNMP Port Update (Olympus Compatibility)

1.2.1.3 03-‐13-‐2014 Single Unit Operation

Damper Control Algorithm Enhancement

1.2.1.4 04-‐25-‐2014 Correct False Damper Alarm Fault

1.2.1.5 07-‐18-‐2014 DC Free-‐Air Algorithm Update. DC Free-‐Air operation is enabled if the outside air dew point is less than 60F and the outside air relative humidity is less than 80%. Previously, the limit for the outside air relative humidity was 90%.

Restore Default Set Points After One Hour. If the cooling set point, cooling second stage differential, heating set point, or heating second stage differential is changed from the operator panel inside the shelter, the set points are returned to their default values after one hour. The default values for cooling set point and differential are 78F and 5F, and the default values for heating set point and differential are 50F and 2F.

Standalone Mode Default Mixed-‐Air Set Point Update. If an HVAC unit loses communications with the CoolLinks PLC, the unit will function in standalone mode. In this mode, the HVAC unit uses the mixed-‐air sensor as its temperature sensor and

13


cools the shelter until the temperature is equal to the mixed-‐air temperature set point. The default value for the mixed-‐air temperature set point is now 75F rather than the previous default value of 55F. This prevents over cooling of the shelter space in standalone mode.

DX Cooling / DC Free-‐Air Cooling Crossover Enhancement. When switching from DX (mechanical) cooling to DC Free-‐Air cooling, the system now requires that the dew point and outside air humidity conditions required to enable DC Free-‐Air cooling are satisfied for a minimum of 30 seconds. This prevents multiple switching between DX and DC Free-‐Air cooling when the enable conditions are marginal and is simply an operational enhancement to the system.

No / Faulty Indoor & Outdoor Sensor Detection. The CoolLinks PLC will now determine if the indoor and outdoor sensors are connected and if the values from theses sensors are valid. In the case of a missing sensor or invalid value, the operator panel will flash “0” and “####” at two second intervals for the invalid sensor value. If an invalid outside temperature or relative humidity value is detected, DC Free-‐Air cooling will be disabled. If an invalid inside temperature is detected, DC Free-‐Air cooling will also be disabled, the unit will run in mechanical cooling and the mixed-‐air sensor value from the lead HVAC unit will be used as the inside shelter temperature.

1.2.1.6 02-‐19-‐2015 DC Free-‐Air Algorithm Update. Revisions to the damper control algorithm to maximize the use of the DC Free-‐Air system in colder temperatures. Use of mechanical cooling is now minimized when the environmental conditions are suitable for DC Free-‐Air cooling.

Software version verification. Pressing the Reset Lockout push button will now display the software version in the indoor temperature field. The value 216 corresponds to release 1.2.1.6 and the value 101 corresponds to release 2.1.0.1.

1.2.1.7 05-‐13-‐2015 Desert Test Application.

14


1.2.1.8 08-‐12-‐2016 CEMPO Thermal Management Program Release. Expanded

temperature range operation from 74F to 88F, with an average shelter temperature of 80F to 82F, as follows:

>88F Mechanical Cooling Lead or Free-‐Air Cooling Lead >90F Mechanical Cooling Lead or Free-‐Air Cooling Lead & Lag >91F Mechanical Cooling Lead >93F Mechanical Cooling Lead & Lag <74F Mechanical Cooling Off or Free-‐Air Cooling Off

In line with the temperature range changes, the NOC high temperature alarm has also been revised:

>98F RBS High Temp (previously 85F) <45F RBS Low Temp (unchanged)

Extended DC Free-‐Air operation to reflect the expanded shelter temperature range operation as follows:

Dew Point <65F (previously 60F) Outside Temperature <75F (previously 70F) Outside Humidity <80% (unchanged)

The evaporator blower will no longer run continuously on the lead HVAC unit. The blower will now stop immediately when the cooling or heating set point is satisfied. The five-‐minute minimum run timer has also been removed and the cooling or heating cycle will again stop when the set point is satisfied.

The Comfort Mode push button will reduce the cooling set point from 88F to 76F for a period of 60 minutes to allow a technician to work comfortably inside the shelter. Pressing the Comfort Mode push button if a smoke alarm is active will allow the HVAC units to run for ten minutes to cool the shelter and to reset the smoke detector high temperature interlock.

The HVAC units will swap lead/lag operation every 24 hours rather than every call for cooling or heating.

The indoor temperature display will now alternate every five seconds between the indoor temperature and the average temperature over the last 24 hours.

1.2.1.8cb 03-‐15-‐2017 Evaporator blower on lead HVAC unit now runs continuously.

15


Software Release History (NSB and EOL Controller):


2.1.0.0 11-‐14-‐2014 Initial Release. EOL and NSB equivalent of the original controller release 1.2.1.5.

2.1.0.1 02-‐19-‐2015 DC Free-‐Air Algorithm Update. Revisions to the damper control algorithm to maximize the use of the DC Free-‐Air system in colder temperatures. Use of mechanical cooling is now minimized when the environmental conditions are suitable for DC Free-‐Air cooling.

Software version verification. Pressing the Reset Lockout push button will now display the software version in the indoor temperature field. The value 216 corresponds to release 1.2.1.6 and the value 101 corresponds to release 2.1.0.1.

2.1.0.2 05-‐13-‐2015 Desert Test Application.

2.1.0.3 08-‐12-‐2016 CEMPO Thermal Management Program Release. Expanded temperature range operation from 74F to 88F, with an average shelter temperature of 80F to 82F, as follows:

>88F Mechanical Cooling Lead or Free-‐Air Cooling Lead >90F Mechanical Cooling Lead or Free-‐Air Cooling Lead & Lag >91F Mechanical Cooling Lead >93F Mechanical Cooling Lead & Lag <74F Mechanical Cooling Off or Free-‐Air Cooling Off In line with the temperature range changes, the NOC high temperature alarm has also been revised: >98F RBS High Temp (previously 85F) <45F RBS Low Temp (unchanged) Extended DC Free-‐Air operation to reflect the expanded shelter temperature range operation as follows:

Dew Point <65F (previously 60F) Outside Temperature <75F (previously 70F) Outside Humidity <80% (unchanged)

16


The evaporator blower will no longer run continuously on the lead HVAC unit. The blower will now stop immediately when the cooling or heating set point is satisfied. The five-‐minute minimum run timer has also been removed and the cooling or heating cycle will again stop when the set point is satisfied. The Comfort Mode push button will reduce the cooling set point from 88F to 76F for a period of 60 minutes to allow a technician to work comfortably inside the shelter. Pressing the Comfort Mode push button if a smoke alarm is active will allow the HVAC units to run for ten minutes to cool the shelter and to reset the smoke detector high temperature interlock. The HVAC units will swap lead/lag operation every 24 hours rather than every call for cooling or heating. The indoor temperature display will now alternate every five seconds between the indoor temperature and the average temperature over the last 24 hours.


17


Software Release History (NSB and EOL Controller 2016):


2.1.0.2 02-‐12-‐2016 Initial Release with version 4 hardware. Equivalent to EOL and NSB controller release 2.1.0.1 with new Siemens S7-‐1212C.

3.1.0.3 08-‐12-‐2016 CEMPO Thermal Management Program Release. Expanded temperature range operation from 74F to 88F, with an average shelter temperature of 80F to 82F, as follows:

>88F Mechanical Cooling Lead or Free-‐Air Cooling Lead >90F Mechanical Cooling Lead or Free-‐Air Cooling Lead & Lag >91F Mechanical Cooling Lead >93F Mechanical Cooling Lead & Lag <74F Mechanical Cooling Off or Free-‐Air Cooling Off In line with the temperature range changes, the NOC high temperature alarm has also been revised: >98F RBS High Temp (previously 85F) <45F RBS Low Temp (unchanged) Extended DC Free-‐Air operation to reflect the expanded shelter temperature range operation as follows:

Dew Point <65F (previously 60F) Outside Temperature <75F (previously 70F) Outside Humidity <80% (unchanged) The evaporator blower will no longer run continuously on the lead HVAC unit. The blower will now stop immediately when the cooling or heating set point is satisfied. The five-‐minute minimum run timer has also been removed and the cooling or heating cycle will again stop when the set point is satisfied. The Comfort Mode push button will reduce the cooling set point from 88F to 76F for a period of 60 minutes to allow a technician to work comfortably inside the shelter. Pressing the Comfort Mode push button if a smoke alarm is active will allow the HVAC units to run for ten minutes to cool the shelter and to reset the smoke detector high temperature interlock.

18


The HVAC units will swap lead/lag operation every 24 hours rather than every call for cooling or heating. The indoor temperature display will now alternate every five seconds between the indoor temperature and the average temperature over the last 24 hours.


Marvair Product Bulletin - Airxcel | AC, Heating & Appliances · PDF file · 2017-09-266" CL-SDCARD-ATT Release 1.5 August 22, 2017 " Verify RBS Temp High...

Documents