small systems #1 - hvac-talk

Environmental Training and Service Manual

TM-70220: Rev. 09/02

Small Systems #1

Mini-Mate - Mini-Mate2 - DataMate

Microprocessor and Solid State

Small Systems Training & Service Manual

2

Small Systems Training & Service

Manual

Includes: mini-MATE,Mini-MATE PlusMini Mate 2 Datamate


3

Disclaimer of Warranties and Limitations of Liabilities

The authors and editors have taken every precaution to ensure accuracy and completenessin this manual. The authors and editors make no expressed or implied warranty of anykind with regard to the documentation in this manual. Liebert Corporation assumes noresponsibility, and disclaims all liability for incidental or consequential damages resultingfrom the use of this information or from errors or omissions. Liebert Corporation maymake improvements and/or changes in the product(s) described in this manual at any time.Information in this manual is subject to change at any time and does not represent acommitment on the part of Liebert Corporation.

Liebert® and the Liebert logo are registered trademarks of Liebert Corporation.Emerson® and the Emerson logo are registered trademarks of Emerson Electric Co. Mini-MateTM , Mini-Mate PlusTM , Mini- MateTM , GlycoolTM and SitemasterTM are trademarksof Liebert Corporation. Datamate® is a registered trademark of Liebert Corporation

Copyright © 2001 by Liebert CorporationAll rights reserved

Printed in the United States of America


4

Table of ContentsChapter 1 Basics of the Microprocessor ------------------------------ 8

Introduction Input Block -------------------------------------------------------------------------- 10Processor Block --------------------------------------------------------------------- 12Memory Block ---------------------------------------------------------------------- 13Output Block ------------------------------------------------------------------------ 14Software ------------------------------------------------------------------------------ 15The Candy Program ---------------------------------------------------------------- 16Summary ----------------------------------------------------------------------------- 17

Chapter 2 Microprocessor Control Mini-Mate2 -------------------- 18

Introduction --------------------------------------------------------------------------19 Control Panel Layout Control Panel Operation ----------------------------------------------------------- 20Programming Menu: 1-5 Ton Units ---------------------------------------------- 21Programming Menu: 8-Ton Units ------------------------------------------------ 22Main Menu Information ----------------------------------------------------------- 23Set Points ---------------------------------------------------------------------------- 24Temperature Control ---------------------------------------------------------------25Compressor Cooling: 1 to 5 Ton Units Chilled Water Cooling: 1 to 5 Ton Units ---------------------------------------- 26Glycool Cooling: 1 to 5 Ton Units Compressor Cooling: 8-Ton Units ----------------------------------------------- 28Chilled Water Cooling: 8-Ton Units Glycool Cooling: 8 Ton Units Heating: Electric or Hot Water 1 to 5 Ton Units ------------------------------- 31Heating: Hot Gas 1 to 1 ½ Ton Units Heating: Electric 8-Ton Units -----------------------------------------------------32 Heating: Hot Water 8-Ton Units Heating: SCR 8-Ton Units Humidity Control -------------------------------------------------------------------34 Dehumidification: Compressorized Units Dehumidification: Chilled Water Units Humidification ---------------------------------------------------------------------- 37Additional Control Programs ----------------------------------------------------- 38Active Alarms and Alarm History Log ------------------------------------------ 39Time and Date Setback Control ---------------------------------------------------------------------40


5

Setup Operation --------------------------------------------------------------------- 41DIP Switches ------------------------------------------------------------------------ 42Change Passwords ------------------------------------------------------------------ 44Calibrate Sensors ------------------------------------------------------------------- 45Alarm Enable, Disable, Time Delay Programming Custom Alarm, Text Programming -----------------------------------------------48 Diagnostics -------------------------------------------------------------------------- 49

Chapter 3 Datamate Microprocessor Control -----------------------51

Introduction Control Panel Layout --------------------------------------------------------------- 52Control Panel Operation ----------------------------------------------------------- 53Programming Menu ---------------------------------------------------------------- 54Main Menu Information ----------------------------------------------------------- 55Set Points ---------------------------------------------------------------------------- 56Temperature Control --------------------------------------------------------------- 57Compressor Cooling Chilled Water Cooling Heating: Electric--------------------------------------------------------------------- 59Humidity Control ------------------------------------------------------------------- 60Dehumidification: Compressorized Units Dehumidification: Chilled Water Units Humidification ---------------------------------------------------------------------- 62Additional Control Programs ----------------------------------------------------- 63Active Alarms and Alarm History Log Time and Date ----------------------------------------------------------------------- 64Setback Control Setup Operation --------------------------------------------------------------------- 66DIP Switches ------------------------------------------------------------------------ 67Change Passwords ------------------------------------------------------------------ 69Calibrate Sensors Alarm Enable, Disable, Time Delay Programming ---------------------------- 70Custom Alarm, Text Programming Diagnostics -------------------------------------------------------------------------- 73

Chapter 4 Microprocessor Control –mini-MATE, mini-MATE +,Datamate 1994 to the Present 75

Introduction Control Panel Descriptions -------------------------------------------------------- 76Operating Procedures -------------------------------------------------------------- 77Range of Control Set Points ------------------------------------------------------- 80Set High Temperature, Cooling Set Low Temperature, Heating Set High Humidity, Dehumidification


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Set Low Humidity, Humidification High and Low Temperature and Humidity Alarms Scheduled Program Modification ------------------------------------------------- 85Sensor Calibration ------------------------------------------------------------------ 87Fan Speed ---------------------------------------------------------------------------- 88DIP Switches ------------------------------------------------------------------------ 89

Mini Mate, Mini Mate Plus Software/Hardware History ------------------------------- 91

Chapter 5 Microprocessor Control – mini-MATE, mini-MATE Plus,Datamate Original Release 1990 to 1994 92

Introduction Control Panel Descriptions -------------------------------------------------------- 93Range of Control Set Points ------------------------------------------------------- 95Set High Temperature, Cooling Set Low Temperature, Heating Set High Humidity, Dehumidification Set Low Humidity, Humidification High and Low Temperature and Humidity Alarms ---------------------------- 99Scheduled Program Modification ------------------------------------------------- 100Sensor Calibration ------------------------------------------------------------------ 101Fan Speed DIP Switches ------------------------------------------------------------------------ 102

Chapter 6 Electrical Connections ------------------------------------------103

Sequence of Operation: mini-MATE, mini-MATE Plus, Datamate --------- 104mini-MATE, mini-MATE Plus Control Board Layout ------------------------ 106mini-MATE, mini-MATE Plus Interface Board Layout ---------------------- 107mini-MATE, mini-MATE Plus Control Board Connections ----------------- 108mini-MATE, mini-MATE Plus Electrical Schematics (127222)-------------- 109Datamate Control Board Layout -------------------------------------------------- 110 Datamate Interface Board Layout ------------------------------------------------ 111Datamate Control Board Connections ------------------------------------------- 112Datamate Electrical Schematics (32467) ---------------------------------------- 113 Mini-Mate2: 1 to 8 Ton Units Control Board Layout -------------------------- 114Mini-Mate2: 1 to 5 Ton Units Interface Board Layout ------------------------ 115Mini-Mate2: 1 to 5 Ton Units Interface Board Connections Mini-Mate2: 8-Ton Units Interface Board Layout ----------------------------- 117Mini-Mate2: 8-Ton Units Interface Board Connections Fuse/ Transformer Board Layout and Plug Connections ---------------------- 120Datamate: 1 to 3 Ton Units Control Board Layout ----------------------------- 121Datamate: 1 to 3 Ton Units Interface Board Layout --------------------------- 122Datamate: 1 to 3 Ton Units Interface Board Connections


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Chapter 7 General Troubleshooting ---------------------------------124

Introduction -------------------------------------------------------------------------- 125Isolation ------------------------------------------------------------------------------ 126Basic Operation of the Triac ------------------------------------------------------ 127Basic Operation of the Opto-Isolator --------------------------------------------- 129Troubleshooting the Opto-Isolator ----------------------------------------------- 1301 to 5 Ton Mini-Mate2 Opto-Isolator and Triac Legends --------------------- 1328 Ton Mini-Mate2 Opto-Isolator and Triac Legends -------------------------- 134Control Input Check (Glycol Sensor) -------------------------------------------- 136Control Input Check (Temperature/ Humidity Sensors) ----------------------- 137Frequency Conversion Chart (Temperature) ------------------------------------ 138Frequency Conversion Chart (Humidity) ---------------------------------------- 139Moisture Content Charts ----------------------------------------------------------- 140Troubleshooting Checklist --------------------------------------------------------- 157

Chapter 8 mini-MATE Solid State Control -------------------------158

Standard and Optional Features, All Systems ----------------------------------- 159Operating Procedures -------------------------------------------------------------- 162First Generation mini-MATE Control Board Layout -------------------------- 165Second Generation mini-MATE Control Board Layout ----------------------- 166mini-MATE Chilled Water Schematic (1C18785)------------------------------ 167mini-MATE DX Schematic, 1st Generation Control Board (2SP-2059/8)--- 168 mini-MATE DX Schematic, 2nd Generation Control Board (2SP-2059/11)- 169Earliest mini-MATE Troubleshooting Charts ---------------------------------- 170

Chapter 9 mini-MATE Plus Solid State Controls -----------------172

Control Theory ---------------------------------------------------------------------- 173Design Features, All Systems Steam Canister Humidifier -------------------------------------------------------- 177 Sequence of Operation ------------------------------------------------------------- 179 mini-MATE Plus Control Board Layout ---------------------------------------- 183mini-MATE Plus 2 and 3 Ton Schematic (1C19528)-------------------------- 184 mini-MATE Plus 2 and 3 Ton 1 Phase Condenser Schematic (1C19600) -- 185mini-MATE Plus 2 and 3 Ton 3 Phase Condenser Schematic(1C19607) - 186mini-MATE Plus Troubleshooting Charts -------------------------------------- 187

Chapter 10 Datamate Solid State Control ------------------------189

Standard and Optional Features, All Systems ----------------------------------- 190Datamate Control Center ---------------------------------------------------------- 194


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Optional Humidity Control -------------------------------------------------------- 195Electrical Operation ---------------------------------------------------------------- 196Datamate Connection Points ------------------------------------------------------ 200Electro-Mechanical Operation ---------------------------------------------------- 203Datamate Schematic (1C16377)--------------------------------------------------- 206Datamate 1 Phase Condenser Schematic (121738) ----------------------------- 207Datamate 3 Phase Condenser Schematic (121739) ----------------------------- 208Datamate 1 Phase Piggyback Condenser Schematic (121191) ---------------- 209Datamate Troubleshooting Charts ------------------------------------------------ 210

Chapter 11 Static Control ------------------------------------------212

Introduction -------------------------------------------------------------------------- 213Identification ------------------------------------------------------------------------ 214Static Controlled Work Station --------------------------------------------------- 215Floor Considerations --------------------------------------------------------------- 216Environmental Considerations ---------------------------------------------------- 217Work Station Maintenance Unit Installation Customer Service ------------------------------------------------------------------- 218

Glossary -----------------------------------------------------------------------------219


9

Chapter 1

Basics of the Microprocessor

• Introduction

• Input Block

• Processor Block

• Memory Block

• Output Block

• Software

• Summary


10

IntroductionLiebert Corporation uses the Motorola® 6800 Series processor for the control in itssystems. As is the case with all processors, there are basic concepts that make theiroperation easy to under stand without having an in-depth knowledge of electronics.

The microprocessor is a sophisticated Integrated Circuit (IC) chip that processesinformation by utilizing a series of instructions.

If you think of the microcomputer as a set of blocks, you can see four distinct blocks thatwe address by the names Input, Processor, Memory and Output.

Building Blocks of a Microcomputer

This chapter describes the information processing in each block of the microcomputer andthe information flow among the blocks.

INPUT(sense)

PROCESOR(decide)

OUTPUT(act)

MEMORY(store)

Signals from theoutside (external)world

Signals to theoutside (external)world


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Input BlockThe first block in the Input Block, or sense function. The Input Block receives the signalsfrom some external source, processes (or converts) the signals, and sends them on to theProcessor.

Signal Flow at the Input Block

Various devices (components) sense information and transmit it to the input block forencoding. Here the real world signals are changed to a language that the Processor canunderstand.

The words, bytes, nibbles and bits are then sent to the Processor or possibly through theProcessor to the Memory, and the information processing begins.

The input can be data about the surrounding conditions such as temperature, pressure,lights and so forth, or it can be a communication and/ or commands that set the machineinto a given mode and tells it where to start. By having the sense elements, a system canreceive information from humans or devices. In the computer system, the functional unitsthat perform the various sense functions are called the input devices of the system.

It is important to note that in this block, the converted information is sent with the properaddress (assigned location) and the information is in order or sequence through the entireprocess.

INPUT BLOCK

External Signalsto the Computer

Address Signals fromthe Microprocessor

Timing and ControlSignals from theMicroprocessorData Signals to the

Microprocessor


Encod

To Memory

Encode:75 = 0111011001010001 = Word52 = 10110111 = ByteHi Temp = 0110 = NibbleSw-6 = 0 = Bit

12

Encoding at the Input Block

ed Input from the Input Block to the Processor

To Microprocessor


Processor BlockThe Processor Block, or the decide function, is much like the reasoning function of thehuman brain. All computations, logical operations, and operational decisions are madehere. These decisions take into account the input and the stored information in thememory. It performs the basic arithmetic and makes all the logical decisions required bythe computer. It also controls the operation of the computer by turning on and off the otherfunctional units in the system at the proper time. The Processor in a microcomputersystem is called the microprocessor.

You can now see

From Input

PROCESSOR

From Memory

13

Signal Flow at the Processor B

the multiple paths for the information flow i

Information Flow at the Processor B

To Output

loc

n th

lo

To Memory

k

e system.

ck


14

Memory BlockThe Memory Block contains the operational programs of the system. It receives signalsand codes from the Processor and sends codes to the Processor.

Signal Flow at the Memory Block

The machine must remember what it is to do, and the information for use in what it does.It must also remember a number of rules used in make decisions, performing arithmeticand controlling the system. The computer system name for this function is Memory. Thestep-by-step sequence of operations (the program) the computer is to perform, and theinstructions and information (data) to be used are stored in the Memory.

The Memory Function

MEMORY

Instruction Codes or Data Codes tothe Microprocessor OrData Codes from the Microprocessor

Address Signals fromthe Microprocessor

Timing and ControlSignals from theMicroprocessor


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Output BlockThe last block is the Output Block, or the act function.

Signal Flow at the Output Block

The act function is as the name implies. Once the Processor has made a decision, thesystem carries out the decision with the outputs or acts of the system. First the encodedinformation is decoded into a language that we can understand to produce the real worldsignals that we understand. Then the act takes place. This may involve activating a devicethat displays information so it can be communicated to humans. Or the act unit may turnon a motor, or turn of a light, or some other similar control operation. The act unit allowsthe system to control something external to the system or to exchange information(communicate) with humans or other machines. In the computer system, the devices thatimplement the act function are called the output devices of the system.

Decoding at the Output Block

OUTPUTAddress Signals fromthe Microprocessor

Timing and ControlSignals from theMicroprocessor Data Signals from

the Microprocessor

External Signalsfrom the Computer


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SoftwareA software program is nothing more that a set of instructions or routines that achieve adesired result. A good comparison is a recipe. Refer to the Candy Program on the nextpage.

The first few steps are an information or data-gathering process. Then we measure, mix,and stir, which is the processing of the gathered information. Note the logical sequence,since we cannot complete some steps unless others are completed first.

The software programs that drive the Liebert units are written by programmers at Liebert.These are the routines that you as air conditioning technicians use daily.

The software is written onto an IC chip called Erasable and Programmable Read-OnlyMemory (EPROM) or Programmable Read-Only Memory (PROM). The device isinstalled simply by inserting it into a designated socket on the proper electronics board inthe Liebert unit.

The software comes standard with the unit: however, revisions are available for upgradeenhancements. Enhancements are addressed in later sessions.


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The Candy Program1. Get a mixing bowl.

2. Get 5 pounds of granulated sugar.

3. Get two 8-ounce cans of evaporated milk.

4. Get a 12-ounce jar of white corn syrup.

5. Get 1 package of pecans.

6. Get 1 package of chocolate chips.

7. Get I stick of butter.

8. Get a 2-ounce bottle of vanilla extract.

9. Measure 2 ½ cups of sugar into the mixing bowl.

10. Measure ¾ cup evaporated milk into the mixing bowl.

11. Measure 1/3 cup white corn syrup into the mixing bowl.

12. Measure 2 tablespoons of butter into the mixing bowl.

13. Get a separate container.

14. Measure 1 cup of nuts and 12 ounces of chocolate chips into the separate container andset aside for later use.

15. Mix all of the ingredients, except the nuts and chocolate chips, together in the mixingbowl.

16. Pour this mixture into a pan and bring to a boil.

17. Boil for exactly 5 minutes. Slowly stir as it boils.

18. Remove from the heat and stir in 1 teaspoon of vanilla extract.

19. Stir in the nuts and chocolate chips (from Step 14) until the chocolate chips melt.

20. Pour the fudge into a buttered pan and let cool.


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SummaryThe computer contains four blocks: Input, Processor, Memory and Output. These blocksact as the sense, storage and act functions of the system.

The Input Block receives the signals from the external world and converts them into alanguage the computer can understand. This information is then sent to the ProcessorBlock for processing or the Memory Block for storage. When a decision is made, thesignal goes to the Output Block where the computer language is converted into a languagewe understand, and the appropriate action takes place.

The entire operation is controlled by the software, which provides the routines needed toachieve the desired result.


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Chapter 2

Mini-Mate2

Microprocessor Control

• Introduction

• Control Panel Layout

• Control Panel Operation Set Points Setback Control Calibrate Sensors Alarm Programming Diagnostics


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INTRODUCTIONThis section applies to the Mini-Mate2 units equipped with microprocessor control. Theprogramming of the system control is performed using the wall mounted control panelsupplied with the Mini-Mate2. The microprocessor control for the Mini-Mate2 unitfeatures an easy to use menu driven LCD display.

The various set points, DIP Switch settings and other selections were made during factorytesting of your unit and are based on typical operating experience. The various defaultselections were made according to the options the factory supplied with your unit. Theparameter ranges of the various programmable points are displayed by pressing the AlarmSilence/ ? (Help) key. A password will be required to modify or change any programmablepoint if the DIP switch is in the password enable position.

Note: Make adjustments to the factory default selections only if they do not meetyour specifications.

With power supplied to the Mini-Mate2 press the ON/OFF (I/O) key located on the wallmounted control panel. The system will begin monitoring room conditions (temperatureand humidity). The display indicates the current system operations. System operation isautomatically controlled by the micro-controller, based on room conditions and theprogrammed set points

Control Panel LayoutThe figure below is an illustration of the Mini-Mate2 wall mounted control panel whichmeasures approximately 5" X 3 1/2" x 1 1/4" (127 mm x 89 mm x 31.8mm). The controlpanel consists of a digital readout display and a keypad comprising of eight keys for thevarious programming functions.

Mini-Mate2 Microprocessor Control Panel


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Control Panel OperationThe Mini-Mate2 control panel is used to monitor room conditions, operational status,active alarms, and all programming functions. The panel contains the ON/OFF key and atwo line back-lit LCD display. The LCD display panel includes control keys for ON/OFF,Main Menu, increase arrow, Escape, HI/LO fan speed selection, alarm silence/ help,decrease arrow, and Enter. These keys are similar to the function keys of a computerkeyboard.

The LCD display is back-lit to provide easy viewing by the user, the contrast of the LCDdisplay can be adjusted using potentiometer “RA1” located in the wall mounted controlpanel. The display provides two lines of 20 characters each, allowing alpha and numericsymbols to be displayed. During normal operation the display shows the current operatingstatus and alarms if present. All set points, alarms, and changes to the system controls areinitially entered and modified through this control panel.

Each key when pressed provides a specific function as described below:

Control Keys Function

ON / OFF Turns the unit ON and OFF. OFF means the unit is turnedOFF with the main power applied.

MENU Enables the user to access the programming menu to changethe control parameters, alarms, setback schedule, etc.

INCREASE(UP)

Raises the value of the displayed parameter while in a setmode function (set points, time, etc.).

ESCAPE(ESC) Allows the user to move back to a previous menu display.

FANHIGH/ LOW

Allows the user to change the unit fan speed between highand low speed.

ALARMSILENCE/ HELP (?)

If an alarm is present, pressing this key pad will silence theaudible alarm beeper. If this key pad is pressed when noalarms are present, help text will appear on the displayscreen.

DECREASE(DOWN)

Lowers the value of the displayed parameter while in a setmode function.

ENTERAfter programming a control point, the user must pressENTER to have the information saved in themicroprocessor memory.


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Status Display75 o F 50 %RHNO ALARMS

MenuSetpoints

StatusActive Alarms

TimeDate

SetbackSetup Operation

Setpoint PasswordSetup Password

Calibrate SensorsAlarm Enable

Alarm Time DelayCommon Alarm Enable

Custom AlarmsCustom TextDiagnosticsEnd of Menu

Setpoints/SetupTemp SetptTemp SensHum SetptHum Sens

Hi Temp AlmLo Temp AlrmHi Hum AlmLo Hum Alm

StatusHeat % 0Dx Cool % 0Dehumidify% 0Humidify% 0

Active AlarmsNo Alarms

orAlarm 01 of 01

High Head

TimeTime HH:MM:SS

DateDate DD DDMMMYY

SetbackWknd Time 1

On/OffWknd Temp 1Wknd Tsens 1Wknd Humd 1Wknd Hsens 1Wknd Time 2

On/OffWknd Temp 2Wknd Tsens 2Wknd Humd 2Wknd Hsens 2Wkdy Time 1

On/OffWkdy Temp 1Wkdy Humd 1Wkdy Hsens 1Wkdy Time 2

On/OffWkdy Temp 2Wkdy Tsens 2Wkdy Humd 2Wkdy Hsens 2

Setup OperationRestart TD

C/F DegreesHumidity Control

Dipswch 00000000Pos 12345678

Valve TimeCW Flush

Mini-Mate 2Control Menu Setpoint Password

Enter New PSWSetpt PSW = 000

Setup PasswordEnter New PSW

Setup PSW = 000

Alarm EnableCustom #1Custom #2High TempLow TempHigh HumLow Hum

Short CycleLoss Pwr

Calibrate sensorsTemp CalHum Cal

Temp DelayHum Delay

Alarm Time DelayCustom #1Custom #2High TempLow TempHigh HumLow HumShort CycLoss Pwr

Common Alarm EnableHi WaterHi Head

Custom #1Custom #2High TempLow TempHigh HumLow HumShort CycLoss Pwr

Custom AlarmsCustom Alarm #1Custom Alarm #2

Custom TextCustom Text #1Custom Text #2

DiagnosticsTest Inputs

Test OutputsTest Microcontroller


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1 to 5 Mini-Mate2 Menu FlowchartNote:1-3 Ton MM2 does not have a CW valve: only 5 ton i.e. CW flush not in 1-3 Ton

Status Display72 oF 50 %RHNO ALARMS

MenuSetpoints

StatusActive AlarmsAlarm History

TimeDate

SetbackSetup OperationSetpt PasswordSetup PasswordCalibrate Sensor

Alarm EnableAlarm Time DelayCom Alarm Enable

Custom AlarmsCustom TextDiagnosticsEnd of Menu

Mini-Mate 2Control Menu

Alarm EnableHum ProbChng FltrLoss Air

Custom #1Custom #2Custom #3High TempLow TempHigh HumLow Hum

Short Cyc1Short Cyc2Fan OvrldLoss Pwr

Alarm Time DelayHum ProbChng FltrLoss Air

Custom #1Custom #2Custom #3High TempLow TempHigh HumLow Hum


Com Alarm EnableHum ProbHi Head 1Hi Head 2Chng FltrLoss Air

Custom #1Custom #2Custom #3Hi Water

High TempLow TempHigh HumLow Hum


Custom AlarmsCustom Alarm #1Custom Alarm #2Custom Alarm #3

Custom TextCustom Text #1Custom Text #2Custom Text #3

DiagnosticsTest OutputsTest InputsTest Micro

SetpointsTemp SetptTemp SensHum SetptHum Sens

Hi Temp AlmLo Temp AlmHi Hum AlmLo Hum Alm

StatusDx Cool % 0CW Valve% 0Econo Cool % 0Heat % 0Dehumidify% 0Humidify% 0

Active AlarmsNo Alarms

orAlarm 01 of 01

High Head

TimeTime HH:MM:SS

Alarm HistoryNo Alarms

orAlm 01:High Head 2

DD-MMM HH:MM:SS...

Alm 10:High Head 1DD-MMM HH:MM:SS

DateDDD DD MMM YYYY

SetbackWknd Time 1





Setup OperationRestart TD


Lead ComprDipswch 00000000Pos 12345678

Valve TimeCW Flush

Setpoint PasswordEnter New PSWSetpt PSW = 000

Setup PasswordEnter New PSW

Setup PSW = 000

Calibrate sensorTemp CalHum Cal

Temp DelayHum Delay


24

8 Ton Mini-Mate2 Menu Flowchart

Status DisplayThe display normally includes the present room temperature and humidity conditions alongwith any active alarms. The status display may also be selected from the Main Menu.

Main Menu <Menu> Press the MENU key to display the Main Menu. The menu selections include thefollowing choices in the order shown. The complete programming menu flowchartspreviously shown for the 1 to 5 Mini-Mate2 and 8 Ton Mini-Mate2.

• Set Points• Status• Active Alarms• Alarm History Log, 8 ton only• Time• Date• Setback• Setup Operation• Set Point Password• Setup Password• Calibrate Sensors• Alarm Enable• Alarm Time Delay• Common Alarm Enable• Custom Alarms• Custom Text• Diagnostics• End of Menu

Use the UP or DOWN arrow keys to scroll the various selections, then when ready toselect a particular function press the “Enter” key.


25

Set PointsThe various Set points and system setup parameters are kept in non-volatile memory.Selecting set points from the main menu will display the following selections.

• Temperature Setpoint• Temperature Sensitivity• Humidity Setpoint• Humidity Sensitivity• High Temperature Alarm• Low Temperature Alarm• High Humidity Alarm• Low Humidity alarm

Scroll through this sub-menu by using the UP or DOWN arrow keys, then press theENTER key to select the particular function to be viewed. To change a particular value,press the ENTER key and use the UP (increase) or DOWN (decrease) ARROW keys tochange the displayed value. When the selected function has been changed to the desiredvalue press the ENTER key to store the value. As an example, to change the temperatureset point from the main status display perform the following steps:

1. Press the MENU key to display the main menu.2. Scroll to the “SETPOINTS” function using the UP or DOWN ARROW keys, then

press the ENTER key.3. Scroll to the “TEMP SETPOINT” function using the UP or DOWN ARROW keys,

then press the ENTER key.4. Use the UP (increase) or DOWN (decrease) ARROW key the change the displayed

value to the new setpoint, then press the ENTER key.

Setpoint Default RangeTemperature Setpoint 72ºF (22.2ºC) 40 - 90ºF (5 - 32ºC)Temperature Sensitivity 2ºF (1.1ºC) 1 – 9.9ºF (0.6 – 5.6ºC)Humidity Setpoint 50% 20 – 80%Humidity Sensitivity 5% 1 – 30%High Temperature Alarm 80ºF (26.7ºC) 35 – 95ºF (2 - 35ºC)Low Temperature Alarm 65ºF (18.3ºC) 35 - 95ºF (2 - 35ºC)High Humidity Alarm 60% 15 – 85%Low Humidity Alarm 40 15 – 85%

Default and Setpoint Allowable Ranges


If no set points are entered into the system, the micro-controller will operate on the systemdefault set points. If the Schedule Program mode is not selected and is completely de-programmed , the control set points will remain as entered in the set pointsprogramming mode. Note that programmed set points are stored in non-volatile memoryand are retained during a power failure. No battery is required.

Temperature ControlCOOLING: 1 to 5 TON SYSTEMS

The temperature control program for the Mini-Mate2 uses a control band to activate thecooling device. The control is established at the temperature set point with the lengthequal to sensitivity plus 1°F (.6ºC).

1 Stage Compressorized Cooling

On 1 to 5 Ton Cdevice whenevecompressorizedcooling. The codecreases to 50%

Note that the co6°F (3.3°C) whiincreases, Cooliair temperature

Set Point = 70°Sensitivity = 5° Cooling On

Increasing Temperature

26

1 Stage Compressorized

ompressorized units the temperature conr the return air temperature increases to 1 systems the hot gas bypass solenoid valvntroller deactivates (stops) cooling when of the control band value.

ntrol band begins at the 70°F (21.1°C) sech is the sensitivity value plus 1°F (.6ºCng is activated at 76°F (24.4ºC) or 100%decreases, Cooling is deactivated at 73°F

70 71 72 73 74 75 76

Decreasing Temperature

Cooling Off

Cooling

troller activates the cooling load00% of the band. One is also energized on a call for the return air temperature

t point and has a length of ). As the return air temperature of the control band. As the return (22.8ºC) or 50% of the control


band. The hysteresis or turn off point in the single compressor system is always equal to50% of the control band. An automatic reset freeze-stat is supplied on all evaporator coils to prevent freezing. If theevaporator temperature falls below 28°F (-2.2°C), the freeze-stat opens, shutting down thecompressor until the evaporator temperature rises to 42°F (5.6°C).

Chilled Water Solenoid Valve Cooling

On 1 to 5 Ton Ccontroller activato 100% of the btemperature dec

Glycool Coolin

The 1 to 5 ton MChilled Glycol Tdetermining syscontrolled by thsensing bulb is mwith the differenin glycool cooli

If the unit contrthe control will above the CGT solenoid valve a

Set Point = 70°Sensitivity = 5° Cooling On


27

Chilled Water Coo

hilled Water units supplied with a Solentes the cooling load device whenever theand. The controller deactivates (stops)

reases to 50% of the control band value.

g

ini-Mate2 units can be supplied with thhermostat (CGT) is supplied on these u

tem operation. Selection of either glycois thermostat that is mounted in the unit

ounted to the unit supply fluid line andtial set at 3°F (1.7°C). For the purpose

ng when the fluid temperature is at 52°F

ol calls for cooling and the CGT stat deteenergize (open) the glycool valve. If thestat set point the unit control will de-enend activate the compressor. Whichever

70 71 72 73 74 75 76


Cooling Off

ling

oid Valve the temperature return air temperature increases

cooling when the return air

e Glycool cooling option. Thenits as the control interface inol or compressorized operation iscontrol section. The remote is factory set at 52°F (11.1°C)of control operation, the system is (11.1°C) or lower.

rmines that glycool is available glycol fluid temperature increasesrgize (close off) the glycoolload device is activated to cool the


space it will work on the same control band calculation as described on the preceding page.The 1 to 5 Ton Mini-Mate2 can only operate only one cooling device at a time.

Glycool Solenoid Valve Cooling

Set Point = 70°Sensitivity = 5° Valve Open


28

Glycool Cooling

70 71 72 73 74 75 76


Valve Closed


COOLING: 8 TON SYSTEMS

The temperature control program for the Mini-Mate2 uses a proportional control band toactivate the stages of cooling. The control is established at the temperature set point withthe length equal to sensitivity plus 1°F (.6ºC) divided by the number of cooling stages.

2 - Stage Compressorized Cooling

The 8 Ton Comrated at 3 tonscooling stage (band and the sare staged on w(compressor #value. The firtemperature de

Note that the c6°F (3.3°C) wincreases Coolair temperaturthe control ban74.5°F (23.6ºCor 25% of the

Set Point = 70°Sensitivity = 5° Cooling 1 On

Cooling 2 On
29

2 Stage Coo

pressorized MiniMate2 unit is suppl and the other rated at 5 tons. The temcompressor #1) when the return air teecond cooling stage (compressor #2) ith hot gas bypass. The controller de

2) when the return air temperature decst cooling stage (compressor #1) is decreases to 25% of the control band va

ontrol band begins at the 70°F (21.1°hich is the sensitivity value plus 1°F (ing 1 is activated at 73°F (22.8ºC) or e continues to increase Cooling 2 willd. As the return air temperature decr) or 75% of the control band and Coo

control band.

70 71 72 73 74 75 76

Cooling 1 Off Cooling 2 Off


ling

ied with two compressors, with oneperature controller activates the firstmperature increases to 50% of theat 100% of the band. The compressorsactivates the second stage of coolingreases to 75% of the control bandactivated when the return airlue.

C) set point and has a length of .6ºC). As the return air temperature50% of the control band, if the return activate at 76°F (24.4ºC) or 100% ofeases, Cooling 2 is deactivated atling 1 is deactivated at 71.5°F (21.9ºC)


Chilled Water Cooling

The 8 Ton Chilled band is establishedrange of the controdetermined by the

Glycool Cooling

The 8 Ton Glycoolband controls the othe compressors. Tglycol fluid tempercapacity is considelower than the retu

The Glycool unit issupply fluid line anof the glycool or cotemperature.

The microprocessoband on top of thiscooling capacity isproportionally. Thshows Glycool ope

Set Point = 70°Sensitivity = 5°

70 71 72 73 74 75 76

Valve50% Open

ValveClosed


30

Chilled Water Cooling

Water MiniMate2 unit uses an actuator valve fo in the same manner as before, except the control band. The time required to drive the valve opeValve Full Travel Time programmed in the “Set

program establishes two control bands for coolperation of the glycool valve and the second conhe microprocessor checks the return air temperaature to determine a capacity. For the purpose ored to be 100% if the entering glycol fluid tempern air temperature.

supplied with a Glycol Sensor (AQ) which is md serves as control interface in determining systmpressorized operation is controlled by this aqu

r makes the first band as in the chilled water me for the compressors as in the normal 2-step con reduced by a rise in the glycol temperature, the is allows the compressor band to move down asration at 100% capacity and the Glycool at 50%

Valve100%

r cooling. The controll is proportional in then or closed is Up Operation” menu.

ing control. The firsttrols the operation ofture and the enteringf control operation, therature is 8°F (4.4°C)

ounted to the unitem operation. Selectionastat sensing the glycol

thod, and the secondtrol method. If thecontrol band shrinks well. The following capacity.


If the microprocessor detethe second band and uses t


70 71 72

ValveClosed

5O


70 71 72

ValveClosed

1O


73 74 75 76 77 78 79 80 81 82

100%Open

0 %pen

Compr#1 On

Compr#2 On

Band 1 Glycool

31

Glycool at 100% C

Glycool at 50% Cap

rmines there is no glycool che compressors for cooling

73 74 75 76 77

00%pen

Compr#1 On

Band 2 Compressors

apacity


78 79 80 81 82

Compr#2 On

Band 1 Glycool
Band 2 Compressors
acity

apacity, it replaces the first band with.


HEATING: 1 to 5 TON SYSTEMS

The temperature control for the Mini-Mate2 uses the control band to activate the heatingdevice. The control band is established at the temperature set point minus the sensitivityminus 1°F (.6°C).

1 Stage Electric or Hot Water Solenoid Valve Heating

On 1 to 5temperatudecreasesair tempe

Note that 6°F (3.3°Cdecreasesair tempeband. Thequal to 5temperatu

Hot Gas

Hot gas rewhen the heating. I


64 65 66 67 68 69 70

Heating On


32

1 Stage Electric or Hot W

Ton units supplied with Electric Reheat or Hre controller activates the heating device whe to 100% of the band. The controller deactivrature increases to 50% of the control band va

the control band begins at the 70°F (21.1°C) ) which is the sensitivity value plus 1°F (.6º

, Heating is activated at 64°F (17.8ºC) or 100rature increases, Heating is deactivated at 67°e hysteresis or turn off point in systems suppl0% of the control band. The electric reheat sre inside the evaporator section of the unit re

Heat

heat is an option on 1 and 1 ½ Ton self contasystem is operating in a call for Dehumidifict is controlled in the same method as is the e


HeatingOff

ater Heating

ot Water Solenoid Valve Reheat thenever the return air temperature

ates (stops) heating when the returnlue.

set point and has a length of C). As the return air temperature% of the control band. As the returnF (19.4ºC) or 50% of the controlied with a single reheat is alwaysafety switch opens if theaches 120°F (49°C).

ined units. It is only activatedation with a simultaneous call forlectric heat, described above.


HEATING: 8 TON SYSTEMS

The temperature control program for the Mini-Mate2 uses a proportional control band toactivate the stages of heating. The control band is established at the temperature set pointminus the sensitivity minus 1°F (.6°C) divided by the number of heating stages.

2 - Stage Electric Heating

The 8 Totemperadecreasecontrolleto 75% otempera

Note tha6°F (3.3decreaseair tempthe contr65.5°F (or 25% o


64 65 66 67 68 69 70


33

2 Stage Heating

n Compressorized MiniMate2 unit is suppliedture controller activates the first heating stage s to 50% of the band and the second heating sr deactivates the second stage of heating whenf the control band value. The first heating sta

ture increases to 25% of the control band value

t the control band begins at the 70°F (21.1°C) °C) which is the sensitivity value plus 1°F (.6ºs Heating 1 is activated at 67°F (19.4ºC) or 50erature continues to decrease Heating 2 will acol band. As the return air temperature increas18.6ºC) or 75% of the control band and Heatinf the control band.


Heat 2 On

Heat 2 Off

Heat 1 On

Heat 1 Off

with two stages of reheat. Thewhen the return air temperaturetage at 100% of the band. The the return air temperature increasesge is deactivated when the return air.

set point and has a length of C). As the return air temperature% of the control band, if the returntivate at 64°F (17.8ºC) or 100% ofes, Heating 2 is deactivated atg 1 is deactivated at 68.5°F (20.3ºC)


34

Hot Water Reheat

On 8 Ton units supplied with Hot Water Solenoid Valve Reheat the temperature controlleractivates the heating device whenever the return air temperature decreases to 100% of theband. The controller deactivates (stops) heating when the return air temperature increasesto 50% of the control band value. This is the same microprocessor control operations asdescribed in the 1 to 5 ton section.

SCR Reheat

The mini-Mate2 can be supplied with an optional SCR (Silicon Controlled Rectifier)Reheat. The SCR controller shall proportionally control the stainless steel electric reheatsto maintain the selected room temperature. During operation of the SCR controller, thecompressor(s) will operate continuously. The reheats are modulated from 100% to 0%over the heating control band, which is established at the temperature set point plus thesensitivity plus 1°F (.6°C). At the temperature set point the reheats are operating at 100%.At the temperature set point plus one half of the sensitivity, the reheats will be on forabout .5 second/ per second. At the temperature set point plus sensitivity plus 1°F (.6°C)the reheats will be off.


Humidity ControlThe Mini-Mate2 control offers the user a choice of either Relative (direct) HumidityControl or Absolute (predictive) Humidity Control. The humidity control is based on thedifference between the humidity set point and the return air humidity condition. In relativehumidity control the system operation is based on the humidity sensor. If absolute controlis selected, the humidity control is automatically adjusted whenever the return air deviatesfrom the desired temperature set point. Relative humidity control is the factory defaultcontrol setting.

This adjustment is called the moisture content band, which set by the temperature set point,humidity set point, and humidity sensitivity. These values provide a band for the programto use as a guide for the on/ off control to meet the humidity demand. Note the followingexample:

Temperature Humidity Humidity Content Level Set Point Set Point Sensitivity Grains/ CU. FT.

75°F 50% +5% 5.2 75°F 50% -5% 4.2

The Moisture (predictive) Humidity Control Flowchart shows what the program is doingand why.

Theimpcon

BAND

Temp Set PointHumidity Set PointHumidity

Moisture Conten

program can be analyzed using theortant to remember that the displaytent. Moisture content (grains) valu

Room TemperatureRoom Humidity

Calculate Band

Calculate Level

t H

M pres

Humidify

Dehumidify

35

umidity Control Flowc

oisture Content Chart supovides the humidity value are used only in the inter

CompareMoisture ContentBand to Leveland MakeDecision

hart

plied on page 140. It is in %RH, not moisturenal control program.


The LCD display will indicate relative humidity percentage for both methods of control. Ifthe absolute method of control is selected, the adjusted humidity reading will be shown.When utilizing the absolute (predictive) humidity control feature, the humidity level isautomatically adjusted ~ 2% RH for each degree difference between the return airtemperature and the temperature set point.

HUMIDITY CONTROL MODESDehumidification Control, Compressorized Systems

The humidity control program for the Mini-Mate2 uses a control band to activate thedehumidification mode of operation. The control band is established at the humidity setpoint with the length equal to the sensitivity.

Dehumidification operation on the 1 to 5 Ton Mini-Mate2 units is accomplished byoperating the system compressor.

On 1 to 5 Ton units thedehumidification whenband. On compressorizcall for dehumidificatiotemperature decreases t

Dehumidification on thcompressors. The end #7 located on the unit incontrol works as previo

Set Point = 50%Sensitivity = 4%

Increasing Humidity

36

1 Stage Compressorized Dehumidif

humidity controller activates the comever the return air humidity level incred systems the hot gas bypass solenon. The controller deactivates (stops) o 50% of the control band value.

e 8 Ton Mini-Mate2 unit is accomplisuser can select either 1 stage or 2 stagterface board. If the user selects 1 st

usly discussed.

50 51 52 53 54 55

Decreasing Humidity

Dehumidification On

Dehumidification Off

ication

pressor to foreases to 100% of the controlid valve is de-energized on acooling when the return air

hed by operating the systeme operation using DIP switchage dehumidification the unit


If the user selects 2 stage dehumidification the compressors are activated as follows. Thecontrol selects the 5 Ton compressor as the lead device and the 3 Ton compressor as thelag device. The dehumidification control band is established at the humidity set point withthe length equal to sensitivity divided by the 2 (number of dehumidification stages).

The humidity cothe return air hu(3 ton compressdehumidificatiocontrol band vawhen the return

Note that as thelevel below tempossible that bosame time durin


DehumidStage 1 On

DehumidStage 2 On
Increasing Humidity
37

2 Stage Compressorized Dehumidific

ntroller activates the first dehumidification stagmidity increases to 50% of the band and the secor) at 100% of the band. The controller deactivn (3 ton compressor) when the return air humidilue. The first dehumidification stage (5 ton com air temperature decreases to 25% of the control

refrigeration system lowers the space humidity perature set point and activate the optional reheath the refrigeration system and optional reheat dg dehumidification.

50 51 52 53 54 55

DehumidStage 1 Off

DehumidStage 2 Off

Decreasing Humidity

ation

e (5 ton compressor whenond dehumidification stageates the second stage ofty decreases to 75% of thepressor) is deactivated band value.

it may cool the room to at device. It is therefore

evice to be operating at the


Dehumidification Control, Chilled Water Systems

Dehumidification operation by Chilled Water units is accomplished by driving the chilledwater valve to open.

Proportional Dehumidification

On Chilled Water units the humidity controller activates the valve for dehumidificationwhenever the return air humidity level increases to 100% of the control band. Thecontroller deactivates (closes) the chilled water valve when the return air humidity to 50%of the control band value.

Humidification Control, All Mini-Mate2 Systems

Humidity control on all Mini-Mate2 systems is accomplished by using a unit mountedoptional Steam Canister Humidifier. The control band is established at the humidity setpoint with the length equal to the sensitivity.

Humidity Set Point = 50%Sensitivity = 4%

46 47 48 49 50


50 51 52 53 54 55

Increasing Humidity

38

Decreasing Humidity

Humidification On

Humidification

Increasing Humidity

Decreasing Humidity

Dehumidification On



39

Humidification

On the Mini-Mate2 units the humidity controller activates the steam canister humidifierwhen the return air humidity level decreases to 100% of the control band. The controllerdeactivates (stops) humidification when the return air humidity increases to 50% of thecontrol band value.

Additional Control ProgramsCompressor Short Cycle Control

This program will watch the compressor activation (turn on) during cooling and preventthe reactivation if within a three minute period from deactivation (turn off). Themicroprocessor will indicate a Short Cycle Alarm for this condition when the cyclesexceed the factory set limit of 10 times in a one hour period.

Sequential Auto Restart Control

This program, when auto restart is selected, allows only one load to be started at a time ona restoration of power to the unit. Each additional load will be activated at a one secondinterval thereafter until the system is at the required operating conditions.

Dehumidification Lockout

Dehumidification is locked out if over cooling occurs during operation. On the 1 to 5 Tonunits it is locked out whenever the return air temperature decreases to the point where125% heating capacity would be required.

On the 8 Ton systems dehumidification is locked out whenever the return air temperaturedecreases to the point where 125% heating capacity for the first stage of dehumidificationand 200% for both stages of dehumidification.

StatusThe operating status sub-menu screen is intended to provide the user with displayedinformation concerning what the control is calling for the system to do. There may be aslight time lapse before the component specified matches the displayed percentage (%)number. As an example, the display indicates a compressor is operating but thecompressor has not yet turned on, it may be off because of the short cycle control. Alsothe display indicates the chilled water valve is 68% open, on a new call for cooling it takesseveral seconds for the valve to travel from full closed to 68% open.

Note that the 8 Ton units will also have a status display for CW Valve % and EconoCool %.


40

Active AlarmsThe Active alarms sub-menu screen is intended to provide the user with displayedinformation concerning any active alarm condition. The alarms are numbered, #1 beingthe most recent. If more than one alarm is activated, use the UP/DOWN ARROW keys toscroll though the list of alarms.

Alarm History Log – 8 Ton units onlyA history of the ten most recent alarms is kept in non-volatile memory complete with thedate and time of its occurrence. The first alarm in the history is the most recent and thetenth is the oldest. If the history log is full (ten alarms) and a new alarm occurs, the oldestis lost and the newest is saved in the alarm history location “1”. The other alarms in thehistory are then moved down the list by one. The alarm history on new units may showalarms as the result of factory testing and start up.

TimeFrom the Main Menu, select TIME. The current time, as previously programmed isdisplayed. This feature allows the time to be read or changed. The clock must be set if theSetback Control Feature is to be used, this feature is enabled/ disabled by a DIP switch andis programmed using the controller.

Note: The clock uses the 24 hour system, for example, 12 midnight is entered as24:00. The controller uses a battery back up to retain the time and date feature.

To change the time shown on the display, press the “ENTER” key to select the “TIME”function on the Main Menu. Once the function has been selected use the UP/ DOWN tochange the first character, then press the enter key to store the value. Repeat these stepsuntil all of the blanks are filled in with the proper time.

Date From the Main Menu, select DATE. The current time, as previously programmed isdisplayed. This feature allows the date to be read or changed. The date must be set if theSetback Control Feature is to be used, this feature is enabled/ disabled by a DIP switch andis programmed using the controller.

To change the date shown on the display, press the “ENTER” key to select the “DATE”function on the Main Menu. Once the function has been selected use the UP/ DOWN tochange the first character, then press the enter key to store the value. Repeat these stepsuntil all of the blanks are filled in with the proper time.


41

Setback Control The microprocessor can be programmed for night and weekend On/ Off or setbackoperation. The setback on/ off feature allows the user to program the unit to shutdown atspecific times during the week or weekend when unit operation is not required. If thesetback feature is used, it allows the user to have different operational control points fortimes of reduced loads. The user can program for two (2) different operating controlranges of temperature and temperature sensitivity, humidity and humidity sensitivity.

Note: The Setback Control function is enabled/ disabled by DIP switch #7, which islocated on the printed circuit board inside the wall mounted control panel. If theSetback Control function is Enabled the LCD display will read ON whenprogramming in setback control values.

The control can be programmed for two (2) events during the five-day work week and two(2) events during the two-day weekend. Thus it is possible to adjust the environmentalcontrol for holidays, week-ends, second and third shift operations, and so forth. If theSetback control feature is disabled, the control set points for temperature and humidityalways remain the same.

Note: The alarm set points are adjusted in the SETPOINTS programming mode andare not affected by the change schedule programming.

The following table can be used as guide to devise the setback schedule.

Event Weekend Week

Setback Time 1Temperature Setpoint 1Temperature Sensitivity 1Humidity Setpoint 1Humidity Sensitivity 1Setback Time 2Temperature Setpoint 2Temperature Sensitivity 2Humidity Setpoint 2Humidity Sensitivity 2

Setback Schedule


42

Setup OperationSelecting Setup Operation from the Main Menu will display the following selections tochose from. Use the UP/ DOWN arrow keys to scroll through the sub-menu, press theENTER key to select the particular function to be viewed or changed.

• Restart Time Delay• C/F Degrees• Humidity Control Method• Lead Compressor (8 Ton only)• DIP Switch position (read only)• Valve Travel Time (actuator valve only)• Chilled Water Valve Flush Time (5 and 8 Ton only)

Restart Time Delay

This feature allows the unit to restart automatically after a loss of main power to the unit.The programmed value is in 0.1 minute (6 second) intervals. A programmed value of zerowould require the user to manually press the ON/ OFF key to start the unit: i.e., no autorestart. The purpose of this feature is to prevent several units from restarting at the sametime after a loss of main power to the units. It is suggested that multiple unit installationsbe programmed with different auto restart time periods.

C/ F Degrees

This microprocessor control can be programmed to show readings and setpoints in eitherdegrees Fahrenheit (F) or Celsius (C). To change the displayed value, use the ENTER keyto select this function from the Setup Operation sub-menu. Use either the UP/ DOWNarrow key to change the value, press the ENTER key to store the change.

Humidity Control Method

The user may select between relative (direct) and absolute (predictive) humidity control. If“relative” is selected, the RH control is taken directly from the RH sensor. If “absolute” isselected, the RH control is automatically adjusted whenever the return air deviates from theprogrammed setpoint (i.e. predictive humidity control).

The LCD display will indicate the percentage (%RH) of relative humidity for bothmethods of control. If the “absolute” humidity control is selected, the adjusted humidityreading will be displayed. When utilizing the absolute (predictive) humidity controlmethod, the humidity control is automatically adjusted approximately 2% for each degreedifference be the return air and the temperature setpoint.

In terms of relative humidity control, unnecessary dehumidification can result whenovercooling occurs during the dehumidification cycle. This is due to a higher than normal


43

RH reading caused by overcooling the room (about 2% RH for each degree of overcooling). This drop in temperature extends the dehumidification cycle. Later, when thedehumidification cycle ends and the temperature rises to the setpoint, the RH reading falls.The final RH reading will be lower than actually desired. If the temperature drop wassignificant enough, the percentage RH could be low enough to activate the humidifier.

If absolute (predictive) humidity control is selected, over-dehumidification may beavoided. When overcooling occurs (i.e., causing an increase in the RH reading) thehumidity control program estimates what the RH will be when the dehumidification cycleends and the temperature returns to the setpoint. This allows the dehumidification cycle toend at the proper time. The predictive humidity control can greatly reduce energyconsumption by minimizing both the compressor and reheat operation and the eliminationof unnecessary humidifier operation.

To change the selected humidity control method, use the ENTER key to select theHumidity Control function from the Setup Operation sub-menu. Use either the UP/DOWN arrow key to select the desired humidity control method, press the ENTER key tostore the change.

Lead Compressor – 8 Ton only

The 8 ton Mini-Mate2 units are supplied with two compressors, one is rated at 3 tons ofcapacity and the second is rated at 5 tons of capacity. The 3 ton compressor is the factoryselected lead compressor. The user can select/ change the lead compressor based on thespace needs.

DIP Switches (Equipment Option Switches)

The Mini-Mate2 system is supplied with two (2) sets of eight (8) DIP switches. One set ofswitches is mounted on the unit control board, located behind the electric access panel, inthe unit suspended in the ceiling. The switch settings and functions, as recognized by themicroprocessor control, can be reviewed at the LCD display panel. A display of “0”means the DIP switch is in the OFF position, a display of “1” means the DIP switch is inthe ON position. The various DIP switches are factory set based on the options providedwith the equipment and should not require any user changes. If the user changes any of theDIP switch positions the microprocessor control must be updated to recognize the changes,this is accomplished by cycling power OFF and ON at the unit disconnect switch.

The second set of DIP switches are located on the circuit board which is located in the wallmounted control panel. This group of DIP switches is not displayed on the LCDcontroller.

Note: The DIP Switch settings and definitions change based on the system tonnage,i.e. the 1 to 5 Ton systems and the 8 Ton systems. Refer to the charts on the nextpage.


44

DIP Switch Setting and Definitions

Switch OFF Position ON Position1 Compressorized Cooling Chill Water Cooling2 Staged Reheat SCR Reheat3 Not Used Not Used4 Not Used Not Used5 Enable Reheat Disable Reheat6 Enable Humidifier Disable Humidifier7 Enable Dehumidifier Disable Dehumidifier8 Electric Reheat Hot Gas Reheat

1 to 5 Ton Unit Interface Board DIP Switch Settings

Switch OFF Position ON Position1 Compressorized Cooling Chill Water Cooling2 Enable Hot Water Heating Enable Stage Heating3 Not Used Not Used4 Enable Glycool Disable Glycool5 Enable Dual Cooling Disable Dual Cooling6 Not Used Not Used7 1 Stage Dehumidification 2 Stage Dehumidification8 Enable SCR Reheat Disable SCR Reheat

8 Ton Unit Interface Board DIP Switch Settings

Switch OFF Position ON Position1 Disable Beeper Enable Beeper2 Not Used Not Used3 Not Used Not Used4 Not Used Not Used5 Not Used Not Used6 Not Used Not Used7 Disable Setback Enable Setback8 Enable Password Disable Password

1 to 8 Ton Wall Mounted Control Panel DIP Switch Settings


45

Valve Travel Time

On systems supplied with the actuator chilled water valve the valve is proportionallyadjusted through its travel range for cooling. This travel time from full closed to full opencan be adjusted by the user in the Setup Operation sub menu. The programmed value canbe adjusted from 50 to 250 seconds. On system startup, when the valve needs to be fullyopened or fully closed, the control will drive the valve for 200% of the programmed valvetravel time to ensure the proper valve position. This operation ensures a new starting pointfor the control. The factory valve travel time is set at 165 seconds.

Chilled Water Flush

This feature will flush the respective coil for three minutes after the programmed numberof hours of non-use has occurred. For example, if the flush time is programmed at 24hours and cooling is not required for a 24 hour period, the chilled water valve will open forthree minutes to allow the coil to be flushed. The programmed value can be from “0” (noflush) to “99” (99 hours of no use). Note 1-3 ton do not use this function.

The following table lists the Setup functions, their factory default values, and the allowablerange of which they can be programmed.

Function Default RangeRestart Time Delay .1 (6 seconds) 0 to 9.9 minutes (0 = manual restart)C/ F Degrees ºF (Fahrenheit) ºC (Celsius) or ºF (Fahrenheit)Humidity Control Relative Relative or AbsoluteLead Compressor 3 Ton Capacity 3 Ton Capacity or 5 Ton CapacityValve Travel Time 165 Seconds 50 to 250 SecondsChilled Water Flush 24 Hours 0 to 99 Hours

Setup Function Default Values and Allowable Ranges

Change PasswordsThe display will prompt the operator to enter a three (3) digit password when attempting tomake changes. The system includes two (2) passwords, one for setpoint programming andone for setup programming. The system allows the password to be changed by firstentering the default password that is set at the factory. The default password is “123” forsetpoints and “321” and for setup. The password function provides system security, so thatonly authorized personnel are allowed to make changes to the system. If unauthorizedchanges are being made, then the passwords may be compromised and new ones should beselected. The password function can be disabled by setting DIP switch #8 in the wallmounted control panel to the OFF position.


46

Calibrate SensorsIf you suspect that the temperature and/or humidity readings are not accurate, you cancalibrate the sensors by adjusting the display to match a customer supplied portablecalibrated test instrument. To ensure best operation and response, calibrate the sensor nearthe center of its calibration range.

Note: When calibrating the Liebert supplied sensors, locate the customer suppliedtest instrument as close to the Liebert sensors as possible to obtain an accuratereading for comparison. Calibrate the sensors only after the unit has maintainedstable operating conditions for at least 15 minutes.

To calibrate the temperature and/ or humidity sensor the user must scroll down the MainMenu and select “CALIBRATE SENSORS”. The temperature sensor calibration range isthe temperature sensor input value +/- 5ºF. The humidity sensor calibration range is thehumidity sensor input +/- 10% RH. When calibrating the humidity sensor, the valueshown will always be %RH, even though absolute humidity control may be selected. Ifabsolute humidity control is selected, the Normal Status Display will display the adjustedreading. This reading may not agree with the relative humidity reading displayed while incalibration.

If the sensors are subject to frequent wide temperature and humidity swings, it may benecessary to shorten the cycling by increasing the sensor time delay. If the sensors arelocated to close to the unit discharge air, they will likely experience rapid swings inmeasurement. Another method that can be used to reduce the compressor cycling is toincrease the temperature and/ or humidity sensitivity values.

SET TEMP CAL Calibrate the temperature sensor ±5°F (±2.8°C)

SET HUM CAL Calibrate the humidity sensor ±10%.

SET TEMP DELAY Set the sensor response delay 10-90 seconds (factoryset at 50 seconds).

SET HUMID DELAY Set the sensor response delay 10-90 seconds (factoryset at 50 seconds).

Alarm EnableEach individual alarm, can be programmed to be ENABLED or DISABLED. If theindividual alarm is ENABLED it will annunciate audibly, visually, and communicate to aLiebert Site Product System. If the alarm is programmed to be DISABLED it will becompletely ignored.


47

To enable/ disable an alarm the operator must select “ALARM ENABLE” on the MainMenu. When the alarm sub-menu appears use the UP/ DOWN arrows to scroll to theindividual alarm to be programmed. When the alarm is selected press the ENTER key toselect either YES (enable) or NO (disable), then press the ESC key to store the change.

The following alarms can be Enabled/ Disabled by the customer:

• Humidifier Problem (8 ton only)• Change Filters (8 ton only)• Loss of Air (8 ton only)• Custom Alarm #1• Custom Alarm #2• Custom Alarm #3 (8 Ton only)• High Temperature• Low Temperature• High Humidity• Low Humidity• Short Cycle #1• Short Cycle #2 (8 ton only)• Main Fan Overload (8 ton only)• Loss of Power

Note: The standard factory installed High Water Alarm and High Head Pressure,can not be disabled. The High Water Alarm and the optional factory installed SmokeDetector Alarm are wired to automatically turn the unit OFF.

Alarm Time DelayEach individual alarm can be programmed with a specific time delay, the adjustment rangeis 0 – 255 seconds in 1 second increments. By programming a time delay period for analarm, the system will delay that specified amount of time before recognizing the alarm.The alarm condition must be present for the amount of time programmed before it will beannunciated, if the alarm is ENABLED. If the alarm condition goes away before the timedelay has timed out, the alarm will not be recognized and the time delay time willautomatically reset. For software alarms such as Loss of Power and Short Cycle, a timedelay will only delay the annunciation of that alarm. The condition of the alarm is notapplicable because the alarm condition has already occurred, the time delay should be leftat the default of 0 seconds. The following shows the factory default time delay set for eachalarm.

To change from the factory set default time delay period the operator must select“ALARM TIME DELAY” from the Main Menu. When the sub-menu appears use the UP/DOWN arrows to scroll to the individual alarm to be programmed. When the alarm is


48

selected press the ENTER key and then use the UP/ DOWN arrow keys to select thedesired time delay period. Then press the enter key again to store the change.

Alarm Default Time Delay(seconds)

Humidifier Problem (8 ton only) 2Change Filter (8 ton only) 2Loss of Air (8 ton only) 3Custom Alarm #1 0Custom Alarm #2 0Custom Alarm #3 (8 ton only) 0High Temperature 30Low Temperature 30High Humidity 30Low Humidity 30Short Cycle #1 0Short Cycle #2 (8 ton only) 0Main Fan Overload (8 ton only) 5Loss of Power 0

Factory Programmed Time Delay Default Values

Common Alarm EnableEach individual alarm can be selected to energize or not energize the unit common alarmrelay. If the energize common alarm function is programmed to YES (enabled), the relayis energized immediately as the alarm is annunciated and is de-energized when the alarmcondition goes away (only after the alarm has been recognized). If the alarm isprogrammed to NO (disabled) the alarm condition will have no effect on the commonalarm relay.

To enable/ disable an alarm the operator must select “COMMON ALARM ENABLE” onthe Main Menu. When the alarm sub-menu appears use the UP/ DOWN arrows to scroll tothe individual alarm to be programmed. When the alarm is selected press the ENTER keyto select YES or NO, then press the enter key again to store the change.


49


• Humidifier Problem• High Head #1• High Head #2 (8 ton only)• Change Filter (8 ton only)• Loss of Air (8 ton only)• Custom Alarm #1• Custom Alarm #2• Custom Alarm #3 (8 Ton only)• High Water• High Temperature• Low Temperature• High Humidity• Low Humidity• Short Cycle #1• Short Cycle #2 (8 ton only)• Main Fan Overload (8 ton only)• Loss of Power

Custom AlarmsThe custom alarm messages can be selected from a list of standard pre-programmedmessages or the operator can write their on messages. A maximum of two (2) Customalarms on the 1 – 5 Ton units, and three (3) Custom Alarms on the 8 Ton unit messagescan be customized. The custom alarms will initially display the previously programmedmessages but can be changed.

The text for the custom alarms can be changed at ant time by selecting “CUSTOMALARMS” on the main menu. To change the text for a custom alarm, select the alarm youwould like to change either alarm #1 or #2. Using the UP/ DOWN Arrow keys stepthrough the list of standard custom alarm messages (listed below) and the two (2) customalarms if previously written by the field service technician. Using the ENTER key selectthe alarm message desired and then press the ENTER key again to store the selection.

• Filter Clog (1 to 5 Ton only)• Humidifier Problem (1 to 5 Ton only)

• Water Flow Loss • Standby unit on• Standby gc pump on

• Loss of Air Flow• Smoke Detected• Custom Text #1• Custom Tex #2• Custom Text #3 (8 Ton only)


50

Custom TextTo modify the two (2) custom alarm messages select “CUSTOM TEXT” on the MainMenu. Using the ENTER key select either “CUS TXT #1” or “CUS TXT #2” to bemodified. The text written into either of the custom alarms can be up to 20 characters inlength and can be either a blank space or any of the following alphanumeric characters andsymbols:

• A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z• #, %,*,-• 0,1,2,3,4,5,6,7,8,9

Use the UP/ DOWN Arrow key to select the desired character, then press the ENTER keyto store. Continue in this method until the message has been written and stored. When thecustom text message has been written and stored the operator must now go to the Customalarm section of the Main Menu and select the message into Custom Alarm #1 or #2.

DiagnosticsBy selecting Run Diagnostics, maintenance personnel can check the various system inputs,outputs, and conduct a test of the micro-controller circuit board, all from the wall mountedcontrol panel. Review of the system inputs and the micro-controller test can be donewithout interrupting normal operation. To test the system outputs, the normal systemcontrol and operations are temporarily suspended. The control system will automaticallyreturn to normal operation in five minutes, if no key is pressed

Test Outputs

When this feature is selected, the unit is effectively turned off. When stepping from oneload device to the next, the previous load if still on, is automatically turned off. The loadscan also be toggled on/ off by pressing the ENTER key. Once turned on, the output willremain on for five minutes unless toggled off by the enter key, or the Test Output functionis exited by pressing the MENU key on the control panel. The compressor test outputfunction is limited to 15 seconds of on time to prevent compressor damage.

CAUTION: Testing the compressor output for more than a few seconds coulddamage to the compressor. To eliminate damaging the compressor during testing,DO NOT test the compressor output for more than a few seconds.

CAUTION: Extended unit operation in the test outputs mode for troubleshootingmay cause damage to the unit. DO NOT leave the unit in the diagnostics mode anylonger than is necessary for troubleshooting.


51

The outputs checked are as follows:

• Normal Fan: normal speed fan contactor• Low Speed Fan: low speed fan contactor• Humidifier: humidifier contactor• Cool: compressor contactor• HGBP: hot gas bypass valve• Reheat: reheat contactor• Common Alarm; common alarm relay

Note: The Fan will turn on with all output load tests.

Test Inputs

With the system on and the fan running, the input state of the following devices may bedisplayed:

• HIGH WATER ALARM: normally off unless the High Water Alarm isactive.

• HIGH HEAD PRESSURE: normally off unless the High Head Pressurealarm is active.

• CUSTOM ALARM #1: normally off unless this special customer selectablealarm is active.


• Power: normally on unless the unit is turned off through the wall mountedcontrol panel, or any of the following optional devices: Fire Stat, SmokeDetector, High Water Alarm. or Remote Shutdown

Test Control Board

By selecting this function, the micro-controller will perform a self test lastingapproximately 10 seconds. When the test is complete, the display will show the ROMchecksum. ROM part number, and the firmware revision number.


52

Chapter 3

Datamate


• Introduction

• Control Panel Layout

• Control Panel Operation Set Points Setback Control Calibrate Sensors Alarm Programming Diagnostics


53

INTRODUCTIONThis section applies to the Datamate units equipped with microprocessor control. Theprogramming of the system control is performed using the wall mounted control panelsupplied with the Datamate. The microprocessor control for the Datamate unit features aneasy to use menu driven LCD display.

The various set points, DIP Switch settings and other selections were made during factorytesting of your unit and are based on typical operating experience. The various defaultselections were made according to the options the factory supplied with your unit. Theparameter ranges of the various programmable points are displayed by pressing the AlarmSilence/ ? (Help) key. A password will be required to modify or change any programmablepoint if the DIP switch is in the password enable position.

Note: Make adjustments to the factory default selections only if they do not meetyour specifications.

With power supplied to the Datamate press the ON/OFF (I/O) key located on the wallmounted control panel. The system will begin monitoring room conditions (temperatureand humidity). The display indicates the current system operations. System operation isautomatically controlled by the micro-controller, based on room conditions and theprogrammed set points

Control Panel LayoutThe figure below is an illustration of the Datamate wall mounted control panel whichmeasures approximately 5" X 3 1/2" x 1 1/4" (127 mm x 89 mm x 31.8mm). The controlpanel consists of a digital readout display and a keypad comprising of eight keys for thevarious programming functions.


54

Datamate Wall Mounted Microprocessor Control Panel


55

Control Panel OperationThe Datamate control panel is used to monitor room conditions, operational status, activealarms, and all programming functions. The panel contains the ON/OFF key and a twoline back-lit LCD display. The LCD display panel includes control keys for ON/OFF,Main Menu, increase arrow, Escape, HI/LO fan speed selection, alarm silence/ help,decrease arrow, and Enter. These keys are similar to the function keys of a computerkeyboard.

The LCD display is back-lit to provide easy viewing by the user, the contrast of the LCDdisplay can be adjusted using potentiometer “RA1” located in the wall mounted controlpanel. The display provides two lines of 20 characters each, allowing alpha and numericsymbols to be displayed. During normal operation the display shows the current operatingstatus and alarms if present. All set points, alarms, and changes to the system controls areinitially entered and modified through this control panel.


Control Keys FunctionON / OFF

(I/O)Turns the unit ON and OFF. OFF means the unit is turnedOFF with the main power applied.

MENU Enables the user to access the programming menu to changethe control parameters, alarms, setback schedule, etc.

INCREASE(UP)

Raises the value of the displayed parameter while in a setmode function (set points, time, etc.).

ESCAPE(ESC) Allows the user to move back to a previous menu display.

FANHIGH/ LOW

Allows the user to change the unit fan speed between highand low speed.

ALARMSILENCE/ HELP (?)

If an alarm is present, pressing this key pad will silence theaudible alarm beeper. If this key pad is pressed when noalarms are present, help text will appear on the displayscreen.

DECREASE(DOWN)

Lowers the value of the displayed parameter while in a setmode function.

ENTERAfter programming a control point, the user must pressENTER to have the information saved in the microprocessormemory.


56

Datamate Menu Flowchart

DatamateControl Menu

Status Display 75 oF 50 %RHNO ALARMS

Menu Setpoints

StatusActive Alarms

TimeDate

SetbackSetup Operation

Setpoint PasswordSetup PasswordCalibrate Sensors

Alarm EnableAlarm Time Delay

Common Alarm EnableCustom Alarms

Custom TextDiagnostics

End of Menu

Setpoints/Setup Temp SetptTemp SensHum SetptHum Sens

Hi Temp AlmLo Temp Alrm

Hi Hum AlmLo Hum Alm

Status Heat % 0Dx Cool % 0Dehumidify% 0Humidify% 0

Active Alarms No Alarms

orAlarm 01 of 01

High Head

Time Time HH:MM:SS

Date Date DD DDMMMYY

Setback Wknd Time 1





Setup Operation Restart TD


Dipswch 00000000Pos 12345678

Valve TimeCW Flush

Setpoint Password Enter New PSWSetpt PSW = 000

Setup Password Enter New PSW

Setup PSW = 000

Alarm Enable Custom #1Custom #2High TempLow TempHigh HumLow Hum

Short CycleLoss Pwr

Calibrate sensors Temp CalHum Cal

Temp DelayHum Delay

Alarm Time Delay Custom #1Custom #2High TempLow TempHigh HumLow HumShort CycLoss Pwr

Common Alarm Enable Hi WaterHi Head

Custom #1Custom #2High TempLow TempHigh HumLow HumShort CycLoss Pwr

Custom Alarms Custom Alarm #1Custom Alarm #2

Custom Text Custom Text #1Custom Text #2

Diagnostics Test Inputs

Test OutputsTest Microcontroller


57

Status DisplayThe display normally includes the present room temperature and humidity conditions alongwith any active alarms. The status display may also be selected from the Main Menu.

Main Menu <Menu> Press the MENU key to display the Main Menu. The menu selections include thefollowing choices in the order shown.

• Set Points• Status• Active Alarms• Alarm History Log, 8 ton only• Time• Date• Setback• Setup Operation• Set Point Password• Setup Password• Calibrate Sensors• Alarm Enable• Alarm Time Delay• Common Alarm Enable• Custom Alarms• Custom Text• Diagnostics• End of Menu

Use the UP or DOWN arrow keys to scroll the various selections, then when ready toselect a particular function press the “Enter” key.


Set PointsThe various Set points and system setup parameters are kept in non-volatile memory.Selecting set points from the main menu will display the following selections.

• Temperature Setpoint• Temperature Sensitivity• Humidity Setpoint• Humidity Sensitivity• High Temperature Alarm• Low Temperature Alarm• High Humidity Alarm• Low Humidity alarm

Scroll through this sub-menu by using the UP or DOWN arrow keys, then press theENTER key to select the particular function to be viewed. To change a particular value,press the ENTER key and use the UP (increase) or DOWN (decrease) ARROW keys tochange the displayed value. When the selected function has been changed to the desiredvalue press the ENTER key to store the value. As an example, to change the temperatureset point from th rform the following steps:

1. Press the M2. Scroll to the

press the EN3. Scroll to the

then press th4. Use the UP

value to the

SetpoinTempeTempeHumidHumidHigh TLow TeHigh HLow H

e main status display pe

58

ENU key to display the main menu. “SETPOINTS” function using the UP or DOWN ARROW keys, thenTER key. “TEMP SETPOINT” function using the UP or DOWN ARROW keys,e ENTER key.

(increase) or DOWN (decrease) ARROWnew setpoint, then press key

t Defaultrature Setpoint 72ºF (22.2ºC)rature Sensitivity 2ºF (1.1ºC)ity Setpoint 50%ity Sensitivity 5%emperature Alarm 80ºF (26.7ºC)mperature Alarm 65ºF (18.3ºC)umidity Alarm 60%umidity Alarm 40

Default and Setpoint Allowab

key the change the displayed.
the ENTER
Range40 - 90ºF (5 - 32ºC)1 – 9.9ºF (0.6 – 5.6ºC)20 – 80%1 – 30%35 – 95ºF (2 - 35ºC)35 - 95ºF (2 - 35ºC)15 – 85%15 – 85%

le Ranges


If no set points are entered into the system, the micro-controller will operate on the systemdefault set points. If the Schedule Program mode is not selected and is completely de-programmed , the control set points will remain as entered in the set pointsprogramming mode. Note that programmed set points are stored in non-volatile memoryand are retained during a power failure. No battery is required.

Temperature ControlCOOLING:

The temperature control program for the Datamate uses a control band to activate thecooling device. The control is established at the temperature set point with the lengthequal to sensitiv

1 Stage Compr

On compressoriwhenever the resystems the hot controller deactthe control band

Note that the co6°F (3.3°C) whiincreases, Cooliair temperature

Set PoSensiti

ity plus 1°F (.6ºC).

59

essorized Cooling

1 Stage Compressorized C

zed units the temperature controller activturn air temperature increases to 100% ogas bypass solenoid valve is also energizivates (stops) cooling when the return air value.

ntrol band begins at the 70°F (21.1°C) sech is the sensitivity value plus 1°F (.6ºCng is activated at 76°F (24.4ºC) or 100%decreases, Cooling is deactivated at 73°F

int = 70°vity = 5°

70 71 72 73 74


Cooling Off

Cooling On

ooling

ates the cooling load devicef the band. On compressorizeded on a call for cooling. The temperature decreases to 50% of

t point and has a length of ). As the return air temperature of the control band. As the return (22.8ºC) or 50% of the control

75 76



band. The hysteresis or turn off point in the single compressor system is always equal to50% of the control band. An automatic reset freeze-stat is supplied on all evaporator coils to prevent freezing. If theevaporator temperature falls below 28°F (-2.2°C), the freeze-stat opens, shutting down thecompressor until the evaporator temperature rises to 42°F (5.6°C).

Chilled Water Solenoid Valve Cooling

On 1 to 5controllerto 100% otemperatu


70 71 72 73 74 75 76



Cooling On

60

Chilled Water Cool

Ton Chilled Water units supplied with a Sole activates the cooling load device whenever tf the band. The controller deactivates (stopsre decreases to 50% of the control band valu

Cooling Off

ing

noid Valve the temperaturehe return air temperature increases) cooling when the return aire.


HEATING:

The temperature control for the Datamate uses the control band to activate the heatingdevice. The control band is established at the temperature set point minus the sensitivityminus 1°F (.6°C).

1 Stage Electric

1 Stag ting

On lectric Reheat the temperature controller adevdeaban

Not6°Fdecair tbanequtem


64 65 66 67 68 69 70



Heating On

HeatingOff

units supplied with E
ice whenever the return air temperactivates (stops) heating when the red value.
e that the control band begins at the (3.3°C) which is the sensitivity valreases, Heating is activated at 64°Femperature increases, Heating is ded. The hysteresis or turn off point ial to 50% of the control band. Theperature inside the evaporator secti

e Electric Hea

ture decreases to 100% of th llerure increase trol
turn air temperat
7 C) set point and has a length of ue (1an eleon

0°F (21.1°
plus 1°F (.6ºC). As the return air temperature7.8ºC) or 100% of the control band. As the return
7°F (19.4ºC) or 50% of the controlplied with a single reheat is always

ctivated at 6 systems sup

61

ctric reheat safety switch of the unit reaches 120°F

ctivates the heatinge band. The contros to 50% of the con

opens if the (49°C).


Humidity ControlThe Datamate control offers the user a choice of either Relative (direct) Humidity Controlor Absolute (predictive) Humidity Control. The humidity control is based on thedifference between the humidity set point and the return air humidity condition. In relativehumidity control the system operation is based on the humidity sensor. If absolute controlis selected, the humidity control is automatically adjusted whenever the return air deviatesfrom the desired temperature set point. Relative humidity control is the factory defaultcontrol setting.

This adjustment is called the moisture content band, which set by the temperature set point,humidity set point, and humidity sensitivity. These values provide a band for the programto use as a guide for the on/ off control to meet the humidity demand. Note the followingexample:

Temperature Humidity Humidity Content Level Set Point Set Point Sensitivity Grains/ CU. FT.

75°F 50% +5% 75°F 4.2

The Moisture (predictivand why.

M

The program can be animportant to remember content. Moisture cont

BAND

Temp Set PointHumidity Set PoinHumidity

Room TemperatureRoom Humidity

50% -5%

62

e) Humidity Control Flowchart shows what the program is doing

oisture Content Humidity Control F

alyzed using the Moisture Content Chthat the display provides the humidityent (grains) values are used only in th

t

Calculate Level

Humidify

Dehumidify

5.2

Compare
Calculate Band
lowchart

art supplied on page 140. It is value in %RH, not moisture

e internal control program.

Moisture ContentBand to Leveland MakeDecision


The LCD display will indicate relative humidity percentage for both methods of control. Ifthe absolute method of control is selected, the adjusted humidity reading will be shown.When utilizing the absolute (predictive) humidity control feature, the humidity level isautomatically adjusted ~ 2% RH for each degree difference between the return airtemperature and the temperature set point.

HUMIDITY CONTROL MODES

Dehumidification Con

The humidity control program for the Datamate uses a control band to activate thedehumidification mode of operation. The control band is established at the humidity setpoint with the length equal to the sensitivity.

Dehumidification operation on the Datamate units is accompli systemcompressor.

Compressorized Dehumidification

On Datamate units the humidity controller activates the compressor to for dehumidificationwhenever the return air humidity level increases to 100% of tcompressorized systems the hot gas bypass solenoid valve is de-energized on a call fordehumidification. The controller deactivates (stops) cooling when the return airtemperature decreases to 50% of the control band value.


50 51 52 53 54 55

Increasing Humidity

Decreasing Humidity

Dehumidification On


63

he control band. On

trol:

shed by operating the


64

Dehumidification Control, Chilled Water Systems

Dehumidification operation by Chilled Water units is accomplished by driving the chilledwater valve to open.

Proportional Dehumidification

On Chilled Water units the humidity controller activates the valve for dehumidificationwhenever the return air humidity level increases to 100% of the control band. Thecontroller deactivates (closes) the chilled water valve when the return air humidity to 50%of the control band value.

Humidification Control:

Humidity control on all Datamate systems is accomplished by using a unit mounted SteamCanister Humidifier. The control band is established at the humidity set point with thelength equal to the sensitivity.

Humidification

Humidity Set Point = 50%Sensitivity = 4%

46 47 48 49 50

Increasing Humidity

Decreasing Humidity

Humidification On

Humidification


50 51 52 53 54 55

Increasing Humidity

Decreasing Humidity

Dehumidification On



65

On the Datamate unit the humidity controller activates the steam canister humidifier whenthe return air humidity level decreases to 100% of the control band. The controllerdeactivates (stops) humidification when the return air humidity increases to 50% of thecontrol band value.

Additional Control ProgramsCompressor Short Cycle ControlThis program will watch the compressor activation (turn on) during cooling and preventthe reactivation if within a three minute period from deactivation (turn off). Themicroprocessor will indicate a Short Cycle Alarm for this condition when the cyclesexceed the factory set limit of 10 times in a one hour period.

Sequential Auto Restart ControlThis program, when auto restart is selected, allows only one load to be started at a time ona restoration of power to the unit. Each additional load will be activated at a one secondinterval thereafter until the system is at the required operating conditions.

Dehumidification LockoutDehumidification is locked out if over cooling occurs during operation. On Datamateunits’ dehumidification is locked out whenever the return air temperature decreases to thepoint where 125% heating capacity would be required.

StatusThe operating status sub-menu screen is intended to provide the user with displayedinformation concerning what the control is calling for the system to do. There may be aslight time lapse before the component specified matches the displayed percentage (%)number. As an example, the display indicates a compressor is operating but thecompressor has not yet turned on, it may be off because of the short cycle control

Active AlarmsThe Active alarms sub-menu screen is intended to provide the user with displayedinformation concerning any active alarm condition. The alarms are numbered, #1 beingthe most recent. If more than one alarm is activated, use the UP/DOWN ARROW keys toscroll though the list of alarms.


66

TimeFrom the Main Menu, select TIME. The current time, as previously programmed isdisplayed. This feature allows the time to be read or changed. The clock must be set if theSetback Control Feature is to be used, this feature is enabled/ disabled by a DIP switch andis programmed using the controller.

Note: The clock uses the 24 hour system, for example, 12 midnight is entered as24:00. The controller uses a battery back up to retain the time and date feature.

To change the time shown on the display, press the “ENTER” key to select the “TIME”function on the Main Menu. Once the function has been selected use the UP/ DOWN tochange the first character, then press the enter key to store the value. Repeat these stepsuntil all of the blanks are filled in with the proper time.

Date From the Main Menu, select DATE. The current time, as previously programmed isdisplayed. This feature allows the date to be read or changed. The date must be set if theSetback Control Feature is to be used, this feature is enabled/ disabled by a DIP switch andis programmed using the controller.

To change the date shown on the display, press the “ENTER” key to select the “DATE”function on the Main Menu. Once the function has been selected use the UP/ DOWN tochange the first character, then press the enter key to store the value. Repeat these stepsuntil all of the blanks are filled in with the proper time.

Setback Control The microprocessor can be programmed for night and weekend On/ Off or setbackoperation. The setback on/ off feature allows the user to program the unit to shutdown atspecific times during the week or weekend when unit operation is not required. If thesetback feature is used, it allows the user to have different operational control points fortimes of reduced loads. The user can program for two (2) different operating controlranges of temperature and temperature sensitivity, humidity and humidity sensitivity.

Note: The Setback Control function is enabled/ disabled by DIP switch #7, which islocated on the printed circuit board inside the wall mounted control panel. If theSetback Control function is Enabled the LCD display will read ON whenprogramming in setback control values.


67

The control can be programmed for two (2) events during the five-day work week and two(2) events during the two-day weekend. Thus it is possible to adjust the environmentalcontrol for holidays, week-ends, second and third shift operations, and so forth. If theSetback control feature is disabled, the control set points for temperature and humidityalways remain the same.

Note: The alarm set points are adjusted in the SETPOINTS programming mode andare not affected by the change schedule programming.

The following table can be used as guide to devise the setback schedule.

Event Weekend 1 Weekend 2 Weekday 1 Weekday 2ON/OFFTime 1Temp 1

Temp Sensitivity 1Humid 1

Humid Sensitivity 1Time 2Temp 2

Temp Sensitivity 2Humid 2

Humid Sensitivity 2

Setback Schedule


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Setup OperationSelecting Setup Operation from the Main Menu will display the following selections tochose from. Use the UP/ DOWN arrow keys to scroll through the sub-menu, press theENTER key to select the particular function to be viewed or changed.

• Restart Time Delay• C/F Degrees• Humidity Control Method)• DIP Switch position (read only)

Restart Time Delay

This feature allows the unit to restart automatically after a loss of main power to the unit.The programmed value is in 0.1 minute (6 second) intervals. A programmed value of zerowould require the user to manually press the ON/ OFF key to start the unit: i.e., no autorestart. The purpose of this feature is to prevent several units from restarting at the sametime after a loss of main power to the units. It is suggested that multiple unit installationsbe programmed with different auto restart time periods.

C/ F Degrees

This microprocessor control can be programmed to show readings and setpoints in eitherdegrees Fahrenheit (F) or Celsius (C). To change the displayed value, use the ENTER keyto select this function from the Setup Operation sub-menu. Use either the UP/ DOWNarrow key to change the value, press the ENTER key to store the change.

Humidity Control Method

The user may select between relative (direct) and absolute (predictive) humidity control. If“relative” is selected, the RH control is taken directly from the RH sensor. If “absolute” isselected, the RH control is automatically adjusted whenever the return air deviates from theprogrammed setpoint (i.e. predictive humidity control).

The LCD display will indicate the percentage (%RH) of relative humidity for bothmethods of control. If the “absolute” humidity control is selected, the adjusted humidityreading will be displayed. When utilizing the absolute (predictive) humidity controlmethod, the humidity control is automatically adjusted approximately 2% for each degreedifference be the return air and the temperature setpoint.

In terms of relative humidity control, unnecessary dehumidification can result whenovercooling occurs during the dehumidification cycle. This is due to a higher than normalRH reading caused by overcooling the room (about 2% RH for each degree of overcooling). This drop in temperature extends the dehumidification cycle. Later, when thedehumidification cycle ends and the temperature rises to the setpoint, the RH reading falls.


69

The final RH reading will be lower than actually desired. If the temperature drop wassignificant enough, the percentage RH could be low enough to activate the humidifier.

If absolute (predictive) humidity control is selected, over-dehumidification may beavoided. When overcooling occurs (i.e., causing an increase in the RH reading) thehumidity control program estimates what the RH will be when the dehumidification cycleends and the temperature returns to the setpoint. This allows the dehumidification cycle toend at the proper time. The predictive humidity control can greatly reduce energyconsumption by minimizing both the compressor and reheat operation and the eliminationof unnecessary humidifier operation.

To change the selected humidity control method, use the ENTER key to select theHumidity Control function from the Setup Operation sub-menu. Use either the UP/DOWN arrow key to select the desired humidity control method, press the ENTER key tostore the change.

DIP Switches (Equipment Option Switches)

The Datamate system is supplied with two (2) sets of eight (8) DIP switches. One set ofswitches is mounted on the unit control board, located behind the electric access panel, inthe upper right hand corner of the unit. The switch settings and functions, as recognizedby the microprocessor control, can be reviewed at the LCD display panel. A display of “0”means the DIP switch is in the OFF position, a display of “1” means the DIP switch is inthe ON position. The various DIP switches are factory set based on the options providedwith the equipment and should not require any user changes. If the user changes any of theDIP switch positions the microprocessor control must be updated to recognize the changes,this is accomplished by cycling power OFF and ON at the unit disconnect switch.

The second set of DIP switches are located on the circuit board located in the wall mountedcontrol panel. This group of DIP switches is not displayed on the LCD controller.


70

DIP Switch Setting and Definitions

Switch OFF Position ON Position1 Compressorized Cooling Chill Water Cooling2 Staged Reheat N/A3 Not Used Not Used4 Not Used Not Used5 Enable Reheat Disable Reheat6 Enable Humidifier Disable Humidifier7 Enable Dehumidifier Disable Dehumidifier8 Electric Reheat N/A

Datamate Unit Interface Board DIP Switch Settings

Switch OFF Position ON Position1 Disable Beeper Enable Beeper2 Not Used Not Used3 Not Used Not Used4 Not Used Not Used5 Not Used Not Used6 Not Used Not Used7 Disable Setback Enable Setback8 Enable Password Disable Password

Wall Mounted Control Panel DIP Switch Settings

The following table lists the Setup functions, their factory default values, and the allowablerange of which they can be programmed.

Function Default RangeRestart Time Delay .1 (6 seconds) 0 to 9.9 minutes (0 = manual restart)C/ F Degrees ºF (Fahrenheit) ºC (Celsius) or ºF (Fahrenheit)Humidity Control Relative Relative or Absolute

Setup Function Default Values and Allowable Ranges


71

Change PasswordsThe display will prompt the operator to enter a three (3) digit password when attempting tomake changes. The system includes two (2) passwords, one for setpoint programming andone for setup programming. The system allows the password to be changed by firstentering the default password that is set at the factory. The default password is “123” forsetpoints and “321” and for setup. The password function provides system security, so thatonly authorized personnel are allowed to make changes to the system. If unauthorizedchanges are being made, then the passwords may be compromised and new ones should beselected. The password function can be disabled by setting DIP switch #8 in the wallmounted control panel to the OFF position.

Calibrate SensorsIf you suspect that the temperature and/or humidity readings are not accurate, you cancalibrate the sensors by adjusting the display to match a customer supplied portablecalibrated test instrument. To ensure best operation and response, calibrate the sensor nearthe center of its calibration range.


To calibrate the temperature and/ or humidity sensor the user must scroll down the MainMenu and select “CALIBRATE SENSORS”. The temperature sensor calibration range isthe temperature sensor input value +/- 5ºF. The humidity sensor calibration range is thehumidity sensor input +/- 10% RH. When calibrating the humidity sensor, the valueshown will always be %RH, even though absolute humidity control may be selected. Ifabsolute humidity control is selected, the Normal Status Display will display the adjustedreading. This reading may not agree with the relative humidity reading displayed while incalibration.

If the sensors are subject to frequent wide temperature and humidity swings, it may benecessary to shorten the cycling by increasing the sensor time delay. If the sensors arelocated to close to the unit discharge air, they will likely experience rapid swings inmeasurement. Another method that can be used to reduce the compressor cycling is toincrease the temperature and/ or humidity sensitivity values.

SET TEMP CAL Calibrate the temperature sensor ±5°F (±2.8°C)

SET HUM CAL Calibrate the humidity sensor ±10%.

SET TEMP DELAY Set the sensor response delay 10-90 seconds (factoryset at 50 seconds).


72

SET HUMID DELAY Set the sensor response delay 10-90 seconds (factoryset at 50 seconds).

Alarm EnableEach individual alarm, can be programmed to be ENABLED or DISABLED. If theindividual alarm is ENABLED it will annunciate audibly, visually, and communicate to aLiebert Site Product System. If the alarm is programmed to be DISABLED it will becompletely ignored.

To enable/ disable an alarm the operator must select “ALARM ENABLE” on the MainMenu. When the alarm sub-menu appears use the UP/ DOWN arrows to scroll to theindividual alarm to be programmed. When the alarm is selected press the ENTER key toselect either YES (enable) or NO (disable), then press the ESC key to store the change.


• Humidifier Problem• Custom Alarm #1• Custom Alarm #2• High Temperature• Low Temperature• High Humidity• Low Humidity• Short Cycle #1• Loss of Power

Note: The standard factory installed High Water Alarm and High Head Pressure,can not be disabled. The High Water Alarm is wired to automatically turn the unitOFF.

Alarm Time DelayEach individual alarm can be programmed with a specific time delay, the adjustment rangeis 0 – 255 seconds in 1 second increments. By programming a time delay period for analarm, the system will delay that specified amount of time before recognizing the alarm.The alarm condition must be present for the amount of time programmed before it will beannunciated, if the alarm is ENABLED. If the alarm condition goes away before the timedelay has timed out, the alarm will not be recognized and the time delay time willautomatically reset. For software alarms such as Loss of Power and Short Cycle, a timedelay will only delay the annunciation of that alarm. The condition of the alarm is notapplicable because the alarm condition has already occurred, the time delay should be leftat the default of 0 seconds. The following chart shows the factory default time delay setfor each alarm.


73

To change from the factory set default time delay period the operator must select“ALARM TIME DELAY” from the Main Menu. When the sub-menu appears use the UP/DOWN arrows to scroll to the individual alarm to be programmed. When the alarm isselected press the ENTER key and then use the UP/ DOWN arrow keys to select thedesired time delay period. Then press the enter key again to store the change.

Alarm Default Time Delay(seconds)

Custom Alarm #1 0Custom Alarm #2 0High Temperature 30Low Temperature 30High Humidity 30Low Humidity 30Short Cycle #1 0Loss of Power 0Humidifier Problem 2High Head Pressure 2

Factory Programmed Time Delay Default Values

Common Alarm EnableEach individual alarm can be selected to energize or not energize the unit common alarmrelay. If the energize common alarm function is programmed to YES (enabled), the relayis energized immediately as the alarm is annunciated and is de-energized when the alarmcondition goes away (only after the alarm has been recognized). If the alarm isprogrammed to NO (disabled) the alarm condition will have no effect on the commonalarm relay.

To enable/ disable an alarm the operator must select “COMMON ALARM ENABLE” onthe Main Menu. When the alarm sub-menu appears use the UP/ DOWN arrows to scroll tothe individual alarm to be programmed. When the alarm is selected press the ENTER keyto select YES or NO, then press the enter key again to store the change.


74

The following common alarms can be Enabled/ Disabled by the customer:

• Humidifier Problem• High Head Pressure• Custom #1 • Custom #2 • High Temperature• Low Temperature• High Humidity• Low Humidity• Short Cycle • Loss Of Power

Custom AlarmsThe custom alarm messages can be selected from a list of standard pre-programmedmessages or the operator can write their on messages. A maximum of two (2) Customalarms massages can be customized. The custom alarms will initially display thepreviously programmed messages but can be changed.

The text for the custom alarms can be changed at ant time by selecting “CUSTOMALARMS” on the main menu. To change the text for a custom alarm, select the alarm youwould like to change either alarm #1 or #2. Using the UP/ DOWN Arrow keys stepthrough the list of standard custom alarm messages (listed below) and the two (2) customalarms if previously written by the field service technician. Using the ENTER key selectthe alarm message desired and then press the ENTER key again to store the selection. Thepre-programmed

• Smoke Detected• Water Flow Loss• Loss Of Air Flow • Filter Clog


75

Custom TextTo modify the two (2) custom alarm messages select “CUSTOM TEXT” on the MainMenu. Using the ENTER key select either “CUS TXT #1” or “CUS TXT #2” to bemodified. The text written into either of the custom alarms can be up to 20 characters inlength and can be either a blank space or any of the following alphanumeric characters andsymbols:

• A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z• #, %,*,-• 0,1,2,3,4,5,6,7,8,9

Use the UP/ DOWN Arrow key to select the desired character, then press the ENTER keyto store. Continue in this method until the message has been written and stored. When thecustom text message has been written and stored the operator must now go to the Customalarm section of the Main Menu and select the message into Custom Alarm #1 or #2.

DiagnosticsBy selecting Run Diagnostics, maintenance personnel can check the various system inputs,outputs, and conduct a test of the micro-controller circuit board, all from the wall mountedcontrol panel. Review of the system inputs and the micro-controller test can be donewithout interrupting normal operation. To test the system outputs, the normal systemcontrol and operations are temporarily suspended. The control system will automaticallyreturn to normal operation in five minutes, if no key is pressed

Test Outputs

When this feature is selected, the unit is effectively turned off. When stepping from oneload device to the next, the previous load if still on, is automatically turned off. The loadscan also be toggled on/ off by pressing the ENTER key. Once turned on, the output willremain on for five minutes unless toggled off by the enter key, or the Test Output functionis exited by pressing the MENU key on the control panel. The compressor test outputfunction is limited to 15 seconds of on time to prevent compressor damage.

CAUTION: Testing the compressor output for more than a few seconds coulddamage to the compressor. To eliminate damaging the compressor during testing,DO NOT test the compressor output for more than a few seconds.

CAUTION: Extended unit operation in the test outputs mode for troubleshootingmay cause damage to the unit. DO NOT leave the unit in the diagnostics mode anylonger than is necessary for troubleshooting.


76

The outputs checked are as follows:

• Normal Fan: normal speed fan contactor• Low Speed Fan: low speed fan contactor• Humidifier: humidifier contactor• Cool: compressor contactor• Chill Water (if present)• Reheat: reheat contactor• Common Alarm; common alarm relay

Note: The Fan will turn on with all output load tests.

Test Inputs

With the system on and the fan running, the input state of the following devices may bedisplayed:

• HIGH WATER ALARM: normally off unless the High Water Alarm isactive.

• HIGH HEAD PRESSURE: normally off unless the High Head Pressurealarm is active.



• Power: normally on unless the unit is turned off through the wall mountedcontrol panel, or any of the following optional devices: Fire Stat, SmokeDetector, High Water Alarm. or Remote Shutdown

Test Control Board

By selecting this function, the micro-controller will perform a self test lastingapproximately 10 seconds. When the test is complete, the display will show the ROMchecksum. ROM part number, and the firmware revision number.


77

Chapter 4

Microprocessor Controlmini-Mate, mini-Mate Plus,

Datamate - 1994 to the Present

• Introduction

• Control Panel Descriptions

• Operating Procedures Set Points Control Set Point Change Schedule Sensor Calibration Fan Speed DIP Switches


78

INTRODUCTIONThis section applies to mini-MATE, mini-MATE Plus , and Datamate units equipped withmicroprocessor controls. The programming of each systems microprocessor control isperformed using either the wall mounted control panel supplied with the mini-MATE andmini-MATE Plus or the unit mounted control panel supplied with the Datamate.

With power supplied to the mini-MATE or mini-MATE Plus unit, press the ON/OFF keylocated on the wall mounted control panel. With power supplied to the Datamate unitpress the ON/ OFF key located on the unit mounted control panel. The system will beginmonitoring room conditions (temperature and humidity). The display indicates the currentsystem operation. System operation is automatically controlled by the micro-controller,based on room conditions and the programmed set points.

DISPLAY SCREEN

Once the system has been started the display screen provides the following information:

During Normal Mode - The control panel will display either ON or the present day andtime. The clock is only displayed if the Scheduled Program mode is enabled (selected byDIP switch #4). The control panel will also display the system operating status: cool, heat,dehumidify, humidify, and low fan speed (manual override selected). The control panelwill also display the system alarms if active: high/ low temperature and high/ lowhumidity.

During Set (adjustment) modes - In any of the set modes (CLOCK, PROGRAM, or SETPOINTS), the value that can be modified with the INCREASE/ DECREASE keypads willflash (blink).

The end user can exit any set mode function by pressing the ON/ OFF keypad, this willreturn the display to the normal mode of operation. If no keypad is depressed for 20seconds the display will automatically return to the normal mode of operation.

The screen will display the temperature/ humidity set points and the alarm set pointswhenever the SET POINTS keypad is depressed.

Whenever the PROGRAM key pad is depressed for 3 seconds the screen displays the timesand control set points for the 2-day/ 5-day automatically Scheduled Program. If theScheduled Program mode is used, the day and time can be set when the CLOCK keypad isdepressed.

During OFF mode - The display screen indicated OFF when the unit is turned off at thecontrol panel, but the power is still supplied to the controls and equipment through thedisconnect switch.


79

CONTROL PANEL DESCRIPTIONSThe two figures below illustrate the mini-MATE and mini-MATE Plus wall mountedcontrol panel and the Datamate unit mounted control panel.

The mini-MATE and mini-MATE Plus wall mounted control panel measuresapproximately 5” x 3 ½” x 1 ¼” (127 mm x 89 x 31.8 mm) and consists of a digital readoutdisplay and a keypad comprising of eight keys for the various programming functions.These keys are similar to the function keys of a keyboard.

mini-MATE and mini-MATE Plus Microprocessor Control Panel


80

Datamate Microprocessor Control Panel

During normal operation the display shows the current day and time, operating status andalarms. The [SILENCE] key shows the current temperature and humidity. Set points,alarms, and the set point change schedule are initially entered and modified from thecontrol box.


81


Control Keys FunctionSET POINTS Selects and/ or allows adjustment of the operating

control set points and alarm set points

Temperature/humidity SILENCE

Initiates a 10 second display of the present roomtemperature and humidity conditions. During an alarmcondition, this key silences the audible alarm and allowsthe alarm to reset when the alarm condition is cleared

PROGRAM Press and hold this key for 3 seconds to allow for reviewand programming of the automatic Schedule Program.Note that this function must be enabled by DIP Switch#4 (located inside the wall mounted control panel) ifrequired for this unit.

CLOCK Sets the present day and clock time (required at start-upand after a power failure) if the Scheduled Programmode is enabled. Also allows access to the extended setpoint adjustment mode (sensor calibration).

INCREASE Raises the value of the displayed parameter while in aset mode function (set points, program, and clock).

DECREASE Lowers the value of the displayed parameter while in aset mode function (set points, program, and clock).

FANHIGH/ LOW

Selects the fan speed control mode, either automatic fanspeed selection (high speed when required), or manualoverride so that low fan speed only is used.

ON / OFF Turns the unit ON and OFF, or returns the display tonormal mode from one of the set (adjustment) modes.Determine the present mode by reading the displayscreen. OFF means the unit is OFF with power applied.The present day and time means the unit is ON and thedisplay is in the normal mode. A flashing or blinkingnumber means the control is in a set mode function.The time and date is only displayed if the ScheduledProgram mode is enabled.


OPERATING PROCEDURESCLOCK SETTING

If the Scheduled Program mode is used, the clock must be set to the present day and timefor a new installation and also when recovering from a power outage. Pressing theCLOCK keypad will display the day of the week and time, the day can now be set. Pressthe CLO nce through the steps required to set the hours and minutes,and agai

SET PO

If no setdefault sprogrammode. Nduring a

Press [Svalue whvalue ofnext parpoints ha

Note: Tdisabledthe valufunction

RANGE

Liebert eheating cstep-typof the soControl

TT

CK keypad to seque
n to return the display to the normal mode.
INTS

pointset poimed , ote th

powe

ET POen dis

the paameteve be

he Co by ade disp is no

of C

nviroapabi

e operftwareare as

empeempe

82

are entered into the system, the micro-controller will operate on the systemnts. If the Schedule Program mode is not selected and is completely de-the control set points will remain as entered in the set points programmingat programmed set points are stored in non-volatile memory and are retainedr failure. No battery is required.

INTS] to display arameter (splayed is blinking REASE] orameter being programmed. Press [SET P

r to be programmed. Continue with this pren programmed.

oling, Heating, Dehumidification, and Hjusting the value out of range. If the se

layed is a set of dashes. If a set point is t available on this unit or a DIP switch

ONTROL SET POINTS

nmental control units are offered with sevlity. This allows the unit to be tailored to ations, that is ON/ OFF Control. The Con design. The standard operating limits offollows:

rature Set Point (Set High/ Low Temp)rature Measurement Range

et point) and associated value, ther [DECREASE] to change the

the system p. Press [INC

OINTS] again to advance to theocedure until all of the control

umidification functions can bet point is adjusted out of range,

not displayed, the controlis not properly set.

eral variations of cooling andindividual needs. The control usestrol Range is the operating limits the LIEBERT Temperature

40°F - 85°F (4°C - 29.4°C)35°F - 90°F (2°C - 32°C)


The Control Set Points are described as follows:

SET HIGH TEMP: The temperature at which cooling is turned on, the upper limit is 85°F (29.4°C). The alarm indicates a high air temperature condition.

When the airsends a signarefrigerationstages of cooair temperatuuntil room te

An automatievaporator tecompressor u

Note: ThaT

Set

1

temperature rises to the hl to the temperature contr

system or the Chilled Waling (evaporator coil in twre rises to 1°F (.6°C) abomperature decreases to 1°

c reset freeze-stat is supplmperature falls below 28ntil the evaporator tempe

t a difference of at least EMPERATURE set poi

High Temp = 70

68


Stage 1 OnStage 2 On

Stage

83

or 2 Stage Cooling

igh temperature set poller. The temperatuter control valve. If to sections), the seco

ve the high temperatuF (.6°C) below set po

ied on all evaporator °F (-2.2°C), the freezrature rises to 42°F (5

2°F between HIGH nts is required by th

69 70

De

1 OffStage 2 Off

2
71 7
oint, the temperature sensorre controller activates thehe refrigeration system has twond stage is activated when there set point. Cooling continuesint.

coils to prevent freezing. If thee-stat opens, shutting down the.6°C).

TEMPERATURE and LOWe control program.

creasing Temperature


SET LOW TEMP: The temperature at which the optional heat device is turned on, the lower limit 40°F (4.4°C). The alarm indicates a low air temperature

condition.

When the airactivates thethe temperatif the temper

Set Low Temp = 68

67 68


Reheat On

temperature drops to the lo electric reheat,ure rises to 1°F (.6°C) abovature inside the evaporator

IncreReheat Off

Electric Heating

asing Temperature

84

w temperature set po ontroller ceiling un

e set point. The elec reaches 120°F (49°C

int, the temperature c

69 70

it. The reheat operates until
which is located in the tric reheat safety switch opens).


Liebert environmental control units are offered with the steam canister humidifier option.The control uses the step-type operation, that is ON/ OFF Control. The Control Range isthe operating limits of the software design. The standard operating limits of the LIEBERTHumidity Control are as follows:

Hum gh/ Low Humidity) 20% RH – 80% RHHum nge 15% RH – 85% RH

The Control

SET HIGH

When the huthe refrigeratThis continurefrigerationtemperature refrigerationdehumidifica

The dehumidand electric r

Note: That of at least 4%required by

idity Set Point (Set Hiidity Measurement Ra

Set Points are described as follows:

HUM: The humidity at which dehumidification er limit is 80%. The alarm indicates a high air humidity condition.

midity rises to the higion system or the Ches until the humidity system lowers the huset point and activate system and electric rtion.

ify function of the meheat package are inc

humidity is measure between the HIG

the control program

Set High Humid = 5n

Dehu

0Dehumidification O

ty
Increasing Humidi
85

Dehumidification

h humidity set point, the hilled Water control valve androps to 2% RH below set midity. This may cool the the electric reheat. It is theeheat are operating at the sa

ini-MATE Plus is active onluded in the system.

d in % Relative HumiditH HUMIDITY and LOW

.

48 49 50 51

midification Off

is turned on, the upp

umidity controller activatesd sets the fan speed to LOW.

point. Note that the room to a level belowrefore possible that both theme time for

ly if the optional humidifier

y (RH) and that a difference HUMIDITY set points is

52

Decreasing Humidity


86

SET LOW HUM: The humidity at which the option humidification device is turned on, the lower limit is 20%. The alarm indicates a low air humidity condition.

Humidification

When humidity drops to the low humidity set point, the humidity controller activates thesteam generating humidifier, which operates until the room humidity increases to 2%RH above set point.

The Alarm Set Points are described as follows:

SET HIGH TEMP ALARM The high temperature condition at which theaudible alarm will sound. The upper limit is90°F (32.2°C).

SET LOW TEMP ALARM The low temperature condition at which theaudible alarm will sound. The lower limit is35°F (1.7°C).

SET HIGH HUM ALARM The high humidity condition at which theaudible alarm will sound. The upper limit is85%.

SET LOW HUM ALARM The low humidity condition at which theaudible alarm will sound. The lower limit is15%.

Set Low Humid = 46

44 45 46 47 48

Increasing Humidity

Decreasing Humidity

Humidification On

Humidification


87

After the last alarm set point is programmed, press [SET POINTS] to return the display tonormal mode.

Note: The high and low temperature and humidity alarms can be disabled byadjusting the value out of range. If the set point is adjusted out of range, the valuedisplayed is a set of dashes.

SCHEDULED PROGRAM MODIFICATION Control set points (high and low temperature, high and low humidity) can be modified forany day of the week and for any time of any day. Thus it is possible to adjust theenvironmental control for holidays, weekends, second and third shift operations, and soforth. If a change schedule is not entered into the system, the control set points alwaysremain the same. Note that alarm set points are adjusted in the SET POINTSprogramming mode and are not affected by the change schedule programming.

Press and hold the [PROGRAM] keypad for 3 seconds to display the automatic ScheduledProgram mode, if enabled by DIP switch #4. Initially the weekend days (SUN-SAT) of the2-day/ 5-day schedule will be displayed. The first display is a prompt for programming thedesired time of the first automatic Scheduled Program change for both weekend days.Press [INCREASE] and/ or [DECREASE] key pads to change the clock. Press[PROGRAM] to continue. This is followed by four prompts, one for each control setpoint. After each piece of information is entered into the system, press [PROGRAM] tocontinue. The next display is the prompt for programming the time to initiate a second setof weekend control set point changes. This is followed by four more prompts, one for eachcontrol set point. Note the following example:

DISPLAY ACTION

CURRENT DATE AND TIME Press [PROGRAM] to enter the control setpoint change schedule program.

SUN SAT SET 12:00 A.M. Set the time for the first set of weekendchanges. Press [INCREASE] or[DECREASE] to change the clock in 15-minute increments. Press [PROGRAM] tocontinue.

SUN SAT SET HI TEMP Set the high temperature set point for the firstchange. Press [PROGRAM] to continue.

SUN SAT SET LOW TEMP Set the low temperature set point for the firstchange. Press [PROGRAM] to continue.

SUN SAT SET HI HUM Set the high humidity set point for the firstchange. Press [PROGRAM] to continue.


88

SUN SAT SET LOW HUM Set the low humidity set point for the firstchange. Press [PROGRAM] to continue.

SUN SAT SET 12:00 P.M. Set the time for the second set of weekendchanges. Press [INCREASE] or[DECREASE] to change the clock in 15-minute increments. Press [PROGRAM] tocontinue through and complete the second setof weekend changes.

When programming the second set of weekend changes are completed, depress thePROGRAM keypad again to display the weekdays (MON-FRI) of the 2-day/ 5-dayprogram schedule. The program continues in a repetitive fashion, the weekdays Mondaythrough Friday are displayed, for the first set of changes and then for the second set ofchanges. Therefore, it is possible for any day to deviate from the 2-day 5-day schedule.

The first display is a prompt to program the desired time of the first automatic ScheduledProgram change for all of the weekdays. Press [INCREASE] and/ or [DECREASE] keypads to change the clock. The next display is the prompt for programming the time toinitiate a second set of weekday control set point changes. This is followed by four moreprompts, one for each control set point. Note the following example: Press [PROGRAM]to continue the programming steps to set the rest of the control points for the first change,followed by the time and control set points for the second change.

DISPLAY ACTION


MON TUE WED THU FRI Set the time for the first set of week day SET AT 12:00 A.M. changes. Press [INCREASE] or

[DECREASE] to change the clock in 15-minute increments. Press [PROGRAM] tocontinue.

MON TUE WED THR FRI Set the high temperature set point for the firstSET HI TEMP change. Press [PROGRAM] to continue.

MON TUE WED THU FRI Set the low temperature set point for the firstSET LOW TEMP change. Press [PROGRAM] to continue.

MON TUE WED THU FRI Set the high humidity set point for the firstSET HI HUM change. Press [PROGRAM] to continue.

MON TUE WED THU FRI Set the low humidity set point for the first


89

SET LOW HUM change. Press [PROGRAM] to continue.

SUN SAT SET 12:00 P.M. Set the time for the second set of weekendchanges. Press [INCREASE] or[DECREASE] to change the clock in 15-minute increments. Press [PROGRAM] tocontinue through and complete the second setof weekend changes.

Note that any program step can be disabled by setting the time for that step to an out ofrange condition (dashed will be displayed). It is also possible to completely shut thesystem down by adjusting all of the control set points to the out of range condition (dasheswill be displayed). Press INCREASE to set the high temperature and high humidity setpoints out of range, and press DECREASE to set the low temperature and low humidity setpoints out of range). The system will automatically start up at the time of the nextscheduled change that contains valid set points.

Keeping either the INCREASE or DECREASE keypad depressed will cause an automaticrepeat of the key pad function. After the last a step is displayed, pressing the PROGRAMkeypad again will return the display screen to the normal mode.

Press [ON/OFF] at any time to exit the Control Set Point Change Schedule program. Forexample, if all the week day (Monday through Friday) schedules are the same, and if theweek end (Saturday and Sunday) schedules are the same, press [ON/OFF] after enteringthe week day schedule and before entering the individual day schedules to exit theprogram. It is not necessary to cycle through the individual day schedules.

SENSOR CALIBRATIONIf you suspect that the temperature and/or humidity readings are not accurate, you cancalibrate the sensors by adjusting the display to match a customer supplied portablecalibrated test instrument. To ensure best operation and response, calibrate the sensor nearthe center of its calibration range.



90

To calibrate the temperature and/ or humidity sensor the user must first depress the SETPOINT keypad to access the SET HIGH TEMP programming mode, next depress theCLOCK keypad. The following programs now may be adjusted as needed, continue topress the SET POINTS keypad to scroll through the various programs.

SET CAL TEMP Calibrate the temperature sensor ±5°F (±2.8°C)

SET CAL HUM Calibrate the humidity sensor ±10%.

SET DE Set the sensor response delay 1-90 seconds (factoryset at 50 seconds).

SET F C Select degrees Fahrenheit or degrees Celsius.

FAN SPEEDPress [FAN] if you want the fan (blower) to operate at low speed only. The displayindicates LOW FAN. If LOW FAN is not indicated, the fan is operating at high speedwhen required, during cooling without dehumidification and automatically switches to lowspeed during dehumidification.


91

DIP SWITCHESThe wall-mounted micro-controller control panel contains four DIP switches. To accessthe DIP switches, remove the front cover of the wall mounted control panel. The DIPswitches are defined as follows:.

DIP Switch ON/ CLOSED OFF/ OPEN

1 No reheat option Reheat available

2 No humidity control option Humidity control available

3 Special control operation forEuropean models only

Standard control operation

4 Scheduled Program modeenabled

Scheduled Program modedisabled

DIP Switch Settings

If DIP Switch #1 is in the ON/ CLOSED position, the Low Temp Set Point will not bedisplayed. If Dip Switch #2 is in the ON/ CLOSED position, the Hi/ Low Humid SetPoints, and the Hi/ Low Humidity Alarm Trip Points will not be displayed.

Note: The unit is shipped with the Scheduled Program mode disabled (DIP switch #4in the OFF/ OPEN position). During installation, determine if the ScheduledProgram mode should be enabled on the unit.


92


mini-MATE and mini-MATE PlusSoftware and Hardware History

* 1990 - Original Software and Hardware

* 1994 - Current Software and Hardware


93

Software / Hardware History1990 - Original Software and Hardware:

1. Control provided with 2-day, 5-day and 7-day Setback Programs.2. DIP Switch (DIP) #4 was used for high/low fan speed capabilities in cooling mode.3. “Program on hold” display warning when program parameters were changed.4. System provided with a 6 minute “On to On” short cycling delay.5. Dehumidification is Not Disabled upon excessive temperature drop.6.Day and Time will flash on Loss of Power.7. Each individual alarm must be silenced by depressing the Silence Button. Simultaneousalarms require multiple depresses of the silence Button.

Hardware:1. No remote shutdown connections.2. TB1 and TB2 on Interface Board had brown plug connections.3. No connections for Liebert Site Monitoring on Microprocessor Board. 1994 - Current Software and Hardware:1. 7-day setback program no longer available.2. DIP Switch (DIP) #4 is used to enable/disable Setback program.3. Program button must be depressed for 3 seconds before entering Setback program.4. If the Setback program is selected by DIP switch the normal status display will remain

the same (day, time, operating status).5. If the Setback program is disabled the normal display will read “On” with the current

operating status (cooling, heating, etc.).6. Depressing the silence button once will silence multiple alarms.7. Dehumidification will be disabled if the room temperature falls 2 degrees below the

lowtemperature setpoint.

8. “Program on Hold” is no longer indicated on the display when the parameters havebeen changed.

9. Short cycle delay is now 3 minutes “Off to On”.10. Current time can be displayed by depressing the clock button when the setback program is disabled.11. Day and Time no longer flash for a Loss of Power indication.

Current Hardware: 1. Remote shutdown connections TB3 are now on the interface board.2. TB1 and TB2 now have green plug connections.3. Site Monitoring connections TB2 are now on the interface board.4. A label has been added to the interface board depicting TB1 wiring color code.


94

Chapter 5

Microprocessor Control mini-Mate and mini-Mate Plus

Original 1990 – 1994

• Introduction• Control Panel• Operating Procedures

Set PointsControl Set Point Change ScheduleSensor CalibrationFan SpeedDIP Switches

• Sequence of Operation


95

INTRODUCTIONThis section applies to mini-MATE and mini-MATE Plus units equipped with wallmounted microprocessor control panel.

With power supplied to the mini-MATE or mini-MATE Plus unit, press the ON/OFF keypad on the wall mounted control panel. The system will begin monitoring room conditions(temperature and humidity). The display indicates the current system operation. Systemoperation is automatically controlled by the micro-controller, based on room conditionsand the programmed set points.

CONTROL PANELFigure 3-1 shows the wall-mounted control panel which measures approximately5" x 3 ½” x 1 ¼” (127 mm x 89 mm x 31.8 mm). During normal operation the displayshows the current day and time, operating status and alarms. The [SILENCE] key showsthe current temperature and humidity. Set points, alarms, and the set point changeschedule are initially entered and modified from the control box.

Microprocessor Control Panel


96

The lower portion of the control box is a key pad comprising eight keys. These keys aresimilar to the function keys of a keyboard. Each key when pressed provides a specificfunction as described below:

Control Keys Function

SET POINTSSELECT CHANGE

Selects and/ or resets the operating control set points andalarm set points

SILENCEALARM

Initiates a 10 second display of the present roomtemperature and humidity. During an alarm condition,this key silences the audible alarm and allows the alarmto reset when the alarm condition is cleared

PROGRAMVIEW MODIFY

Displays and/ or resets the automatic control set pointchange schedule.

CLOCKDISPLAY SET

Sets the present day and clock time (required at start-upand after a power failure). Also allows access to theextended set point adjustment mode (sensor calibration).

INCREASE Raises the value of the displayed parameter while in a setmode (set points, program, and clock).

DECREASE Lowers the value of the displayed parameter while in aset mode (set points, program, and clock).

FANHIGH LOW

Selects the fan speed control mode, either automatic fanspeed (high speed when required), or manual override sothat low fan speed only is used.

ON / OFF Turns the unit ON and OFF, or returns the display tonormal mode from one of the set (adjustment) modes.Determine the present mode by reading the displayscreen. OFF means the unit is OFF with power applied.The present day and time means the unit is ON and thedisplay is in the normal mode. A flashing or blinkingnumber means the control is in a set mode.


OPERATING PROCEDURESSET POINTS

If no set poinset points. Ifsame seven dmemory andPress [SET Pvalue when dvalue of the next paramet

Note: The Cdisabled by the value disfunction is n

RANGE of C

Liebert envirheating capastep-type opeof the softwaControl are a

TemperatureTemperature

ts are entered into the system, the syste ate on the system default no schedule is entered into the system, the control set points will remain theays a med set points are stored in non-volatile

are reOINTisplay

paramer.

oolinadjusplayeot ava

ONT

onmebility.rationre dess follo

Set P Mea

week. Note that program

97

tained during a power failure. No battery is required.] to display the system parameter (set point) and associated value, theed is blinking. Press [INCREASE] or [DECREASE] to change the

eter being programmed. Press [SET POINT] again to advance to the

g, Heating, Dehumidification, and Humidification functions can beting the value out of range. If the set point is adjusted out of range,d is a set of dashes. If a set point is not dilable on this unit or a DIP switch is no

ROL SET POINTS

ntal control units are offered with several v This allows the unit to be tailored to indivs, that is ON/ OFF Control. The Control ign. The standard operating limits of the Lws:

oint (Set High/ Low Temp) 40°F - 8surement Range 35°F - 9

isplayed, the controlt properly set.

m will oper

ariations of cooling andidual needs. The control uses

Range is the operating limitsIEBERT Temperature

5°F (4°C - 29.4°C)0°F (2°C - 32°C)



SET HIGH TEMP: The temperature at which cooling is turned on, the upper limit is 85°F (29.4°C). The alarm indicates a high air temperature condition.

When the airsends a signarefrigerationstages of cooair temperatuuntil room te

An automatievaporator tecompressor u

Note: ThaT

1

temperature rises to thel to the temperature con

system or the Chilled Wling (evaporator coil in re rises to 1°F (.6°C) abmperature decreases to 1

c reset freeze-stat is suppmperature falls below 2ntil the evaporator temp

t a difference of at leasEMPERATURE set po

Set High Temp = 70

68


Stage 1

Stage 2 On

98

or 2 Stage Cooling

high temperature set ptroller. The temperatuater control valve. If t

two sections), the secoove the high temperatu°F (.6°C) below set po

lied on all evaporator 8°F (-2.2°C), the freezerature rises to 42°F (5

t 2°F between HIGH ints is required by th

69 70

Stage 1 OffStage 2

On

72
71
oint, the temperature sensorre controller activates thehe refrigeration system has twond stage is activated when there set point. Cooling continuesint.

coils to prevent freezing. If thee-stat opens, shutting down the.6°C).

TEMPERATURE and LOWe control program.


Off


SET LOW TEMP: The temperature at which the optional heat device is turned on, the lower limit 40°F (4.4°C). The alarm indicates a low air temperature

condition.

When the airactivates thethe temperatopens if the tLiebert envirThe control uthe operatingHumidity C

HumHum

Set Low Temp = 68

El

temperature drops to the lo electric reheat, which is loure rises to 1°F (.6°C) aboemperature inside the evaponmental control units are ses the step-type operation limits of the software desi

ontrol are as follows:

idity Set Point (Set High/ Lidity Measurement Range

6

Increasing Temperatu

Decreasing TemperatureReheat On

7 68 69 70

99

ectric Heating

w temperature set pocated in the ceiling unve set point. The elecorator reaches 120°Foffered with the steam, that is ON/ OFF Cogn. The standard ope

ow Humidity) 21

re

Rehe
at Off
int, the temperature controllerit. The reheat operates untiltric reheat safety switch (49°C).

canister humidifier option.ntrol. The Control Range israting limits of the LIEBERT

0% RH – 80% RH5% RH – 85% RH



SET HIGH HUM: The humidity at which dehumidification is turned on, the upper limit alarm indicates a ondition.

When the huthe refrigeratThis continurefrigerationtemperature refrigerationdehumidificaThe dehumidand electric r

Note: That of at least 4%required by

Is 80%. The

midity rises to the higion system or the Ches until the humidity system lowers the huset point and activate system and electric rtion. ify function of the meheat package are inc

humidity is measure between the HIG

the control program

Set High Humid = 50

Increasing Humidity

Dehumi

Dehu

48 49 50 51 52

100

Dehumidification

h humidity set point, the hilled Water control valve androps to 2% RH below set midity. This may cool the the electric reheat. It is theeheat are operating at the sa

ini-MATE Plus is active onluded in the system.

d in % Relative HumiditH HUMIDITY and LOW

.

midification Off

dification On

high air humidity c

midity
Decreasing Hu
umidity controller activatesd sets the fan speed to LOW.

point. Note that the room to a level belowrefore possible that both theme time for

ly if the optional humidifier

y (RH) and that a difference HUMIDITY set points is


101

SET LOW HUM: The humidity at which the option humidification device is turned on, the lower limit is 20%. The alarm indicates a low air humidity condition.

Humidification

When humidity drops to the low humidity set point, the humidity controller activates thesteam generating humidifier, which operates until the room humidity increases to 2%RH above set point. The Alarm Set Points are described as follows:

SET HIGH TEMP ALARM The high temperature at which an audiblealarm will sound. The upper limit is 90°F(32.2°C).

SET LOW TEMP ALARM The low temperature at which an audiblealarm will sound. The lower limit is 35°F(1.7°C.)

SET HIGH HUM ALARM The high humidity at which an audible alarmwill sound (The upper limit is 85%.)

SET LOW HUM ALARM The low humidity at which an audible alarmwill sound (The lower limit is 15%.)

After the last set point is set, press [SET POINTS] to return the display to normal mode.

Note: The high and low temperature and humidity alarms can be disabled byadjusting the value out of range. If the set point is adjusted out of range, the valuedisplayed is a set of dashes.

Set Low Humid = 46

44 45 46 47 48

Increasing Humidity

Decreasing Humidity

Humidification On

Humidification


102

SCHEDULED PROGRAM MODIFICATIONControl set points (high and low temperature, high and low humidity) can be modified forany day of the week and for any time of any day. Thus it is possible to adjust theenvironmental control for holidays, week-ends, second and third shift operations, and soforth. If a change schedule is not entered into the system, the control set points alwaysremain the same. Note that alarms are not affected by the change schedule.

Press [PROGRAM] to display the Control Set Point Change Schedule. Initially theweekend days are displayed. The first display is a prompt for the time to initiate the firstset of weekend control set point changes. Press [INCREASE] or [DECREASE] to changethe clock. Press [PROGRAM] to continue. This is followed by four prompts, one for eachcontrol set point. After each piece of information is entered into the system, press[PROGRAM] to continue. The next display is a prompt for a time to initiate a second setof weekend control set point changes. This is followed by four more prompts, one for eachcontrol set point. Note the following example:

DISPLAY ACTION


SUN SAT SET 12:00 A.M. Set the time for the first set of weekendchanges. Press [INCREASE] or[DECREASE] to change the clock in 15-minute increments. Press [PROGRAM] tocontinue.

SUN SAT SET HI TEMP Set the high temperature set point. Press[PROGRAM] to continue.

SUN SAT SET LOW TEMP Set the low temperature set point. Press[PROGRAM] to continue.

SUN SAT SET HI HUM Set the high humidity set point. Press[PROGRAM] to continue.

SUN SAT SET LOW HUM Set the low humidity set point. Press[PROGRAM] to continue.

SUN SAT SET 12:00 P.M. Set the time for the second set of weekendchanges. Press [INCREASE] or[DECREASE] to change the clock in15-minute increments. Press [PROGRAM] tocontinue.


103

The program continues in an iterative fashion. First the weekend days are displayed for thefirst set of control set point changes. This is followed by the second set of control set pointchanges. Then the weekdays Monday through Friday are displayed, for the first set ofchanges and for the second set of changes. Finally each day of the week beginning withSunday and ending with Saturday is displayed, again for two sets of changes. Therefore, itis possible for any day to deviate from the 2-day 5-day schedule. It is also possible to shutthe system down completely by adjusting all the control set points out of range (that is,press [INCREASE] to set the high temperature and high humidity set points out of range,and press [DECREASE] to set the low temperature and low humidity set points out ofrange). The system will automatically start up at the time of the next change schedule withset points within range.

Press [ON/OFF] at any time to exit the Control Set Point Change Schedule program. Forexample, if all the week day (Monday through Friday) schedules are the same, and if theweek end (Saturday and Sunday) schedules are the same, press [ON/OFF] after enteringthe week day schedule and before entering the individual day schedules to exit theprogram. It is not necessary to cycle through the individual day schedules.

SENSOR CALIBRATIONIf you suspect that the temperature and/or humidity readings are not accurate, you cancalibrate the sensors by adjusting the display to match a test instrument. Press [SETPOINT], then press [CLOCK]. The following adjustments are possible:

SET CAL TEMP Calibrate the temperature sensor ±5° (±2.8°C).

SET CAL HUM Calibrate the humidity sensor ±10%.

SET DE Set the sensor response delay 1-90 seconds (factoryset at 50 seconds).

SET F C Select degrees Fahrenheit or degrees Celsius.

FAN SPEEDPress [FAN] if you want the fan (blower) to operate at low speed only. The displayindicates LOW FAN. If LOW FAN is not indicated, the fan is operating at high speedwhen required (that is, during cooling without dehumidification and during cooling withdehumidification if the room temperature rises to 2°F (1.1°C) above the high temperatureset point).


104

DIP SWITCHESThe wall-mounted control box contains four DIP switches. Remove the front cover of thecontrol panel to get to the switches.

DIP Switch ON OFF

1 No reheat option Reheat available

2 No humidity controloption

Humidity controlavailable

3 Special control operationfor European modelsonly

Standard controloperation

4 Single speed fan option Dual speed fan control

Wall Mounted Control Panel DIP Switch Settings

If DIP Switch #1 is in the ON/ CLOSED position, the Low Temp Set Point will not bedisplayed. If Dip Switch #2 is in the ON/ CLOSED position, the Hi/ Low Humid SetPoints, and the Hi/ Low Humidity Alarm Trip Points will not be displayed.

Note that the DIP switches are set at system startup. Unless the system configurationis altered, the DIP switch settings do not need to be changed.


105

Chapter 6

Electrical Connections

• mini-MATE and mini-MATE Plus ControlBoardand Interface Board ConnectionPoints,1994 to Present

Schematic: 127222 - mini-MATE Plus, 2 and 3 Ton

• Mini-Mate2 Control Board and Interface BoardConnection Points, 1 to 5 Ton Units Connection Points, 8 Ton Units

• Data-Mate Control Board and Interface BoardConnection Points, 1994 to Present.

Schematic: 132467 - Datamate, 1.5 to 3 Ton

Connection Points, 1 to 3 Ton Units, 2000 to Present


106

Sequence of Operationmini-MATE, mini-MATE Plus and Data-Mate

Power Up

Pressing the ON/OFF keypad on the wall mounted control panel energizes the K4 relay onthe system interface board. The normally open K4 contact will close allowing the 24 VACpower to distribute to the following points on the PCB:

P2-11 HWA (Normally Open)K8 Contacts (Normally Open)K8 Contacts (Normally Closed)K1 Contacts Cool1K6 Contacts Cool2P2-7 MR Fan CoilK7 Contact DehumidifyK3 Contact HumidifyK2 Contact Reheat

At this point all circuits are ready to operate in response to a signal from the Temperatureor Humidity Sensor.

Fan Start

With 24 VAC applied to P2-7 for the MR (Main Fan) coil, the fan energizes, closing theMR contact. Line voltage is applied to the Main Fan motor through the normally closed1DHR contact. The motor starts on high speed. However, if a call for dehumidification ispresent, by switching 1DHR (high speed) and 2DHR (low speed), the fan drops to lowspeed.

Cooling

When the temperature input requires Cool1, the K1 relay energizes, closing the K1contacts which energizes the Compressor Coil (CC) closing the 1CC contacts allowingline voltage to be applied to the compressor. At the same time, line voltage is applied from1CC to the L1 terminal of the Fan Speed Control (FSC) for the condenser fan. Note thatthe FSC is supplied only on self-contained air cooled systems.

If the input requires Cool2, the K6 relay energizes the Capacity Control Relay (CCR) toutilize the entire cooling coil for full operation. Note that on a normal call for cooling, thisis only 1/2 of the DX coil capacity.

If a low temperature or freeze condition exists at the evaporator coil, the FR opensstopping the cooling process.


Dehumidification

When a need for dehumidification exists, the K7 relay is energized, activating the DHR(DeHumidification Relay) and switching the 1DHR (high speed) and the 2DHR (lowspeed) contacts on the evaporator motor to provide the correct air movement for properdehumidification. Note that both stages of cooling (K1 and K6) are also energized to usethe full coil capacity.

If a low temperature or fre ondition s at the evaporator coil, the FR opens,stopping the cooling proce

Humidificat

When a call the 1H contaThe humidif

Reheat

On a call forenergizing thSafety Stat (R

Note that th

ion

for humidificacts located iny control sequ

reheat (an ope RH contactHS-1) is clo

e 1-RH and 2

eze c
ss.
tion takes pla the line voltaence follows

tion), the K2 or closised, it w

-RH contact

exist

ce, the K3 relay energizes the H coi hich closesge circuit, to energize the canister ty umidifier. the standard canister operation defin arlier.

contactor energizes closing the K2 c cts, and 2RH contacts. If the Rehe i-Tempte circuit and bring on reheat.

ng the 1RHill comple

1

s are

07

high-voltage.

l, wpe hed e

ontaat H


108

mini-MATE and mini-Mate Plus Control BoardLayout, 1994 to the presentBelow shows the mini-MATE and mini-MATE Plus Control Board that is located in thewall mounted control panel. The connection legend follows.

mini-Ma mini-Mate Plus Wall

Plug P1: Front Display/KeypadP1-1: Silence P1-6: ProgramP1-2: Clock P1 IncreaseP1-3: Decrease P1-8: FanP1-4: On/Off P1-9: GndP1-5: Setpoint P1-10: ESD Gnd

TB1: Wall Panel to Control Board Cable TB1-1: Gnd TB1-5: Cool1TB1-2: +5 VDC TB1-6: Cool2TB1-3: Temperature Signal TB1-7: ReheatTB1-4: Humidity Signal TB1-8: Humid

TB2: Site Monitoring System InterfaceTB2-1: T+ TB2-2: T-

123456789101112

TB1

Alarm

DIP Switches

1 4

ON

P1109876

MicroprocesMemory

5

321sor/

Mounted Control Bo
te/
-7:

TB1-9: umid/Fan TB1-10: On/Off TB1-11: mon Alarm

ification TB 12:

4

trol Gnd
ComCon
ard

Deh

1-

TB2

1 2


109

mini-Mate and mini-Mate Plus Interface Board Layout,1994 to the presentBelow shows the mini-MATE and mini-MATE Plus Interface Board that is located in theunit mounted in the suspended ceiling. Terminal Block TB1 is shown with the pinsexposed. TB2 is shown with the snap on screw adjustment in place. The connectionlegend follows.

mini-MATE and mini-MATE Plus Unit Mounted Interface Board

K8

K7

K6

K5

K4

K3

K2

K1

16 14 12 10 8 6 4 2

15 13 11 9 7 5 3 1P2

TB2

4321

T1

TB1

121110987654321

P1

TB3

1 2


110

mini-MATE, mini-MATE Plus Interface Board Connections

P1: Connection to the Temperature/ Humidity Conversion Board

P1-1: GND P1-3: Humidity SensorP1-2: +5 VDC P1-4: Temperature Sensor

P2: 24 VAC Load DevicesP2-1: 24 VAC P2-9: Low Speed Fan (Out)P2-2: 24 VAC RTN P2-10: Fan CommonP2-3: CooL1 (Out) P2-11: HWA (High Water Float Switch)P2-4: Cool Common P2-12: HWAP2-5: CooL2 (Out) P2-13: Reheat (Out)P2-6: Freeze Stat (FR) Out P2-14: Reheat CommonP2-7: Fan (Out) P2-15: Humidifier (Out)P2-8: Freeze Stat (FR) Common P2-16: Humidifier Common

TB1: Interconnecting Cable to the Wall Mounted Control Panel

TB1-1: GND TB1-7: Reheat (In)TB1-2: +5 VDC TB1-8: Humidification (In)TB1-3: Temperature Signal TB1 9: Dehumid/Fan (In)TB1-4: Humidity Signal TB1-10: ON/OFF (In)TB1-5: CooL1 (In) TB1-11: Common Alarm (In)TB1-6: CooL2 (In) TB1-12: Control GND

TB2: Compressor, Remote Condensing Unit, or Chilled Water Valve and CommonAlarm ConnectionsTB2-1: Compressor/ Remote Condensing Unit/ Chilled Water Valve (Out)TB2-2: Compressor/ Remote Condensing Unit/ Chilled Water Valve CommonTB2-3: Common Alarm ContactTB2-4: Common Alarm Contact

TB3: Remote Shutdown Device Connections

TB3-1: RSD (Out) TB3-2: RSD Common

Voltages: 5 VDC, 10 VDC (Unregulated), 24 VAC Transformer: 10 VA, 24/24 VAC


Schem
atic 127222 -
1

min

11

i-MATE Plus, 2 and 3 Ton


112

Datamate Control Board Layout, 1994 to 2000.

Below shows the Datamate LCD Control Board that is located in the upper right handcorner of the Datamate unit. The connection legend follows.

tamate Unit Mounted

TB1: Display Panel to Control Board Ca

TB1-1: GndTB1-2: +5 VDCTB1-3: Temperature Signal

TB1-4: Humidity SignaTB1-5: Cool1TB1-6: Blank

TB2: Site Monitoring System Interface

TB2-1: T+ TB2-2: T-

123456789101112

TB1

TB2

2Alarm

DIP Switches

1 4

ON

Microp cesMemory

sor/

Control Board
Da
ble

TB1-7: Reheat
TB1-8: HumidificationTB1-9: Dehumid/FanTb1-10: On/OffTB1-11: Common Alarm
l

TB1-12: Control Gnd

ro

1


113

Datamate Interface Board Layout, 1994 to 2000.

Below shows the Datamate Board that is located in the upper right hand corner of the unitbehind the LCD Display Panel. Terminal Block TB1 is shown with the pins exposed. TB2is shown with the snap on screw adjustment in place. The connection legend follows.

Datamate Unit Mounted Interface Board

K8

K7

K6

K5

K4

K3

K2

K1

16 14 12 10 8 6 4 2

15 13 11 9 7 5 3 1P2

TB2

4321

T1

TB1

121110987654321

P1

TB3

1 2


114

Datamate Interface Board ConnectionsP1: Connection to the Temperature/ Humidity Conversion BoardP1-1: GND P1-3: Humidity SensorP1-2: +5 VDC P1-4: Temperature Sensor

P2: 24 VAC Load DevicesP2-1: 24 VAC P2-9: Low Speed Fan (OUT)P2-2: 24 VAC RTN P2-10: Fan CommonP2-3: Chilled Water Valve Out P2-11: HWS (High Water Switch)P2-4: Chilled Water Valve Common P2-12: HWSP2-5: Not Used P2-13: Reheat (OUT)P2-6: Common Jumper P2-14: Reheat CommonP2-7: Fan (OUT) P2-15: Humidifier (OUT)P2-8: Common P2-16: Humidifier Common

TB1: Interconnecting Cable to the Front Control Panel

TB1-1: GND TB1-7: Reheat (IN)TB1-2: +5 VDC TB1-8: Humidification (IN)TB1-3: Temperature Signal TB1 9: Dehumid/Low Speed Fan (IN)TB1-4: Humidity Signal TB1-10: ON/OFF (IN)TB1-5: CooL1 (IN) TB1-11: Common Alarm (IN)TB1-6: Not used TB1-12: Control GND

TB2: Compressor, Remote Condensing Unit, and Common Alarm ConnectionsTB2-1: Compressor/ Remote Condensing Unit (OUT)TB2-2: Compressor/ Remote Condensing Unit CommonTB2-3: Common Alarm ContactTB2-4: Common Alarm Contact

TB3: Remote Shutdown Device Connections

TB3-1: RSD (OUT) TB3-2: RSD Common

Voltages: 5 VDC, 10 VDC (Unregulated), 24 VAC Transformer: 10 VA, 24/24 VAC


Sch
ematic: 13246
115

7 - Datamate, 1.5 to 3 To
n


116

Mini-Mate2: 1 to 8 Ton Unit Control Board Layout

Below shows the Mini-Mate2 LCD Control Board that is located in the wall mountedcontrol panel. The connection legend follows.

Mini- ate2Wall M nted Control B rd

TB3: Display Panel to Interface Board CableTB3-1: GndTB3-2: +5 VDCTB3-3: T+ SignalTB3-4: T- Signal

Alarm

3

1234

HumiditySensor

TemperatureSensor

8

1ON

1-DIPs

TB

oa
ou M
SW


117

Mini-Mate2: 1 to 5 Ton Units Interface Board Layout

Below shows the Mini-Mate2 Interface Board that is located in the unit mounted in thesuspended ceiling. The connection legend follows.

1 to 5 Ton Mini-Mate2 Unit Mounted Interface Board

P1: Transformer T1 Secondary, T6 Primary, 24 VAC CircuitsP1-1: 24 VAC (T1 Secondary and T6 primary) P1-6: MR, BR, DHR Common P1-2: 24 VAC Return P1-7: Dehumidification Relay (Out)P1-3: High Water Alarm Float Switch P1-8: 24 VAC Out (Optional Firestat)P1-4: HWA P1-9: 24 VAC ReturnP1-5: Main Fan Relay, Backup Reheat Contactor

P2: 24 VAC Load DevicesP2-1: Reheat (Out) P2-3: Not Used P2-5: Not UsedP2-2: Reheat Common P2-4: Not Used P2-6: Not Used

P3: 24 VAC Load Devices

P3-1: Humidification Activation Relay (HA) Out P3-4: 24 VAC OutP3-2: HA Common P3-5: RAD1 InputP3-3: Steam Canister Humidifier Out

1 2 3 4

P16

2 1

TB4

4 3 2 1

TB3

9 8 7 6 5 4 3 2 1

TB1

4 3 2 1

TB2

Micro.

9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 5 4 3 2 1 9 8 7 6 5 4 3 2 1 5 4 3 2 1

Memory

P5P4P3P2P1

T6

1

8

SW1-DIPs

ON

321

P6


118


P4-1: 24 VAC (Out) P4-6: 24 VAC (Out) Optional CGT and CGVR P4-2: 24 VAC (Out) P4-7: Optional CGT and CGVR CommonP4-3: Freeze Stat (FZ) Out P4-8: 24 VAC (Out) Remote Condensing ModuleP4-4: FZ Return P4-9: 24 VAC (Out)P4-5: Common


P5-1: 24 VAC (Out) Optional Smoke Detector P5-4: 24 VAC (Out) P5-2: Common P5-5: 24 VAC ReturnP5-3: RAD1 Device Alarm Input

P6: 24 VAC Alarm Circuits

P6-1: 24 VAC (Out) Filter Clog Switch P6-3: RAD2 DeviceP6-2: Filter Clog Switch and RAD1 Device

P16: Optional Remote Return Air Sensors

P16-1: GND P16-3: Humidity SensorP16-2: +5 VDC P16-4: Temperature Sensor

TB1: 24 VAC Alarm Circuits TB1-1: 24 VAC to RAD1/ RAD2 TB1-6: Common Alarm ContactTB1-2: From RAD1 Device TB1-7: Common Alarm ContactTB1-3: From RAD2 Device TB1 8: 24 VAC to Opt. Condensate Sw.TB1-4: RSD Out TB1-9: Opt. Condensate Pump Sw. Common

TB1-5: RSD Common

TB2: Remote Condensing Module

TB2-1: 24 VAC Common TB2-3: HP1 Alarm Input TB2-2: 24 VAC Out TB2-4: HGBP Out

TB3: Interconnecting Cable to the Wall Mounted Control Panel

TB3-1: GND TB3-3: T- CommunicationsTB3-2: +5 VDC TB3-4: T+ Communications

TB4: Site Monitoring Systems InterfaceTB4-1: T+ Communications


119

TB4-2: T- Communications Mini-Mate2: 8 Ton Units Interface Board Layout

Below shows the Mini-Mate2 Interface Board that is located in the unit mounted in thesuspended ceiling. The connection legend follows.


120

8 Ton Mini-Mate2Unit Mounted Interface Board

Note: The BLACKENED circle indicates Pin #1 of each plug

P1: Hot Water Reheat P2: Not UsedP1-1: 24 VAC Out P2-1: N.C. *P1-2: N.C. * P2-2: N.C. *P1-3: N.C. * P2-3: N.C. *P1-4: 24 VAC Gnd (E1) P2-4: N.C. *

P3: Not Used P4: 24 VAC Power P16: Not UsedP3-1: N.C. * P4-1: Fuse 1P3-2: N.C. * P4-2: Fuse 2P3-3: N.C. * P4-3: Fuse 3P3-4: N.C. * P4-4: Fuse 4

P8: 24 VAC Alarm Inputs P22: Glycool Actuator ValveP8-1: 24 VAC (RAD1) P22-1: 24 VAC Out (Close Q18)P8-2: 24 VAC (RAD2) P22-2: DCV SignalP8-3: N.C. * P22-3: 24 VAC Out (Open Q17)P8-4: 24 VAC (RAD3) P22-4: DCV Signal

P7 P25


121

P8-5: 24 VAC (Humid. Problem) P22-5: 24 VAC Gnd (E2)P8-6: 24 VAC Out P22-6: +5 VDCP8-7: N.C. *

P25: Site Monitoring Communications P10: Not UsedP25-1: + 5VDCP25-2: - 5 VDC

P32: 24 VAC Load Devices P33: 24 VAC Load DevicesP32-1: N.C. * P33-1: 24 VAC Out (HGBP1) P32-2: N.C. * P33-2: E1P32-3: N.C * P33-3: N.C. *P32-4: 24 VAC Out P33-4: 24 VAC Out (HGB2)P32-5: 24 VAC Out P33-5: N.C. *P32-6: 24 VAC Out (Q14) P33-6: N.C. *P32-7: 24 VAC Out (Q10) P33-7: N.C. *P32-8: N.C * P33-8: N.C. *P32-9: 24 VAC (HP1) P33-9: 24 VAC (HP2)P32-10: 24 VAC Out (Cooling 1) P33-10: N.C. *P32-11: E1 (FR1) P33-11: 24 VAC Out (R5 Relay)P32-12: 24 VAC Out (Cooling 2) P33-12: E1P32-13: E2 (FR2)

P34: 24 VAC Reheats P35: Steam HumidifierP34-1: 24 VAC (RS1, RS2) P35-1: 24 VAC Out (Humidifier) P34-2: E3 P53-2: N.C. *P34-3: 24 VAC P53-3: N.C. *P34-4: 24 VAC (RH1, HWRH) P35-4: N.C. *P34-5: N.C. * P35-5: E3P34-6: 24 VAC Out (RH2, RH3) P35-6: N.C. *P34-7: N.C. *P34-8: N.C. *P34-9: N.C. *P34-10: E3P34-11: N.C. *P34-12: 24 VAC Out (BR)


P36: Basic Unit Connections P40: Basic Unit ConnectionsP36-1: 24 VAC Out (Filter Clog) P40-1: 24 VAC Out (HWA)P36-2: 24 VAC (Filter Clog Alarm) P40-2: 24 VAC Rtn. (HWA)P36-3: 24 VAC Out ( MF Overload) P40-3: 24 VAC Out (TB60, CPSS)P36-4: 24 VAC Out P40-4: 24 VAC Rtn. (TB61)P36-5: N.C. * P40-5: 24 VAC Out (N.O. HWAR) P36-6: 24 VAC (MF Overload Alarm) P40-6: 24 VAC Rtn.P36-7: 24 VAC P40-7: 24 VAC Out (HWAR)P36-8: E4 P40-8: E4P36-9: N.C. P40-9: N.C. *P36-10: N.C. P40-10: N.C. *P36-11: 24 VAC P40-11: N.C. *P36-12: N.C. * P40-1 Out (SDC)P36-13: K3 (Common: TB75) P40-13: 24 VP36-14: K3 (N.O.: TB76)P36-15: K3 (N.C.)

P38: Smoke DetectorP38-1: 24 VAC Out (SDCP38-2: E4P38-3: 24 VAC (RAD1)P38-4: N.C. *

P43: T6 TransformerP43-1: 24 VAC GndP43-2: 24 VAC

TB1: 24 VAC Alarm CirTB1-1: 24 VAC (T2)TB1-2: 24 VAC (T3)TB1-3: 24 VAC (T4)TB1-4: 24 VAC (T5)

TB3: Interconnecting CaTB3-1: GNDTB3-2: +5 VDC

: Firestat emote Shutdown) 4 VA ut (Firestat)

cuits TB1TB1TB1TB1

ble to the WalTB3-3: T- TB3-4: T+

P39P39

122

P39-2: 24 VAP39-3: 24 VAP39-4: 24 VA

-5: E1 (G2)-6: E2 (G3) 7: E3 (G4)-8: E4 (G5)

l Mounted Control PaneCommunications Communications

AC

& RC O
-1: 2
2: 24 VAC

C Rtn. (Firestat)C Out (RDS1)C Rtn. (RSD1)

l


123

Fuse/ Transformer Board Layout – 8 Ton Only

Fuse/ Transformer Board P24: T1 ansformer P43: T6 TransformerP24-1: 2 AC Gnd P43-1: 24 VAC GndP24-2: 24 VAC P43-2: 24 VAC

P4: 24 V Power P44: H AR ContactP4-1: Fuse 1 P44-1: 24 VAC (N.C. HWAR)P4 P44 ACP4-3: Fuse 3P4-4: Fuse 4

E1: Transformer Secondary Ground

-2: Fuse 2
-2: 24 V
W
AC
Tr4 V


124

Datamate: 1 to 3 Ton Unit Control Board Layout, since 2000

Below shows the Mini-Mate2 LCD Control Board that is located in the wall mountedcontrol panel. The connection legend follows.

Datamate Wall Mounted Control Board

TB3: Display Panel to Interface Board Cable

TB3-1: GndTB3-2: +5 VDCTB3-3: T+ SignalTB3-4: T- Signal

Alarm

TB3

1234

HumiditySensor

TemperatureSensor

8

1ON

SW1-DIPs


125

Datamate: 1 to 3 Ton Units Interface Board Layout, since 2000

Below shows the Datamate Interface Board that is located in the upper right hand corner ofthe unit. The connection legend follows.

1 to 3 Ton Datamate Unit Mounted Interface Board

P1: Transformer T1 Secondary, T6 Primary, 24 VAC CircuitsP1-1: 24 VAC (T1 Secondary and T6 primary) P1-6: MR, BR, DHR Common P1-2: 24 VAC Return P1-7: Dehumidification Relay (Out)P1-3: High Water Alarm Float Switch P1-8: 24 VAC Out (Optional Firestat)P1-4: HWA P1-9: 24 VAC ReturnP1-5: Main Fan Relay, Backup Reheat Contactor

P2: 24 VAC Load DevicesP2-1: Reheat (Out) P2-3: Not Used P2-5: Not UsedP2-2: Reheat Common P2-4: Not Used P2-6: Not Used

P3: 24 VAC Load DevicesP3-1: Humidification Activation Relay (HA) Out P3-4: 24 VAC OutP3-2: HA Common P3-5: RAD1 InputP3-3: Steam Canister Humidifier Out

1 2 3 4

P16

2 1

TB4

4 3 2 1

TB3

9 8 7 6 5 4 3 2 1

TB1

4 3 2 1

TB2

Micro.

9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 5 4 3 2 1 9 8 7 6 5 4 3 2 1 5 4 3 2 1

Memory

P5P4P3P2P1

T6

1

8

SW1-DIPs

ON

321

P6


P4: 24 VAC Load DevicesP4-1: 24 VAC (Out) P4-6: 24 VAC (Out) Optional CGT and CGVR P4-2: 24 VAC (Out) P4-7: Optional CGT and CGVR CommonP4-3: Freeze Stat (FZ) Out P4-8: 24 VAC (Out) Remote Condensing ModuleP4-4: FZ Return P4-9: 24 VAC (Out)P4-5: Common

P5: 24 VAC Load DevicesP5 4 VAC (Out) Optional Smoke Detector P5-4: 24 VAC (Out) P5 ommon P5-5: 24 VAC ReturnP5

P6P6P6

P1P1P1

TBTBTBTBTB

TB

TBTBTB

TBTBTB

TBTBTB

-1: 2-2: C

126

-3: RAD1 Device Alarm Input

: 24 VAC Alarm Circuits-1: 24 VAC (Out) Filter Clog Switch P6-3: RAD2 Device-2: Filter Clog Switch and RAD1 Device

6: Optional Remote Return Air Sensors6-1: GND P16-3: Humidity Sensor6-2: +5 VDC P16-4: Temperature Sensor

1: 24 VAC Alarm Circuits 1-1: 24 VAC to RAD1/ RAD2 TB1-6: Common Alarm Contact1-2: From RAD1 Device TB1-7: Common Alarm Contact1-3: From RAD2 Device TB1 8: 24 VAC to Opt. Condensate Sw.1-4: RSD Out TB1-9: Opt. Condensate Pump Sw. Common

1-5: RSD Common

2: Remote Condensing Module2-1: 24 VAC Common TB2-3: HP1 Alarm Input 2-2: 24 VAC Out TB2-4: HGBP Out

3: Interconnecting Cable to the Wall Mounted Control Panel3-1: GND TB3-3: T- Communications3-2: +5 VDC TB3-4: T+ Communications

4: Site Monitoring Systems Interface4-1: T+ Communications4-2: T- Communications


Chapter 7

General Troubleshooting Data

• Introduc

• Isolation

• Basic Op

• Basic Op

• Troubles

• ol I

• Frequenc

• Frequenc

• Troubles

127

tion

eration of the Triac

eration of the Opto

hooting the Opto-Isolato

nput Check (Se

y Conversion Chart (Tem

y Conversion Chart (Hu

hooting Checklist

r

Contr
nsors)
perature)

midity)


Introduction

The temperature sensor senses a rise in temperature. The rise is transmitted to the CentralProcessing Unit (CPU). The CPU looks into the its memory for information andinstructions on what to do with the rise in temperature. The CPU then makes the decisionto call for cooling. Below shows the communication path.

How a Call for Cooling Takes Place

This chapter covers only very basic electronics. The major components, such as triacs andopto-isolators are briefly described and related to the Liebert units that you have come tostudy. It is our hope that this brief introduction to electronics stimulates your interest andencourages you to go further in the field.

T/H

INPUT MICRO

MEMORY

OUTPUT

C P U

128


Isolation

We use the opto-isolator and the triac to isolate areas of control and voltage. There arethree areas of control and two voltage levels. Digital control comes from themicroprocessor at 5 VDC and the other voltage level is 24 VAC. One voltage is used toturn on the triac and the other is used to operate the load device.

Areas of Control

OPTO

TRIACTransformerPower 24 VAC

DIGITAL CONTROL POWER

Processor5 VDC Signal

5 VDCGround

ISOLATION ISOLATION

TransformerPower 24 VAC

LoadDevice

129


BASIC OPERATION OF THE TRIAC

To better understand the operation of the triac, we need to look at the movement ofelectrons in a special type of material used in electronics. Here we have a semiconductormaterial with what is called a depletion region. The depletion region restricts the flow ofelectrons to a point.

Depletion Region

Semiconductor

By forcing mo e depletion region, we c of theseelectrons resulflow, the devic

If we add a thiBy sending eleoverflow coNow to putplace every ha

+ + + ++ + + ++ + + +

- - - -- - - -- - - -

re electrons in to th

130

ting in electron flow that in turn produces ce is on.

Depletion Region

Semiconductor Showing No Moveme

rd terminal to this simple device and call it ctrons to the gate, which is connected to th

this device can be voltage circuits,

lf cycle. When the AC voltage is removed

GATE

Semiconductor Showing Movement

+ + + ++ + + ++ + + +

- - - - - - -- - - -

+ + + ++ + + ++ + + +

- - -- - -- - -

+++---+++---+++---+++---+++---

+ + +

IN

an cause an overflow
urrent. When we have current
nt of Electrons

the Gate, we have a basic triac.e depletion region, we create an

ess.akes

-

ndition. You can see how this in perspective with AC

turned on or off by this procthis ON and OFF condition t

from the gate, conduction stops.

of Electrons

- - -

- - -

OUT


The triacs that Liebert uses are standard in the industry and are rated at a 2-amp capacity.You can check these devices for proper operation while they are connected in the circuit.If the load is removed from the device, you can get a false reading from the meter. This isbecause the voltage potential is present and is detected by the meter. When the load isapplied to the device, the potential is not detected by the meter.

To test a triac for proper operation, energize the circuit and connect the load. Refer belowto determine the pin locations of this device.

Heat Sink

Front View

F

As your view the triac from

TerLefMidRig

Below is a simple schema

O

24 VACTransformerPower

1

Triac

Body

Terminals

131

L

ront and Left Side Views of the T

the front, the terminal are number

minal Connectiont #2 Connects to thdle #1 Connects to thht G(ate) Connects

tic drawing for the triac using Liebe

Schematic Drawing for the Tria

Opto

4 2

16

G

2

eft Side View

riac

ed as follows:

e Loade Transformer Powerto the Opto-Isolator

rt symbols.

c

LoadDevice


Basic Operation of the Opto-Isolator

The purpose of the opto-isolator is to provide isolation of two voltage sources. This allowsa DC voltage source to activate an AC voltage load device or allows an AC voltage sourceto provide a DC signal.

We are working with two two types of opto-isolators

The output opto uses a DCinternal to the IC chip. Thallowing current to flow to

No Curren

The input opto uses an ACpass the DC voltage and a

No Curren

LED

DCSource

Dual LEDs

ACSource

pes of circuits, an input and an ou ut. Therefore, we requirereferred to as optos).

ty (

oltage source to activate a Light E itting Diode (LED)
v
132

is causes a triac, also internal to the the AC load device. Below shows

t Flow

Output Opto-Isolator

voltage source to activate dual LEDllow current to flow. Below shows a

t Flow

Input Opto-Isolator

Triac LED

DCSource

ACSource

Transistor Dual

ACSource

DCSource

m

tp

IC chip, to switch ON an output opto.

Current Flow

s and turn on a transistor ton input opto.

Current Flow

Triac

ACSource

LEDs Transistor

DCSource


133

Troubleshooting the Opto-IsolatorThe opto-isolator IC chips used in these circuits are the H11AA (input) and theH11J (output). Below shows the pin location for component checks on the output opto. Theindented circle in the upper left hand corner of this chip indicates the location of Pin 1. Notethat the number sequence is in a "U" format: down 1, 2, 3, on the left andup 4, 5, 6, on the right.

Output Opto-Isolator Pin Location

OUTPUT VOLTAGE CHECK

Pin 1 Receives the DC source voltage (5 VDC range).

Pin 2 Completes the DC source to the digital ground.

Pin 3 No voltage signal at this point.

Pin 4 Completes the AC voltage path to the gate of the triac (24VAC).


Pin 6 Receives the AC source voltage signal from the input device.

Note that all AC source checks are referenced to the associated transformer neutraland/or the safety ground, and that the DC source reference is to V- or digital ground.

1

2

3 4

5

6


134

Below shows the pin location for component checks on the input opto. The indented circlein the upper left hand corner of this chip indicates the location of Pin 1. Note that thenumber sequence is in a "U" format: down 1, 2, 3, on the left and up 4, 5, 6, on the right.

Input Opto-Isolator Pin Location

INPUT VOLTAGE CHECK

Pin 1 Receives the AC source voltage (This voltage is 24VAC prior to the Opto and is about 1.2 VAC at theopto).

Pin 2 Completes the AC source to the neutral and or safetyground.


Pin 4 Completes the DC source to the digital ground.

Pin 5 Receives the DC voltage source from themicroprocessor (This voltage level is 5 VDC when notactivated and is 0 VDC when activated).


Note that all AC source checks are referenced to the associated transformer neutraland/or the safety ground, and that the DC source reference is to V- or digital ground.

1

2

3 4

5

6


135

Alarm Input Opto Legend:1 to 5 Ton Mini-Mate2 and 1 to 3 Ton Datamate Units

Opto Purpose Opto Purpose

U8 High Water Alarm U11 Custom Alarm 1

U9 High Head Pressure U12 Power On

U10 Custom Alarm 2

Input Opto-Isolator Chart

Note: Use Pin 5 on the input opto with reference to the V- terminal for voltage check.The voltage level is 5 VDC.

Control Output Opto Legend:1 to 5 Ton Mini-Mate2 and 1 to 3 Ton Datamate Units


U1 Low Fan U4 Cooling

U2 Reheat U5 Hot Gas Bypass

U3 Humidifier

Output Opto-Isolation Chart

Note: Use Pin 4 on the output opto with reference to the correct transformer neutral/ground. The voltage level is 24 VAC.

Control Output Triac Legend:1 to 5 Ton Mini-Mate2 and 1 to 3 Ton Datamate Units

Triac Purpose Triac Purpose

Q1 Low Fan Q4 Cooling

Q2 Reheat Q5 Hot Gas Bypass

Q3 Humidifier

Triac Chart


136

Unit Control Opto and Triac Typical Locations:1 to 5 Ton Mini-Mate2 and 1 to 3 Ton Datamate Units

1 to 5 Ton Mini-Mate2 Opto-Isolators and Triac Locations


137

Alarm Input Opto Legend: 8 Ton Mini-Mate2 Units. .


U15 Air Safety Switch U23 Power On

U16 Custom Alarm 1 U24 Compressor 2 Overload

U17 Custom Alarm 2 U25 Low Pressure Switch 2

U18 High Water Alarm U26 High Hea

U19 Custom Alarm 3 U27 Compress d

U20 Humidifier Problem U28 Low Pres

U21 Filter Clog switch U29 High Hea

U22 Main Fan Overload

Input Opto-Isolator Chart

Note: Use Pin 5 on the input opto-isolator with reference to thcheck. The voltage level is 5 VDC.

Control Output Opto Legend: 8 Ton Mini-Ma

Opto Purpose Opto P

U1 Reheat 1 U10 Compress

U2 Reheat 2 U11 Econ-O-C

U3 Reheat 3 U12 Liquid Li

U4 Humidifier U13 Hot Gas B

U5 Main Fan U14 Compress

U8 Liquid Line Solenoid 2 U17 CW Actu

U9 Hot Gas Bypass 2 U18 CW Actu

Output Opto-Isolator Chart

Note: Use Pin 4 on the output opto-isolator with reference to neutral/ ground. The voltage level is 24 VAC.

d Pressure 2

or 1 Overloa

sure Switch 1

d Pressure 1

e V- terminal for voltage

te2 Units

urpose

or 2

ycle Relay (R5)

ne Solenoid 1

ypass 2

or 1

ator

ator Close

the correct transformer


138

Control Output Triac Legend: 8 Ton Mini-Mate2 Units.

Triac Purpose Triac Purpose

Q1 Reheat 1 Q10 Compressor 2

Q2 Reheat 2 Q11 Econ-O-Cycle Relay (R5)

Q3 Reheat 3 Q12 Liquid Line Solenoid 1

Q4 Humidifier Q13 Hot Gas Bypass 2

Q5 Main Fan Q14 Compressor 1

Q8 Liquid Line Solenoid 2 Q17 CW Actuator

Q9 Hot Gas Bypass 2 Q18 CW Actuator Close

Triac Chart


139


140

8 Ton Mini-Mate2 Opto-Isolators and Triac Locations

Control Input Check (Glycol Sensors)The 8 Ton Mini-Mate2 unit supplied with the Glycool option is supplied with a sensor toprovide the needed input to the control board, this is the glycol fluid temperature. Thecontrol input check allows the end user to better troubleshoot the glycool type units. Thesensor is located on the entering glycol line to the unit. The return air sensor is used as aninput to the unit control software program to calculate the needed capacity. The chart thatfollows can help to troubleshoot this circuit.

Glycol Comparator Circuit

Use the table below to check the glycool thermistor sensor for accuracy. To read theresistance value of the thermistor it must be electrically removed from the circuit.

TemperatureºF (ºC)

Resistance ValueOhms

TemperatureºF (ºC)

Resistance ValueOhms

50.0ºF (10ºC) 19,899.0 73.4ºF (23ºC) 10,922.051.8ºF (11ºC) 18,970.0 75.2ºF (24ºC) 10,450.053.6ºF (12ºC) 18,089.0 77.0ºF (25ºC) 10,000.055.4ºF (13ºC) 17,254.0 78.8ºF (26ºC) 9,572.057.2ºF (14ºC) 16,462.0 80.6ºF (27ºC) 9,165.059.0ºF (15ºC) 15,711.0 82.4ºF (28ºC) 8,777.460.8ºF (16ºC) 14,998.0 84.2ºF (29ºC) 8,408.362.6ºF (17ºC) 14,332.0 86.0ºF (30ºC) 8,056.864.4ºF (18ºC) 13,680.0 87.8ºF (31ºC) 7,721.866.2ºF (19ºC) 13,071.0 89.6ºF (32ºC) 7,402.668.0ºF (20ºC) 12,492.0 91.4ºF (33ºC) 7,098.369.8ºF (21ºC) 11,419.0 93.2ºF (34ºC) 6,808.271.6ºF (22ºC) 11,419.0 95.0ºF (35ºC) 6,531.4

Mini-Mate2Control BoardA/Q

Plug Pin P7 1 P7 2


141

Sensor Temperature to Resistance Table

Control Input Check (Temperature/ Humidity Sensors)Troubleshooting input signals requires knowledge of devices, programs, and Liebertwiring symbols. All points indicated in this text are on the standard wiring diagramsupplied with each Liebert unit. Follow the procedure below when troubleshooting aninput problem.

Step 1: Read and record all programmed and displayed information. (This information will aid in diagnostics. For example, is there a true call for an output function).

Step 2: Use a good digital meter to check all required voltage sources (check for 24 VAC and 5VDC).

Step 3: Inspect all connection points for a proper connection.

When having a problem with either the temperature or humidity control, first check thesensors. This board is static sensitive and should be handled with care. The power sourcefor this board is 5 VDC. The sensor operation can be checked while functioning in thecircuit. First take a frequency measurement and then compare to the Frequency charts onpages 137 and 138 for temperature accuracy and humidity accuracy.

Use a Fluke Multimeter and take the frequency readings at the following points.

Point 1: Read between PINS 4 and V- for temperature and PINS 3 and V- for humidity on the temperature conversion board (normally located in the unit return air section).

Conversion BoardPin Callout: 1: V- (5 VDC) 2: V+ (5 VDC) 3: Humidity Signal 4: Temperature Signal

Point 2: Read the same PIN numbers at the unit microprocessor board.

1 2 3 4 Plug P1

Pins


142

Frequency Conversion Chart (Temperature)The older style mini-Mate, mini-Mate Plus and Datamate units are supplied with a plug instyle of temperature sensor, the field technician can also read the resistance of the sensorand compare to the above table. The following resistance values may also be used by thefield service technician to validate the microprocessor interpretation of the roomenvironmental conditions. By substituting a known resistance value, the technician cancheck the accuracy of the unit control by determining the required outputs and checking foractual unit load activation.

Example, based on the following program points: Set High Temp of 75ºF, Set High TempAlarm of 85ºF, and no temperature calibration, replacing the temperature sensor with aresistance of 724 ohms (90ºF) the following should occur at the unit:

* Cooling Status Display * Numerical display should indicate 90ºF* Unit full cooling operation * Audible/ visual high temperature alarms

Temp (ºF) Ohms Hertz Temp (ºF) Ohms Hertz Temp (F) OhmsH35 2833 317 54 1739 494 73 1100 733

36 2767 324 55 1700 504 74 1075 74737 2695 332 56 1659 515 75 1048 76338 2635 339 57 1619 526 76 1023 77839 2569 347 58 1582 537 77 1000 79340 2498 356 59 1542 549 78 976 80941 2439 364 60 1505 561 79 951 82642 2381 372 6 1471 572 80 929 84243 2327 380 62 1437 584 81 906 85944 2268 389 63 1401 597 82 884 87645 2205 399 64 1369 609 83 862 89446 2152 408 65 1335 622 84 840 91247 2089 419 66 1304 635 85 820 93048 2030 430 67 1273 648 86 800 94849 1974 441 68 1241 662 87 781 96650 1916 453 69 1213 675 88 762 985


143

51 1870 463 70 1184 689 89 743 100452 1826 473 71 1156 703 90 724 102453 1783 483 72 1127 718

Frequency Conversion Chart (Temperature)


144

Frequency Conversion Chart (Humidity)The older style mini-Mate, mini-Mate Plus and Datamate units are also supplied with aplug in style of humidity sensor, the humidity sensor should never be measured forresistance, this will damage sensor. The following resistance values may also be used bythe field service technician to validate the microprocessor interpretation of the roomenvironmental conditions. By substituting a known resistance value, the technician cancheck the accuracy of the unit control by determining the required outputs and checking for

actual unit load activation.

RH (%) KOHMs Hertz RH (%) KOHMs Hertz22 3420 28.11018 52 60 573.600324 2200 35.27863 54 42 734.817826 1700 41.15389 56 32 872.277928 1300 49.05784 58 28 943.179530 900 63.83209 60 23 1050.202032 750 73.32796 62 18 1185.123034 600 87.41595 64 15 1284.390036 450 110.48940 66 13 1360.487038 316 148.50520 68 10 1493.430040 250 181.08070 70 8.5 1570.266042 200 218.75000 72 7.42 1630.726044 160 263.92310 74 6.2 1704.936046 120 334.84300 76 5.2 1771.048048 942 406.85970 78 4.5 1820.491050 80 462.29470 80 3.6 1888.3050

Frequency Conversion Chart (Humidity)


145

Mini-Mate2 and Datamate SystemsThe Mini-Mate2 and Datamate systems are normally supplied with the temperature andhumidity sensors installed on the wall mounted control board, they can not be removed.To perform the above described test procedure, the field technician must modify a sparetemperature/ humidity board. The modification consists of carefully removing the factoryinstalled sensors from a spare temperature/ humidity board and replacing them withinsulated leads that can be connected to the know resistance device. Use an additional P1cable to connect the modified temperature/ humidity board to the control board for testpurposes.

The field technician must unplug the factory installed P1 cable from its socket on thecontrol board and plug the P1 cable from the test temperature/ humidity board. When thetest procedure has been completed, remove technician must remove the test board from theunit and return the factory installed cable to its original plug connection.

Use the previous tables to determine the required resistance values for performing thevarious tests.

Moisture Content Charts

The following charts show moisture content of various levels of relative humidity forgiven temperatures. Follow the procedures below to use the charts:

STEP 1 - Locate the chart for the temperature with which you are working.

STEP 2 - Locate the line with the relative humidity with which you are working.

STEP 3 - Read the moisture content of the relative humidity in either grains per cubic foot or grains per pound of air.

For example, you have a room temperature of 70°F and 50% relative humidity.

STEP 1 - Locate the chart for 70°F.

STEP 2 - Locate the line with relative humidity 50%.

STEP 3 - Read the moisture content value of 50% relative humidity (4.0275 grains per cubic foot of air OR 55.86143 grains per pound of air).


146

Moisture Content at Temperature = 80°F (26.7ºC)RH Grains Per Cu Ft Grains Per Lb.

35 3.864 53.5936836 3.9744 55.1249337 4.0848 56.6561838 4.1952 58.1874339 4.3056 59.7186840 4.416 61.2499241 4.5264 62.7811642 4.6368 64.3124143 4.7472 65.8436744 4.8576 67.3749245 4.968 68.9061646 5.0784 70.4374147 5.1888 71.9686548 5.2992 73.499949 5.4096 75.0311550 5.52 76.562451 5.6304 78.0936552 5.7408 79.624953 5.8512 81.1561554 5.9616 82.6873955 6.072 84.2186456 6.1824 85.7498957 6.2928 87.2811258 6.4032 88.8123959 6.5136 90.3436260 6.624 91.8748861 6.7344 93.4061262 6.8448 94.9373863 6.9552 96.4686264 7.0656 97.9998765 7.176 99.53111


147


35 3.7485 51.991736 3.8556 53.4771737 3.9627 54.9626538 4.0698 56.4481339 4.1769 57.933640 4.284 59.4190841 4.3911 60.9045642 4.4982 62.3900443 4.6053 63.8755144 4.7124 65.3609945 4.8195 66.8464746 4.9266 68.3319447 5.0337 69.8174248 5.1408 71.302949 5.2479 72.7883850 5.355 74.2738551 5.4621 75.7593352 5.5692 77.244853 5.6763 78.7302854 5.7834 80.2157555 5.8905 81.7012356 5.9976 83.1867157 6.1047 84.6721858 6.2118 86.1576759 6.3189 87.6431460 6.426 89.1286261 6.5331 90.614162 6.6402 92.0995863 6.7473 93.5850464 6.8544 95.0705265 6.9615 96.55601


148


35 3.633 50.3897136 3.7368 51.8294237 3.8406 53.2691338 3.9444 54.7088339 4.0482 56.1485440 4.152 57.5882441 4.2558 59.0279542 4.3596 60.4676543 4.4634 61.9073644 4.5672 63.3470745 4.671 64.7867746 4.774801 66.2264847 4.8786 67.6661848 4.9824 69.1058949 5.0862 70.545650 5.19 71.985351 5.2938 73.42552 5.3976 74.8647153 5.5014 76.3044154 5.605201 77.7441355 5.709 79.1838356 5.812801 80.6233557 5.9166 82.0632558 6.0204 83.5029559 6.1242 84.9426560 6.228 86.3823661 6.3318 87.8220762 6.4356 89.2617663 6.5394 90.7014864 6.6432 92.1411865 6.747 93.58089


149


35 3.521 48.8362836 3.6216 50.231637 3.7222 51.6269138 3.8228 53.0222439 3.9234 54.4175640 4.024 55.8128841 4.124601 57.2082142 4.2252 58.6035343 4.3258 59.9988544 4.4264 61.3941745 4.527 62.7894946 4.6276 64.1848147 4.7282 65.5801348 4.8288 66.9754649 4.9294 68.3707850 5.03 69.766151 5.1306 71.1614352 5.2312 72.5567453 5.3318 73.9520654 5.4324 75.3473855 5.533001 76.7427156 5.6336 78.1380357 5.734201 79.5333658 5.8348 80.9286859 5.935401 82.3240160 6.036001 83.7193361 6.136601 85.1146562 6.237201 86.5099663 6.3378 87.9052964 6.438401 89.3006165 6.539 90.69593


150


35 3.41215 47.3265236 3.50964 48.6787137 3.60713 50.0308938 3.70462 51.3830739 3.80211 52.7352740 3.8996 54.0874541 3.99709 55.4396442 4.09458 56.7918243 4.19207 58.1440144 4.28956 59.496245 4.38705 60.8483846 4.48454 62.2005747 4.58203 63.5527648 4.67952 64.9049449 4.77701 66.2571350 4.8745 67.6093151 4.97199 68.961552 5.06948 70.3136853 5.16697 71.6658754 5.26446 73.0180555 5.36195 74.3702456 5.45944 75.7224357 5.55693 77.0746158 5.65442 78.426859 5.75191 79.7789860 5.8494 81.1311861 5.94689 82.4833662 6.04438 83.8355563 6.14187 85.1877364 6.23936 86.5399265 6.336849 87.8921


151


35 3.3068 45.8653236 3.40128 47.1757537 3.49576 48.4861938 3.59024 49.7966339 3.68472 51.1070740 3.7792 52.417541 3.87368 53.7279442 3.96816 55.0383843 4.06264 56.3488244 4.15712 57.6592645 4.251601 58.969746 4.34608 60.2801347 4.44056 61.5905748 4.53504 62.90149 4.62952 64.2114550 4.724 65.5218851 4.81848 66.8323152 4.91296 68.1427653 5.00744 69.4531954 5.10192 70.7636355 5.1964 72.0740756 5.29088 73.3845157 5.38536 74.6949558 5.479841 76.0053959 5.57432 77.3158160 5.6688 78.6262561 5.76328 79.936762 5.85776 81.2471363 5.95224 82.5575764 6.04672 83.8680165 6.1412 85.17844


152


35 3.20355 44.4332436 3.29508 45.7027637 3.38661 46.9722838 3.47814 48.241839 3.56967 49.5113240 3.6612 50.7808541 3.75273 52.0503742 3.84426 53.3198943 3.93579 54.5894144 4.02732 55.8589345 4.11885 57.1284546 4.21038 58.3979747 4.30191 59.6674948 4.39344 60.9370149 4.48497 62.2065450 4.5765 63.4760551 4.66803 64.7455852 4.75956 66.015153 4.85109 67.2846154 4.94262 68.5541455 5.03415 69.8236656 5.12568 71.0931857 5.21721 72.362758 5.30874 73.6322359 5.40027 74.9017360 5.4918 76.1712661 5.58333 77.4407962 5.67486 78.710363 5.76639 79.9798364 5.85792 81.2493565 5.94945 82.51887


153


35 3.10345 43.0448536 3.19212 44.274737 3.28079 45.5045638 3.36946 46.7344139 3.45813 47.9642640 3.5468 49.1941241 3.63547 50.4239742 3.72414 51.6538243 3.81281 52.8836744 3.90148 54.1135245 3.99015 55.3433846 4.07882 56.5732347 4.16749 57.8030948 4.25616 59.0329449 4.34483 60.2627950 4.4335 61.4926451 4.52217 62.7224952 4.61084 63.9523553 4.69951 65.182254 4.78818 66.4120655 4.87685 67.6419156 4.96552 68.8717657 5.05419 70.1016158 5.14286 71.3314659 5.23153 72.5613260 5.3202 73.7911761 5.40887 75.0210262 5.49754 76.2508763 5.58621 77.4807364 5.67488 78.7105865 5.76355 79.94044


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35 2.9988 41.5933636 3.08448 42.7817437 3.17016 43.9701238 3.25584 45.158539 3.34152 46.3468840 3.4272 47.5352741 3.51288 48.7236542 3.59856 49.9120343 3.68424 51.1004144 3.76992 52.2887945 3.8556 53.4771746 3.94128 54.6655547 4.02696 55.8539348 4.11264 57.0423249 4.19832 58.230750 4.284 59.4190851 4.36968 60.6074652 4.45536 61.7958453 4.54104 62.9842254 4.62672 64.1726155 4.7124 65.3609956 4.79808 66.5493757 4.88376 67.7377558 4.96944 68.9261359 5.05512 70.1145260 5.1408 71.3028961 5.22648 72.4912862 5.31216 73.6796663 5.39784 74.8680564 5.48352 76.0564265 5.5692 77.2448


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35 2.91165 40.3845936 2.99484 41.5384337 3.07803 42.6922838 3.16122 43.8461339 3.24441 44.9999740 3.3276 46.1538141 3.41079 47.3076642 3.49398 48.4615143 3.57717 49.6153544 3.66036 50.769245 3.74355 51.9230446 3.82674 53.0768847 3.90993 54.2307348 3.99312 55.3845849 4.07631 56.5384250 4.1595 57.6922751 4.24269 58.8461152 4.32588 59.9999653 4.40907 61.153854 4.49226 62.3076555 4.57545 63.4614956 4.65864 64.6153357 4.74183 65.7691858 4.825021 66.9230459 4.908211 68.0768860 4.9914 69.2307261 5.07459 70.3845762 5.15778 71.5384163 5.240971 72.6922664 5.32416 73.846165 5.40735 74.99994


156


35 2.81925 39.10336 2.8998 40.2202337 2.98035 41.3374638 3.0609 42.4546939 3.14145 43.5719240 3.222 44.6891441 3.30255 45.8063742 3.3831 46.923643 3.46365 48.0408344 3.5442 49.1580645 3.62475 50.2752946 3.7053 51.3925247 3.78585 52.5097548 3.8664 53.6269749 3.94695 54.744250 4.0275 55.8614351 4.10805 56.9786652 4.1886 58.0958853 4.269151 59.2131154 4.349701 60.3303555 4.43025 61.4475756 4.510801 62.564857 4.59135 63.6820358 4.6719 64.7992559 4.75245 65.9164860 4.833 67.0337161 4.91355 68.1509462 4.994101 69.2681863 5.074651 70.385464 5.1552 71.5026365 5.23575 72.61986


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35 2.7293 37.8553936 2.80728 38.9369737 2.88526 40.0185638 2.96324 41.1001439 3.04122 42.1817340 3.1192 43.263341 3.19718 44.3448942 3.27516 45.4264743 3.35314 46.5080544 3.43112 47.5896445 3.5091 48.6712246 3.58708 49.752847 3.66506 50.8343848 3.74304 51.9159649 3.82102 52.9975550 3.899 54.0791351 3.97698 55.1607252 4.05496 56.242353 4.13294 57.3238954 4.21092 58.4054655 4.2889 59.4870456 4.36688 60.5686357 4.44486 61.6502158 4.52284 62.7317959 4.60082 63.8133860 4.6788 64.8949661 4.75678 65.9765362 4.83476 67.0581163 4.91274 68.139764 4.99072 69.2212865 5.0687 70.30286


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35 2.64985 36.7534236 2.72556 37.8035237 2.80127 38.8536238 2.87698 39.9037139 2.95269 40.9538140 3.0284 42.0039141 3.10411 43.0540142 3.17982 44.1041143 3.25553 45.154244 3.33124 46.204345 3.40695 47.254446 3.48266 48.3044947 3.55837 49.3545948 3.63408 50.4046949 3.70979 51.4547950 3.7855 52.5048951 3.86121 53.5549952 3.93692 54.6050953 4.01263 55.6551854 4.08834 56.7052855 4.16405 57.7553856 4.23976 58.8054757 4.31547 59.8555758 4.39118 60.9056759 4.46689 61.9557660 4.5426 63.0058761 4.61831 64.0559662 4.694021 65.1060663 4.76973 66.1561664 4.84544 67.2062565 4.92115 68.25635


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35 2.5578 35.4766936 2.63088 36.4903137 2.70396 37.5039338 2.77704 38.5175539 2.85012 39.5311640 2.9232 40.5447941 2.99628 41.558442 3.06936 42.5720243 3.14244 43.5856544 3.21552 44.5992645 3.2886 45.6128846 3.36168 46.6265147 3.43476 47.6401248 3.50784 48.6537449 3.58092 49.6673650 3.654 50.6809851 3.72708 51.694652 3.80016 52.7082253 3.87324 53.7218454 3.94632 54.7354655 4.0194 55.7490856 4.09248 56.762757 4.16556 57.7763258 4.238641 58.7899459 4.31172 59.8035660 4.3848 60.8171861 4.45788 61.830862 4.53096 62.8444263 4.60404 63.8580464 4.67712 64.8716665 4.750201 65.88528


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35 2.4759 34.3407336 2.54664 35.321937 2.61738 36.3030638 2.68812 37.2842239 2.75886 38.2653940 2.8296 39.2465541 2.90034 40.2277242 2.97108 41.2088843 3.04182 42.1900544 3.11256 43.1712145 3.1833 44.1523746 3.25404 45.1335447 3.32478 46.114748 3.39552 47.0958749 3.46626 48.0770350 3.537 49.0581951 3.60774 50.0393552 3.67848 51.0205253 3.74922 52.0016854 3.81996 52.9828555 3.8907 53.9640156 3.96144 54.9451757 4.03218 55.9263458 4.10292 56.907559 4.17366 57.8886660 4.2444 58.8698361 4.31514 59.8509962 4.38588 60.8321663 4.45662 61.8133264 4.52736 62.7944965 4.5981 63.77564


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35 2.39575 33.2290536 2.4642 34.1784637 2.53265 35.1278538 2.6011 36.0772639 2.66955 37.0266640 2.738 37.9760641 2.80645 38.9254642 2.8749 39.8748643 2.94335 40.8242644 3.0118 41.7736645 3.08025 42.7230746 3.1487 43.6724747 3.21715 44.6218748 3.2856 45.5712749 3.35405 46.5206750 3.4225 47.4700851 3.49095 48.4194752 3.5594 49.3688853 3.62785 50.3182854 3.6963 51.2676855 3.76475 52.2170856 3.8332 53.1664857 3.90165 54.1158958 3.9701 55.0652859 4.03855 56.0146960 4.107 56.9640961 4.17545 57.9134962 4.2439 58.8628963 4.31235 59.8122964 4.3808 60.7616965 4.44925 61.7111


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Troubleshooting Checklist1. Check the obvious before beginning troubleshooting.

A. Be sure that a remote control switch has not been shut off. B. Be sure that the communication cable is properly connected. C. Be sure that power is reaching all modules associated with the system.

2. Power down the entire unit during the process of removing or replacing any component orcable.

A. Serious damage to components may result if this step is not taken.B. After removal or replacement actions, power may be restored to the unit.

3. Wear a personal ground strap when handling printed circuit boards or associated connectingcables. Static electricity, besides being annoying, can damage delicate electronic components.

4. Protect exposed components from accidental contact by personnel or dropped hardware ortools.

5. When checking voltage, use the correct reference (ground) points. The chassis is not alwaysthe correct ground point, especially within the electronic housing.

6. Reassemble modules correctly.

A. Observe assembled appearance prior to disassembly.B. Replace all hardware (especially insulating or nylon hardware) in the same places and in the

same relationship as the original.

7. When advised to check and replace cables, do the following:

A. Inspect for damaged insulation, broken conductors, and/or loose connectors. B. Check continuity with an ohm meter (Flex cable while checking.). C. Make certain that connectors mate firmly with proper receptacles.

8. When changing set points to cause a call for heating or cooling, set the points at least 10°-15°above (for heating) or below (for cooling) the present room temperature.

9. Bring the room temperature level to within the working range of the equipment (35°-90°F)before attempting troubleshooting.

10. Bring the room humidity level to within the working range of the equipment (35%-65%) before attempting troubleshooting.


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Chapter 9

mini-MATE Solid State Control

• Standard and Optional Features

• Operating Procedures

• Schematics (Drawing Number Order) 1C18785 mini-MATE Chilled Water2SP-2059 Earliest mini-MATE

2SP-2059 2nd Generation mini-MATE

• Troubleshooting


164

Standard and Optional Features

Air Cooled DX Module Standard Features:

Compressor - High efficiency rugged design hermetic with suction gas cooled motor,internal vibration isolating mountings, internal current/thermal overloads, internal pressurerelief; operates at 3500 RPM @ 60 Hz.

Evaporator and Condensing Coils - Constructed of copper tubes in staggered tubepattern; tubes expanded into continuous high efficiency aluminum plate type fins;evaporator coil set in stainless steel condensate drain pan.

Refrigeration System (Single Circuit) - Includes externally equalized expansion valve,liquid line filter dryer, high pressure switch set at 360 PSIG, and access fittings on suctionand discharge lines; module is pre-charged with refrigerant and sealed for reliability andefficiency.

Fan Assembly - Centrifugal type, double width, double inlet, with direct drive fan motormounted to blower housing and includes lifetime lubricated bearings.

Controls - Solid state design including unit stop/run switch, temperature set point controland optional humidity set point control on units with humidifier package; mounted indecorative wall box for remote mounting.

Cabinet and Chassis - Constructed of zinc-coated steel for strength aresistance with thermal insulation to prevent co ation iwith the chassis for mounting.

Grill/Filter Pack urn and supply air grills sized to fit standard 21219 mm) opening of standard dropped ceiling; grills hinged to allowcomponent access.

Water Cooled DX Module Standard Features:

Compressor - High efficiency rugged design hermetic with suction ginternal vibration isolating mountings, internal current/thermal overlorelief; operates at 3500 RPM @ 60 Hz.

Evaporator Coil - Constructed of copper tubes in staggered tube pattinto continuous high efficiency aluminum plate type fins; evaporator steel condensate drain pan.

nd corrosionsolators provided

ft x 4 ft (609 mm x
- Ret
ndensation; vibr

filter removal and

as cooled motor,ads, internal pressure

ern; tubes expandedcoil set in stainless


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Refrigeration System (Single Circuit) - Includes externally equalized expansion valve,liquid line filter dryer, high pressure switch set at 360 PSIG, and access fittings on suctionand discharge lines; module is pre-charged with refrigerant and sealed for reliability andefficiency.



Cabinet and Chassis - Constructed of zinc-coated steel for strength and corrosionresistance with thermal insulation to prevent condensation; vibration isolators providedwith the chassis for mounting.

Grill/Filter Pack - Return and supply air grills sized to fit standard 2 ft x 4 ft (609 mm x1219 mm) opening of standard dropped ceiling; grills hinged to allow filter removal andcomponent access.

Unit Water Circuits - Includes condenser, regulating valve, piping and female pipe threadconnectors on both supply and return lines; circuit designed for maximum system waterpressure of 150 PSIG (1304 kPa).

Water Cooled Condenser - Heavy duty tube-in-tube coaxial counter flow condenser,painted with black polyurethane paint.

Regulating Valve - Pressure operated 2-way water regulating valve maintains accuratecondensing temperature for various entering water flow rates and temperatures.

Chilled Water Module Standard Features:

Cooling Coil - Constructed of copper tubes in staggered tube pattern; tubes expanded intocontinuous high efficiency aluminum plate type fins; evaporator coil set in stainless steelcondensate drain pan.

Chilled Water Circuit - Single circuit includes chilled water piping, 2-way chilled watersolenoid valve, bleed valve, and female pipe thread connectors on both supply and returnlines; maximum working pressure is 300 PSIG.



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Cabinet and Chassis - Constructed of zinc-coated steel for strength and corrosionresistance with thermal insulation to prevent condensation; vibration isolators providedwith the chassis for mounting.

Grill/Filter Pack - Return and supply air grills sized to fit standard 2 ft x 4 ft (609 mm x1219 mm) opening of standard dropped ceiling; grills hinged to allow filter removal andcomponent access.

Optional Features include the following:

Reheat/Humidity Control Package, all Systems - Package provides reheat,humidification and dehumidification control; consists of a reheat element, pad typehumidifier, fill valve, y-strainer and electric controls; maximum working pressure 150PSIG.

Winch/Rigging Device, all Systems - Easily attached rigging device, consisting of winch,cable, lifting hook and lifting brace, to allow one person to raise or lower the unit chassisup to 10 ft (305 cm).

Condensate Pump, all Systems - Capacity of 89 GPH (335 l/h) at 10 ft (29 kPa) of headfor 277V units, and 120 GPH (454 l/h) at 10 ft (29 kPa) of head for 208/230V units; pumpcomplete with integral float switch, pump, motor assembly and reservoir; pump assemblydesigned to mount to side of unit cabinet.

Indoor Condenser Fan, Air Cooled Systems only - Uses dropped ceiling as condenserair plenum; includes centrifugal type, double width, double inlet blower, with direct drivesingle speed fan motor, and enclosure for direct mounting to the condenser end of module;condenser electrical connection to cooling module made by connecting the factory wiredplug.

Outdoor Condenser Fan, Air Cooled Systems only - Designed for use with ducted air at.5" (124.5 pa) external static pressure; includes centrifugal type, double width, double inletblower, direct drive 3-speed motor and enclosure for direct mounting to condenser end ofmodule; multiple step thermostat provides head pressure control and system operationdown to 30°F (-1°C); condenser electrical connection to cooling module made byconnecting factory wired plug.


167

Operating Procedures

With voltage supplied and the Stop/Run toggle switch (located on the wall mountedcontrol box) in the Run position, the evaporator fan motor is energized. If the temperaturesensor senses a rise in room temperature, the temperature controller starts the compressor(and the condenser fan if the unit is air cooled). As the room temperature drops, thecontroller shuts down the compressor.

Units with Reheat and Humidifier

If the room temperature drops below the set point (on the control box), the reheatenergizes. Room humidity is controlled by the humidity sensor. If room humidity dropsbelow the set point (on the control box), the humidifier solenoid and water heater areactivated and water begins to flow. When the room is satisfied, the water heater de-energizes but water continues to flow through the heater and pad until the heater is cooled.If room humidity rises beyond the set point (on the control box), the controller activatesthe compressor and condenser.

Electrical Control Theory

The basis for the solid-state control operation is resistance. This is best explained bylooking at an example of actual operation.

Control operation of temperature begins at the temperature set point adjustment knob. Thedesired temperature set point that is dialed in is converted to resistance. This resistancelevel is sent to the control board in the unit. The temperature sensor is also sending aresistance level equivalent to the temperature in the room to the control board. The controlboard compares the two resistance values and activate either a call for cooling, or ifequipped, a call for heating.

Control operation takes place using DC circuitry. The components to be activated(compressor contactor or reheat contractor) operate on AC circuitry. In order for the DCcircuitry to activate the AC components, a device called an opto-isolator is used. Thisopto-isolator, when activated by the DC circuit, activates an AC switch called a triac. Thetriac, because of its amperage handling capability, is used to switch on the contactor.

Humidifier

The need for humidity is established by the humidity sensor that is located in the remotewall mounted control box. A signal is sent to the Printed Circuit Board (PCB) within theunit. A triac closes, energizing the time delay relay (TDR). This relay has two sets ofcontacts for control of the heating element and make-up valve. When the call is present,the TDR energizes the TDR1 contact at the same time, thus holding TDR2 contact OFF for10 seconds. This allows the make-up valve to open and supply water to the water heater


168

assembly before the heater is energized by the TDR2 contact. During the sustained call forhumidity, water is circulated through the water heater assembly, reaching an approximatetemperature of 140°F (60°C). This temperature setting is made by adjusting the needlevalve in the water supply line after the water solenoid valve (HMV) (see humidifiermaintenance). If for some reason the outlet water temperature of the heater assemblyreaches 150°F (66°C), a safety stat shuts off the heating element.

During normal operation, water saturates the evaporative pad, and air flow across the padpicks up moisture to provide the needed room humidity requirement. When the call forhumidity is satisfied, the TDR (time delay relay) de-energizes and TDR2 contact opens atthe same time, holding TDR1 ON for an additional 10 seconds. This allows water to flowafter the heating element is turned off to cool it down, ending the sequence (see schematicfor electronic component locations).

Humidifier Maintenance

CAUTION: Before servicing the humidifier, make certain the unit power supply is turnedoff and water in the drain pan is no hotter than lukewarm.

If a humidifier is provided in the unit, the evaporative pad must be checked for a buildupof mineral deposits, especially in areas of high water impurity and continuous humidifierusage. The pad should be checked on a monthly basis and replaced when mineral buildup

High WaterTemp Stat150ºF (HTH)*

WaterHeater(H)

Unit FlowControlValve**

SolValve(HMV)

NeedleValve

StrainerEvaporativePad

Drain

Condensate Pan

* Excessive Temperature Deactivates the (HMV) and (H).** Flow Rate is ¼ GPM


169

begins to restrict the air flow through the pad. Remove the evaporative pad by lifting theretaining bracket on the inside top left of the pad and pulling it in and down.

Warning: Do not attempt to clean the humidifier evaporative pad. It should bediscarded and replaced if mineral accumulation impairs operation.

It is also necessary to periodically clean deposits from the humidifier drain pan. The panshould be cleaned with a stiff brush and flushed with water. It is also important to checkthe needle valve adjustment in the water supply line to ensure the proper water flow on amonthly basis.

Unit Startup

To start the unit, turn on the main power supply. Set the Stop/Run switch to Run. Tocheck the cooling operation, adjust the thermostat to a setting below room temperature.The compressor starts when the contactor closes. A time delay control is provided toprevent against rapid compressor restarts. To check the heating operation, adjust thethermostat to a setting above room temperature.

Unit Shutdown

To shut the unit off, set the Stop/Run switch to the Stop position.

The unit is equipped with a float switch that shuts the unit down if the drain is notfunctioning. Restart the system at the control box by turning the selector switch to Stopand then to Run.

To reset a high head pressure condition, manually reset at the control box by turning theselector switch to Stop and then to Run.

Wall Mounted Control Box

The solid-state wall mounted control box is available is three different control variationsdepending on unit configuration and factory or field installed options.

Standard, Cooling Only Control - Includes a Stop/Run switch and a temperature setpoint selector. The temperature sensor is mounted in the control box.

Complete, Temperature and Humidity Control - Includes a Stop/Run switch, atemperature set point selector. The humidity and temperature sensors are mounted in thecontrol box.

Stop/Run Control Only - Includes the Stop/Run switch. Temperature and/or humiditysensors are mounted internally in the unit.


170

First Generation mini-MATE Control Board Layout


171


172

Second Generation mini-MATE Control Board Layout


173


174


175

mini-MATE Chilled Water Schematic


176


177

mini-MATE DX Schematic, 1st Generation Control Board


178


179


180

mini-MATE DX Schematic, 2nd. Generation Control Board


181

Troubleshooting

1st Solid State mini-MATE Control

** Do not measure the resistance of the sensor with an OHM meter since the DCpotential will polarize the sensor element.


182

Troubleshooting

2nd Generation mini-MATE Control

** Do not measure the resistance of the sensor with an OHM meter since the DCpotential will polarize the sensor element.


183

mini-MATE Plus Solid State Control

• Control Theory

• Standard and Optional Features

• Sequence of Operation

• mini-MATE Design Upgrade

• Schematics (Drawing Number Order) 1C19528 MM Plus Evaporator, Solid State, 2 & 3 Ton 1C19600 MM Plus Condenser, 1 Phase 60 Hz, 2 & 3 Ton 1C19601 MM Plus Condenser, 3 Phase, 3 Ton (Indoor)

• Troubleshooting


184

Control TheoryThe basis for solid state control is resistance. This is best explained by looking at anexample of actual operation.

Temperature control begins at the temperature set point adjustment knob. The temperatureset point that is "dialed in" is converted to resistance. The resistance level is sent to thecontrol board. The temperature sensor is also sending to the control board a resistancelevel equivalent to the temperature in the room. The control board compares the tworesistance values and activates either a call for cooling or, if equipped, a call for heating.

The control operation described above takes place using DC circuitry. The componentsactivated (compressor contactor or reheat contactor) operate on AC circuitry. In order forthe DC circuitry to activate the AC components a device called an opto-isolator is used.The opto-isolator when activated by the DC circuit activates an AC switch called a triac.The triac then switches on the contactor.

Design FeaturesThe fan/coil module features a solid state control board that provides heating and coolingmodes. If the optional humidity control package is applied, the control boards alsoprovides humidifying and dehumidifying modes. The humidifier package is self-containedand includes the steam generator, drain valve, fill valve and electrical controls. Thepackage is available as a factory installed option or as a field retrofit.

The control transformer is set for a primary of 240 ACV and has a tap change of 208 VAC.The secondary is 24 VAC with a 12 VAC center tap. A 3.2 amp control circuit breaker ismounted to the control transformer.

The electric, fin tubular, low watt density single stage reheat is supplied with a line breaksafety that cuts out at 120°F (49°C).

The multi-speed fan motor is supplied with internal line break overload protection. Whenthe fan speed selector is at a high setting, the fan speed automatically changes from high tolow speed during dehumidification, and returns to high speed when dehumidification stops.

The remote wall box includes a fan speed select switch to select high or low fan speed, unitstop/run switch to shut the unit down, temperature set point control knob to set roomtemperature and humidity level (option).

A liqui-tect sensor is mounted in the evaporator coil drain pan and shuts down the unit inthe event of a blocked drain, thereby preventing overflow. Reset is accomplished byturning the unit off and on.


185

An automatic reset freezestat is supplied on all evaporator coils to prevent freezing. Ifevaporator temperature falls to 29°F (-1.7°C), the freezestat opens, shutting down thecondensing module until the evaporator temperature rises to 42°F (5.6°C).

Chilled water units are supplied with a 2-way solenoid valve. The valve is fully openwhile there is a call for cooling or dehumidification. When the call for cooling ordehumidification is satisfied, the valve closes.

The temperature and optional humidity sensors are located in the return air section of theunit. This location minimizes the effects of room loads on control system performance.

Customer connections are to the following points on the Fan/Coil module:

• The power distribution block for high voltage 208/230 VAC - 1 PH - 60 Hz• The ground lug for earth ground• The low voltage terminal strip 1 and terminal strip 2 for the condensing

module control circuit interlock• The low voltage terminal strip 5 and terminal strip 6 for the optional humidity

set point control• The PCB terminal block to position 1 and position 2 for the unit fan speed

select switch• The PCB terminal block two position 3 and 4 for the unit stop/run switch

Remote unit shutdown is available by replacing the OR jumper between P2-6 and P2-12 with customer supplied non-powered NC contacts.

Air Cooled Condensing Units

The mini-MATE Plus air cooled centrifugal condensing units are available in two modelsizes, 3 ton and 2 ton. Both sizes are available in 208-230/1/60 power. The 3 ton model isalso available in 208-230/3/60 power. Air cooled condensing units are rated for 95°F(35°C) ambient and .5" (124.5 pa) external static pressure.

Cabinet Design

The cabinet is constructed of galvanized steel and measures 21.5"w x 46.75"l x 22.38"h(546 mm x 1188 mm x 567 mm) and lined with thermal insulation. Service to thecompressor and the electric panel is from the end of the unit. Service access to the blowerand motor is from the bottom of the unit.The mini-MATE Plus centrifugal air cooled condensing unit is not suitable for outdooruse. If the condensing unit is located close to the outside of the building, rain hoods mustbe installed.


186

Hood intake dimensions should be the same as condenser return air dimensions. Inaddition, install triple layer bird screen over the rain hood openings to eliminate insects,birds, water or debris from entering the unit.

The condensing unit is hung from suspended threaded rods 3/8" SAE Grade 1 minimum(10 mm). The rods are attached to factory provided vibration isolators. The rubbervibration isolators are put into hanging brackets that bolt into the captive nuts on thebottom of the unit. Refer to the installation manual for your unit for more specific hangingdetails.

The inlet and discharge duct connections are provided with a 1" (25.4 mm) duct flange. Adrain pan is provided under the condenser coil for use during condenser coil wash-down.When the air cooled condensing unit is piggybacked with a fan/coil unit, the top of thecabinet is flush, while the bottom of the condensing unit is 1 3/4" (44.5 mm) higher thanthe bottom of the fan/coil unit. This height difference is included to permit the ceiling tileunderneath the condensing unit to be removed (for servicing the blower) after the unit andduct work are in place. Rubber spacers are provided to separate the fan/coil andcondensing unit in piggybacked installations. All eight support rods are required in apiggybacked installation.

Blowers/Motors

The mini-MATE Plus air cooled condensing units use direct drive centrifugal blowers anda draw through air pattern. The units are rated at .5" external static pressure. The 3 tonmodel, which uses a Lau DD 10 x 8A blower and a 1/23 horsepower motor, is rated at1650 cfm. The 2 ton model, which uses a Lau DD 9 x 9A blower and a 1/3 horsepowermotor is rated at 1000 cfm. Both motors are totally enclosed, use ball bearings, and aresingle phase (even on three phase models). The blower housing is provided withremovable inlet rings to allow servicing the blowers from the bottom of the unit.Discharge pressure is controlled by a solid state motor controller that senses dischargepressure and modulates fan speed from 0 to 1050 rpm. The fan motor begins to run whenthe discharge pressure rises above 190 PSIG and reaches full speed at 250 PSIG.

Humidifier

The mini-MATE Plus is available with a factory installed humidity control package. Thepackage is also available separately for field installation. The humidifier operates on240 VAC in its primary circuit and 24 VAC in its control circuit. The humidifier useselectrodes to induce a current through the water in a plastic bottle to generate steam.The humidifier is UL approved per UL standard 998 for humidifiers. It offers easy steambottle and inlet water strainer replacement through the electric box access panel. Thehumidifier assembly is completely self contained with the exception of power, watersupply, drain and steam distributor connections.


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Operation

The theory behind the humidifier operation is based on Ohm's Law, Volts + Amps xResistance. In a steam generating humidifier, volts remain constant at 230 VAC. Theresistance between the electrodes varies depending on several factors includingconductivity of the water, amount of electrode surface under water, and the condition ofthe electrodes. The amount of heat added to the water is equal to Amps x Volts, thussteam output is proportional to the amp draw. (Volts are constant). As the humidifieroperates, the conductivity of the water in the bottle increases as it boils down, and theamount of electrode surface area exposed increases as the water level increases. These twofactors contribute to increasing current draw over time. The current is limited by anautomatic reset overload relay. In this design we desired an output no greater than 5 lb./hrto limit the risk of excess moisture in the air stream condensing and dripping from the unit.An overload relay was selected which controls the peak output to under 5 lb./hr. At lowfan speed the output must be lowered further to avoid excess moisture. This was done byadding a second overload relay. This relay is brought into the circuit any time the fanmotor is switched to low speed.

Water flows into the bottle continuously during a call for humidification. The water flowrate is regulated through a pressure sensitive orifice in the water inlet valve and through alength of capillary tubing. If the fill rate is greater than the steam output then the waterlevel in the bottle will rise. The water level will rise until steam output equals the fill rateor until the water level reaches the system overflow tube and bypasses the drain valve. Ifthe overflow plugs, the water will overflow through the air gap, drain into the secondarydrain and run into the evaporator drain pan. During normal operation, when the outputlimiting relay trips, the drain valve will open until the relay resets and closes the valve.During this time, the water level in the bottle will fall. The water in the bottle can also bedrained through the drain valve by using the manual drain switch in the upper right handcorner of the humidifier cabinet. The humidifier drain flows directly into the condensatedrain pan.

An important feature of the humidifier design is its UL listing. To meet UL's requirementas described in section 45 of UL 998, the humidifier must not exceed a leakage ofelectricity to ground from any source in the system of greater than .5 milli-amp (.005A)during any operating mode. To meet this requirement, the entire drain system in thehumidifier is isolated from any ground sources by using nylon fittings, nylon tubing and aplastic drain valve whose stem and coil is isolated from the water by a nonconductivediaphragm in the valve body. The inlet fill tube (copper) was moved from the top of thebottle to a separate fill cup mounted on the cabinet and fills through the bottom of thebottle. To isolate the system during drain (manual or auto) a relay was added whichbreaks the circuit to the humidifier electrodes. This design produces a leakage current ofless than .5 milli-amps. A prototype set up using Columbus water had a leakage current of.1 milli-amp in normal operation.


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Major Components of the Humidifier System

Steam Bottle - A plastic throw away bottle made by Environheat LTD., England. It is the same as the one used in the Datamate.

Fill Valve - A cast bronze flow control with removable strainer and 240 volt solenoidvalve made by Hays. Its flow orifice is rated at .2 gpm.

Drain Valve - A 240 volt solenoid valve made of Noryl plastic with a viton isolation diaphragm. Its orifice is 5/32 in.

Control Relays:

1. Essex 1P2T. One is used for humidifier on/off control, the other is for high/low steamoutput selection. Coil is 24 volts.

2. ETA 1P1T bimetal thermal limit with automatic reset. One has a 4.5 amp nominalsetting for high output, the other has a 3 amp nominal setting for low output. Rated at240 volts.

3. Essex 3P2T. Added to break electrode leads in manual of automatic drain modes forlimiting leakage current. 240 volt coil.

Drain Switch - ALCO 2P2T latching switch for breaking humidification circuit andenergizing drain valve coil to open the valve. 240 volt.

Fill Capillary - .042 in. ID x 72 in. long copper tube to control fill rate. Maintainsadequate flow at low pressures (10 PSI) yet prevents excesswaste of water out overflow at high pressure (50 psi). FillCup - Liebert made nylon blocks with several functions:

1. Fill line attachment and 1" (25.4 mm) air gap for water supply codes.

2. Overflow anti-siphon.

3. Overflow to maintain water height in bottle.

4. Overflow hole in case drain plugs.


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Maintenance

The humidifier can be inspected for proper operation by visually inspecting the bottle forwater level and boiling and checking the nylon overflow line for water flow if the bottle isfull. The bottle and distributor tube will be hot! By pressing the manual drain switch, fillcan be stopped and drain started. Distinct solenoid "clicks" will be heard when workingproperly. If after some time of operation it appears the fill rate isn't keeping up with thesteam output, the fill valve screen, orifice and the capillary tube should be checked forobstructions. To do this, the bottle must be removed.

If the bottle must be removed or replaced, drain it first. Be sure to disconnect power to theunit. The run/stop switch does not disconnect the 240 volt supply to the humidifier!Remove the distributor connected to the bottle and the two electrode terminals. Lift thebottle out and swing around to loosen the drain fitting locknut. The new bottle is installedthe same way but does not require new water fitting locknuts and ferrules on the bottleconnections. When restarting, the bottle will take about 20 minutes to fill and 30 minutesto produce steam. If it won't start producing steam, some salt or other electrolyte should beadded to the water.

Applications Limitations

The humidifier is designed to operate with water systems having 10 to 150 psig waterpressure. Steam output varies greatly with water condition. Testing shows 3 to 4 lb./hraverage output is expected with Columbus water at high output. At a low setting, theoutput is 2.5 to 3 lb./hr. The humidifier on/drain cycle which limits output will carrydepending on water condition. Normal duration of this cycle is 2 to 3 minutes.


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Sequence of OperationFan/Coil Module

Power is applied to L1 and L2 of the power distribution block. The primary of the controltransformer is energized allowing the secondary to provide 24 VAC to the circuit breakerCB, and to the remote shutdown terminals P2-6 and P2-12. Power is then available atterminals TB2-3 and TB2-4, which are the customer connection points for the remoteSTOP/RUN switch S1.

When the stop/run switch S1 is closed the evaporator motor relay MR energizes and theevaporator fan motor starts. Power is also available at terminals TB2-1 and TB2-2, whichare the customer connection points for the remote fan speed select switch S2.

Note: The speed of the motor (high or low) is determined by the position of the fan speedselect switch S2. At the same time, 24 VAC is supplied to terminals 3 and 4 which are thecustomer connection points for the temperature set point switch TSP and terminals 5 and 6which are the customer connection points for the humidity set point switch HSP. Power isthen available for any mode of operation required, cooling, heating, humidifying ordehumidifying.

With a call for cooling, power is supplied to terminals 1 and 2 which are customerconnection points for the heat rejection interlock to the condensing module on DX units, orfactory connection points to open the chilled water valve on CW units.

With a call for heating, power is supplied to the Reheat contactor RH which closescontacts 1RH and 2RH to energize the reheat element. With a call for dehumidification,power is supplied to terminal 1 and 2 for the Heat rejection interlock to the condensingmodule on DX units, or to open the chilled water valve on CW units. In addition, power issupplied to the dehumidifier relay DHR, which when energized, changes the evaporatorfan motor speed from high to low. The humidity capacity relay HC is also energizedwhich switches the HC contacts for low humidifier capacity.

With a call to humidify, power is supplied to the humidifier contactor H which closes thecontact H to energize the humidifier. As the humidifier sees power, the fill valve opensand the humidifier relay R1 energizes, closing contacts 1R1 and 2R1 which turn on theelements in the steam bottle and opens contacts 3R1 to prevent the drain valve fromopening. The humidity capacity relay HC determines whether the humidifier operates inhigh or low capacity. As the humidifier runs the amp draw will continue to rise until theoverloads drop out. (OL1 at 4.5 amps for high capacity and OL2 at 3.0 amps for lowcapacity). When the overload drops out R1 de-energizes, opening 1R1 and 2R1 whichdisconnects power from the humidifier electrodes. At the same time 3R1 closes energizingthe drain valve. A manual drain can be accomplished by pressing the manual drain pushbutton switch S3. This closes the fill valve and de-energizes the R1 relay, dropping out the


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humidifier by opening contacts 1R1 and 2R1. At the same time the drain valve opens,allowing the bottle to drain.

In the event refrigerant temperature in the evaporator coil drops to 28°F (-2.2°C), thefreezestat F2 opens, breaking the circuit for the heat rejection interlock thus dropping outthe condensing module. The freezestat resets at 42°F (5.6°C) and is supplied on air andwater models only. In the event of a clogged evaporator drain the Liqui-tect sensor LTwill close, energizing the Control relay R. When the control relay R energizes it will lockitself in and drop out all other contactors and relays.

NOTE: In order to reset the control relay R, the unit stop/run switch S1 needs to beswitched off and then back on again.

Air Cooled Condenser (1 phase)

When power is applied to L1 and L2 of the power distribution block, the crankcase heaterCCH is energized. After receiving 24 VAC power from the Evaporator (Fan/Coil) moduleto terminals 1 and 2, the compressor contactor C1 energizes, closing contacts 1C1. Thecompressor COMP starts and the Fan speed control motor FS starts. A pressure operatedSolid State fan speed controller FS1 modulates the motor speed between 0 and 1050 RPM.

In the event of high pressure of 360 PSI in the discharge line, the high pressure stat HOPwill open, breaking the 24 VAC control circuit which will de-energize the compressorcontactor C1, opening contacts 1C1 and shutting down the Fan speed motor FS andcompressor COMP.

Air Cooled Condenser (3 phase)

When power is applied to L1, L2, and L3 of the power distribution block, the crankcaseheater CCH is energized. After terminals 1 and 2 have received 24 VAC power from theEvaporator (Fan/ Coil) module, the compressor contactor C1 energizes, closing contacts1C1, 2C1, and 3C1. The compressor COMP starts and the Fan speed control motor FSstarts. A pressure operated Solid State fan speed controller FS1 modulates the motor speedbetween 0 and 1050 RPM.

In the event of high pressure of 360 PSI in the discharge line, the high pressure stat HP willopen, breaking the 24 VAC control circuit which will de-energize the compressorcontactor C1, opening contacts 1C1 and shutting down the Fan speed motor FS andcompressor COMP.

Water Cooled Condenser (1 phase)

When power is applied to L1 and L2 of the power distribution block, the crankcase heaterCCH is energized. After terminals 1 and 2 have received 24 VAC power from the


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Evaporator (Fan/Coil) module, the compressor contactor C1 energizes, closing contacts1C1, and the compressor starts.

In the event of high pressure of 360 PSIG in the discharge line, the high pressure stat HPwill open, breaking the 24 VAC control circuit which will de-energize the compressorcontactor C1, opening contacts 1C1 and shutting down the Compressor COMP.

Water Cooled Condenser (3 phase)

When power is applied to L1, L2, and L3 of the power distribution block, the crankcaseheater CCH is energized. After terminals 1 and 2 have received 24 VAC power from theEvaporator (Fan/Coil) module, the compressor contactor C1 energizes, closing contacts1C1, 2C1, and 3C1, and the Compressor COMP starts.

In the event of high pressure of 360 PSI in the discharge line, the high pressure stat HP willopen, breaking the 24 VAC control circuit which will de-energize the compressorcontactor C1, opening contacts 1C1, 2C1, and 3C1 and shutting down the CompressorCOMP.

mini-MATE Plus Design Upgrade

The mini-MATE board was redesigned for the Mini-Mate Plus to incorporate thefollowing:

1. Fan speed control for dehumidification

2. 10 second response sensors

3. Sensor response adjustment potentiometer

4. Off cycle time delay

The general operation of the mini-Mate Plus control is the same as the old mini-Matecontrol except for the dehumidification stage and the off cycle time delay. A triac wasadded to the circuit to change fan speed in addition to turning on the compressor during acall for dehumidification. An off cycle time delay circuit prevents rapid compressorrecycling during cooling and dehumidification. The heating and humidification circuitryremained the same.

The following is a brief description of operation on the electronics for the new Mini-MatePlus control as well as the wall box assembly and the fast response temperature sensor.

The major change to the electronics was the addition of the fan speed change fordehumidification. When calling for dehumidification, a signal is sent to the triac (Q4)


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which puts the fan in low speed. The dehumidification circuit is designed with a manualfan speed select switch which is located on the wall box.

Connector P1 is a new connector location which may be used for status indicators in thefuture. 24 VAC signals are present which indicate when the reheat, cooling,dehumidification, or humidification stages are on. P1 may also be used as a test point tocheck the outputs for each stage. Refer to the schematic for pin location of each stage.

A fast response temperature sensor has been incorporated into the system to provide bettertemperature control. The sensor has a 10 second response time as compared to 90 secondson the current Mini-Mate control. This sensor will react faster to a change in temperature,therefore allowing for better control of the room temperature. Another feature of the mini-Mate Plus control is the sensor response time adjustment. The sensor response time wasshortened and a field adjustable response time circuit was added to the PC board to slowthe response time if necessary in the field. The range for the response time is from 10 to70 seconds (approximately) and is adjusted by the 500K Ohm trimmer located on the PCboard. When shipped from the factory, the trimmer is set for the fastest response time(trimmer pot is set for 0 Ohms) and can be adjusted for slower response if desired.

The off cycle time delay starts when a call for compressor operation (cooling ordehumidification) is turned off. This delay prevents the compressor from coming back onfor approximately 60 to 90 seconds. The delay is to prevent compressor short cycling.

The mini-MATE Plus wall box assembly has a HI/LO fan speed switch for manual fanspeed control. The potentiometers on the wall box are for temperature and humidityadjustment. The temperature potentiometer is 500 Ohms and has a temperature range of65°F (18.3ºC) to 85°F (29.4ºC). The humidity potentiometer is 1000 Ohms with a range of40% RH to 60% RH relative to R66 resistor. By increasing the value of R66, a lessermaximum RH may be achieved.

The mini-MATE Plus PC board is also equipped with two barrier strips (TB1 and TB2).The temperature sensor, humidity sensor, temperature set potentiometer are all connectedinto TB1. For exact locations of hookups, refer to the system electrical schematic. All 24VAC connections are connected to TB-2. Refer to system schematic for properconnections.


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mini-MATE PLUS CONTROL BOARD (PIN OUT)


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mini-MATE Control Board Layout


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mini-MATE Plus Schematic 2 and 3 Ton


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mini-MATE Plus 1 Phase Condenser Modules 2 and 3 Ton


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mini-MATE Plus 3 Phase Condenser Modules 2 and 3 Ton


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Troubleshooting


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Troubleshooting


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Chapter 10

Datamate Solid State Control

* Standard and Optional Features

* Control Relay BoardConnection PointsRelay Sockets

* Electro-Mechanical OperationPower UpStart CircuitCoolingHeatingDehumidificationHumidification

* Troubleshooting Guidelines

* Datamate Schematics (Drawing Number Order) 1C16377 - Datamate Electrical Schematic

121738 - DM Condenser, 1 Phase 60 Hz121739 - DM Condenser, 3 Phase 60 Hz121191 - PB Condenser, 1 Phase 60 Hz


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Standard and Optional Features

The Datamate consists of two components, an indoor evaporator module and a condensingmodule. The evaporator is installed indoors against a wall. Models are available in 1 1/2,2 and 3 ton capacities for use with either air, water, glycol or integral water/glycol cooledcondensing units.

Air Cooled - includes the evaporator section plus one of the following condensing units,95°F (35°C) ambient design.

Centrifugal Fan Unit - includes the compressor, condenser coil, centrifugal blowerassembly, high pressure switch, electronic head pressure control, filter dryer andsight glass. The unit must be mounted indoors. Duct flanges are provided.

Propeller Fan Unit - includes the compressor, condenser coil, prop fan, high pressure switch, Lee Temp head pressure control, filter dryer and sight glass. The unit isdesigned for outdoors.

Water/Glycol Cooled - includes the evaporator section plus a water/glycol cooledcondensing unit. The condensing unit includes the compressor, condenser, 2-way waterregulating valve, filter dryer and sight glass. Design pressure is 150 PSI. The condensingunit is designed to attach directly to the evaporator section to create a self-containedsystem.

Optional equipment and ship-with kits include a steam generating humidifier, condensatepump to remove humidifier drain water and evaporator condensation, pre-chargedrefrigerant line sets, a refrigerant line sweat adapter kit, and a 277V transformer.

Direct Expansion Fan Coil Module:

Evaporator Coil - constructed of copper tubes in a staggered tube pattern; tubesexpanded into continuous high efficiency aluminum plate type fins; coil set in stainlesssteel condensate drain pan

Refrigeration System (Single Refrigeration Circuit) - includes an externally equalized expansion valve, and quick-connect female couplings on both the suction and liquid lines;each female coupling provided with an access valve connection; module pre-charged withrefrigerant and sealed

Fan Assembly - quiet, direct drive 2-speed fan assembly with centrifugal type, doublewidth, double inlet blowers, and includes permanently lubricated bearings

Electro-Mechanical Controls - consist of a fan speed select switch, ON/OFF switch and atemperature select switch; mounted on unit behind a decorative dust cover for easy access


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Cabinet and Chassis - constructed of galvanized steel for strength and corrosionresistance; designed for easy installation and service access; painted removable exteriorpanels allow access to the electric box or refrigeration components for service andmaintenance; return and discharge air grilles heavy duty steel with baked enamel finish;evaporator module designed for either floor or wall mounting

Electric Reheat - low watt density tubular reheat element with non-corrosive metalsheath; provides one stage of non-ionizing reheat to maintain room dry bulb temperature

Filters – Reusable are located within the cabinet and serviceable without shutting downthe system

Optional Features include the following:Humidity Control Package - steam-generating humidifier factory installed and tested; adds pure water vapor to the room to maintain humidity within the levels specified by themanufacturer; consists of the steam canister with automatic flushing circuit, strainer, inletand drain, solenoid valves and a solid-state control system with both humidification anddehumidification controls

Pre-charged Refrigerant Line Set - one pre-charged liquid line and one insulated coppersuction line; each line has one male quick-connect coupling and one female quick-connectcoupling with an access valve connection; lines available in 15 ft (4.6m) and 30 ft (9.1m)lengths for interconnection of the remote condenser module (The maximum recommendeddistance between evaporator and condenser modules is 45 ft (13.7m.)

Condensate Pump - capacity of 18 GPH (68 l/h) at 20 ft (58 kPa); complete with integralfloat switch, pump, motor assembly and reservoir; designed to mount on the right end ofthe evaporator (indoor) module to allow condensate drainage into the reservoir; removeshumidifier drain water and evaporator condensation (When the evaporator is installedbelow the level of the gravity-fed drain line, the condensate must be installed.)

Indoor Centrifugal Air Cooled Condensing Module:Compressor - high efficiency rugged design hermetic with a suction gas cooled motor,internal vibration isolating mountings, internal current/thermal overloads, internal pressurerelief, internal solid state self-regulating crankcase heater; operates at 3500 RPM at 60 Hz.

Condenser Coil - constructed of copper tubes in a staggered tube pattern; tubesexpanded into continuous, high efficiency aluminum plate type fins; coil set in a drain panfor condenser coil wash down.

Refrigeration System (Single Circuit) - includes a liquid line filter dryer, refrigerant sightglass with moisture indicator, high pressure switch, and suction and liquid line quickconnect male couplings; module pre-charged with refrigerant and sealed


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Fan Assembly - centrifugal type, double width, double inlet, with a direct drive fan motormounted to the blower housing; includes lifetime lubricated bearings; pressure operatedsolid state motor controller modulates the motor speed from 0 to 1500 RPM to maintaindischarge pressure during ambient temperatures to -20°F (-28.9°C).

Cabinet and Chassis - constructed of galvanized steel for strength and corrosionresistance with 1/2" (12.7mm) 1 1/2 lb. (.68kg) thermal insulation to minimize heat loss

andprevent condensation; removable panels allow access to the electric panel, to thecompressor, and to the condenser blower; vibration isolators provided with the chassis formounting

Outdoor Lee-Temp Prop Fan Control Module Features:Compressor - high efficiency rugged design hermetic with a suction gas cooled motor, internal vibration isolating mountings, internal current/thermal overloads, internal pressurerelief, internal solid state self-regulating crankcase heater; operates at 3500 RPM at 60 Hz

Condenser Coil - constructed of copper tubes in a staggered tube pattern; tubes expandedinto continuous, high efficiency aluminum plate type fins; coil set in a drain pan forcondenser coil wash down

Refrigeration System (Single Circuit) - includes a liquid line filter dryer, refrigerant sightglass with moisture indicator, suction and liquid line quick connect male couplings, 3-wayhead pressure control valve, check valve and receiver; module pre-charged and sealed

Fan Assembly - propeller type blades, constructed of zinc plated steel or aluminum,secured to the motor shaft by a heavy duty hub with set screws; direct drive fan motorsprovided with rain slingers, lifetime lubricated bearings, and internal overload protection

Cabinet and Chassis - designed for outdoor use, horizontal air flow, and either roof orground level mounting; condenser module constructed of galvanized and galvaneal paintedsteel for corrosion resistance; both inlet and outlet air grilles are heavy duty steel withdurable PVC coating; removable exterior panels allow access to electric panel orrefrigeration components for service and maintenance

Head Pressure Control (Liebert Lee-Temp) - includes an insulted heater receiver tank with pressure relief valve and head pressure operated 3-way valve; system allows operationat ambient conditions as low as -30°F (-34°C)


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Integral Water/Glycol Cooled Condensing Module: Compressor - high efficiency rugged design hermetic with a suction gas cooled motor,internal vibration isolating mountings, internal current/thermal overloads, and internalpressure relief; operates at 3500 RPM at 60 Hz


Cabinet and Chassis - chassis constructed of galvanized steel for strength and corrosionresistance; designed for easy installation and service access; removable exterior panelsallow access to electric box or refrigeration components for service and maintenance;module designed for floor or wall mount

Unit Water/Glycol Circuits - includes a condenser, regulating valve, and piping; circuitdesigned for a maximum system water/glycol pressure 150 PSIG (1304 kPa)

Water/Glycol Cooled Condenser - heavy duty high efficiency brazed plate typecounter flow condenser constructed of high grade stainless steel

Regulating Valve - pressure operated 2-way water regulating valve that maintainsaccurate condensing temperature for various entering water/glycol flow rates andtemperatures.

Remote Water/Glycol Cooled Module Features:Compressor - high efficiency rugged design hermetic with a suction gas cooled motor,internal vibration isolating mountings, internal current/thermal overloads, internal pressurerelief, internal solid state self-regulating crankcase heater; operates at 3500 RPM at 60 Hz


Cabinet and Chassis - constructed of galvanized steel for strength and corrosionresistance with 1/2" (12.7mm) 1 1/2 lb. (.68kg) thermal insulation to minimize heat loss

andprevent condensation; removable panels allow access to the electric panel, to thecompressor, and to the condenser blower; vibration isolators provided with the chassis formounting

Unit Water/Glycol Circuits - includes a condenser, regulating valve, piping and femalepipe thread connectors on both the supply and return lines; circuit designed for a maximum


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system water/glycol pressure 150 PSIG (1304 kPa)

Water/Glycol Cooled Condenser - heavy duty tube-in-tube coaxial counter flowcondenser, painted with black polyurethane paint

Regulating Valve - pressure operated 2-way water regulating valve that maintainsaccurate

condensing temperature for various entering water/glycol flow rates and temperatures

Datamate Control Center

The Datamate Control Center panel comprises a fan section, a status section, and atemperature section. A humidity control section is part of the optional steam generatinghumidifier. Figure C-1 shows the control center panel, actual size is 7 1/2" x 7 1/2"( 190.5 mm x 190.5 mm). The individual components are described following the figure.

Datamate Control Center

Fan Section - The fan section comprises two buttons, an ON/OFF button and a fan HI/LObutton.


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ON/OFF Button - The button lights when it is in the ON position. This is a maintaincontact switch that energizes the fan contactor and supplies control voltage to theremaining component switches.

HI/LOW Button - The button controls the evaporator fan speed. When the button ispressed in, it energizes the high speed fan contactor. The speed is also indicated by thestatus LED. HIGH fan speed is overridden when the dehumidification contactor has beenenergized by the low humidistat, and LOW fan speed is automatically selected.

Temperature Section - This section consists of a thermostat thumb-wheel that can berotated to the desired setting. Note that temperature is not marked on the wheel. Allowenough time for room conditions to stabilize before re-adjusting the wheel. Avoid frequentadjustments.

Status Section - The status section comprises six LEDs: Humidify, Dehumidify, Cooling,Heating, High Speed, and Low Speed. The Humidify and Dehumidify status LEDs are notpresent if the unit is not equipped with the optional steam generating humidifier.

Humidify - The LED is energized when the low humidistat senses a humidity level lowerthan the selected low humidity level, and the unit is in Humidify mode.

Dehumidify - The LED is energized when the high humidistat senses a humidity levelhigher than the selected high humidity level, and the unit is in Dehumidify mode.

Cooling - The LED is energized when the unit is in Cooling mode.

Heating - The LED is energized when the unit is in Heating mode.

Low Speed - The LED is energized when the evaporator fan is operating at low speed.

High Speed - The LED is energized when the evaporator fan is operating at high speed.

OPTIONAL HUMIDITY CONTROL

Two humidity controllers are supplied on units that have the optional steam generatinghumidifier. The controllers are located behind the access panel in the lower left-handcorner of the evaporator. One controls humidification. The second controlsdehumidification.

Humidification - Set the humidistat controller for the desired room humidity.

Dehumidification - Set the dehumidistat controller for no less than 5% above the setting of the humidity controller. For example, if the desired room humidity is 50%, set the


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dehumidification controller at 55% or higher.

Datamate Dehumidistat and Humidistat Controls

Electrical Operation

When the evaporator receives a call for cooling from the temperature stat or dehumidifyingfrom the dehumidification relay 1, the condensing unit is energized. The high-pressureswitch must be in the closed position. C and Y pigtails are low-voltage from theevaporator to the coil of the compressor contactor.

When the contactor is energized, 208/230 V is applied to the compressor R winding, thestart capacitor, the fan speed control and to the condensing unit fan motor. When the208/230 V supply power is ON to the condensing unit, the crankcase heater is alsopowered.


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Mechanical OperationThe condensing units that contain the compressor, condenser coil, fan and electrical andlow ambient controls, are equipped with crankcase heaters installed on the compressorsump. This prevents refrigerant migration into the compressor during the off cycle andallows smoother startup. A manual reset high pressure cut-out is supplied and is factorypreset at 360 PSIG. The reset protrudes through the front of the condensing unit cabinetnext to the fan inlet. All models have a filter drier and sight glass through which you cansee the condition of the refrigerant.

Air Cooled Units - There are two different air cooled units, the indoor, centrifugal fancondensing unit and the outdoor, propeller fan condensing unit. The outdoor propeller fanunit incorporates a flood back head pressure control (Lee-Temp), which consists of areceiver and head pressure control valve. This control floods the condenser coil withrefrigerant that is warmed in a special receiver during low ambient temperatures tomaintain head pressure.

The indoor centrifugal condensing unit uses a fan speed control device to help regulatecooling when there are variances in the ambient temperature indoors. The indoor unit doesnot have a receiver that warms the refrigerant.

Water, Glycol and Integrated Water/Glycol Cooled Units - There are three differentunits available. The water cooled unit is a split system designed for above ceilingapplications and uses a coil tube diameter appropriate for water heat transfer. The glycolcooled unit can be installed above the ceiling and uses a coil tube diameter appropriate forglycol heat transfer. Both water and glycol units are connected to the evaporator with pre-charged refrigerant lines. The integral water/glycol cooled unit is designed to be installedat the left end of the evaporator. Pre-charged refrigerant lines are not needed for this unit.

Water regulating valves are factory installed on all three units. Valves automatically openas refrigerant pressure increases and close as pressure decreases.

Water Regulating Valve Adjustment: Complete the following procedures to adjust thewater regulating valve:

1. Adjust the Head Pressure - Attach refrigeration gauges to the compressor discharge andsuction lines. Raise the head pressure by turning the adjusting screw clockwise.Lower the head pressure by turning the adjusting screw counter-clockwise. Allowenough time between adjustments for the system to stabilize.

2. Test the Function of the Valve - When the refrigeration system has been off forapproximately 10 to 15 minutes, the water flow should stop. If the water continues toflow, the valve is either improperly adjusted (head pressure too low) or the pressure-sensing capillary tube is not properly connected to the condensing unit.


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3. Flush the Valve - Insert a screw driver or similar tool under the two sides of the mainspring and lift. This will open the valve seat and flush out any dirt particles.

Humidifier

The optional humidifier system consists of a water canister with an internal set ofelectrodes that generate the steam used for humidification. The steam is introduced intothe air through a discharge plenum separate from the conditioned air discharge.

The humidifier RUN/DRAIN switch is located near the humidifier canister. This switchshould be in the RUN position when the humidifier is in normal operation, and in theDRAIN position when a manual drain sequence is required.

The humidifier is designed to operate with water systems having 10 to 150 PSIG waterpressure. Steam generating capacity is 4.5 lbs./hr.

During startup, when the controller calls for humidification, the fill valve opens and waterenters the canister. When the water level reaches the electrodes, current flows and thewater begins to warm. The canister fills continuously as long as there is a call forhumidification. As the water warms, its conductivity increases and the current flow rises.Boiling soon commences and the humidifier operates normally.

Steam output varies greatly with water conditions. The humidifier ON/DRAIN cycle,which limits output, varies depending on the water condition. Normal duration of thecycle is 2-3 minutes.

If the conductivity of the local water is extremely low or high, a non-standardcanister may be required. Contact your sales representative if the humidifierdoes not operate properly with the standard canister.

If the current flow in the canister reaches a set level above the normal operating amperage,an over-current breaker shuts off power to the electrodes while the drain valve opens,flushing some of the water out of the canister. Within about 15-20 seconds, the overcurrent breaker automatically resets. Less water is then exposed to the electrodes and thecurrent flow should resume without tripping the over-current breaker. Boiling soonresumes and the canister operates normally.

If the conductivity of the water is high, steam is generated with the less of the electrodesexposed to the water. The humidifier cycle time (from fill to drain) is shorter.

If the conductivity of the water is low, the canister fills until the water level reaches theoverflow bypass level and drains. Boiling should commence in time. As water is boiledoff, the mineral concentration in the canister increases and current flow also increases. Thecanister eventually reaches full output and goes to normal operation.


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Over a period of time, the electrode surface becomes coated with a layer of insulatingminerals that cause a drop in current flow. As this happens, the water level in the canisterslowly rises because less steam is being produced. This exposes more electrode surface tothe water and maintains normal output. Eventually, the steady state water level reaches theoverflow tube and drain. At this point, the electrode surface is used up and the canistershould be replaced.

After the entire electrode surface has been coated, the output slowly decreases. Thisshould allow enough time to schedule maintenance.

POST START CHECKLIST

After the entire control circuit is energized, complete the following checklist:

1. Check the cooling system startup. Make sure that there are no signs of leakingcompressor oil or refrigerant.

2. Check the blower wheels. Make sure that there is no unusual noise and that the blowerrotates freely.

After you have determined that the Datamate is functioning properly, instruct the user tooperating the unit. Replace all panels before leaving the job site.

SHUTDOWN PROCEDURE

To shut down the Datamate, press the ON/OFF button.

If a remote shutdown device is installed, the unit can be shut down from a remote location.The remote shutdown device is a normally closed switch that is wired across Terminals 3and 4 in the evaporator electric box in place of the jumper that is normally across theterminals.

The condensing unit is equipped with a High Pressure switch that can also shut down thesystem. To restart the unit after it has been shut down by the High Pressure switch, pressthe High Pressure Reset switch located in the compressor compartment.


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CONTROL RELAY BOARD

The Control Relay Board is mounted to the back of the Control/Display panel in the upperright corner of the unit. Below shows the board configuration with the optional humidifier,actual size 5" x 6 3/4" (127 mm x 171.5 mm).

Relay Control Board Layout

Datamate Connection Points

PCB PLUG PIN OUT

PLUG A CONNECTOR

Pin 1 FAN HI (Line Volts)Pin 2 FAN LO (Line Volts)Pin 3 FAN COMMON (Line Volts)

PCB TERMINALS

1 REMOTE CONDENSER (GND)2 REMOTE CONDENSER (24 VAC)3 REMOTE SHUTDOWN (24 VAC)4 REMOTE SHUTDOWN (24 VAC)5 HTR1 (Line Volts)


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PLUG B CONNECTOR

Pin 1 HS (24 VAC)Pin 2 HS (24 VAC)Pin 3 DHS (24 VAC)Pin 4 DHS (24 VAC)

PLUG C CONNECTOR

Pin 1 S1 (24 VAC to D1)Pin 2 S2 (24 VAC to D2)Pin 3 HUM (24 VAC to D4)Pin 4 DEHUM (24 VAC to D4)Pin 5 COOL (24 VAC to D5)Pin 6 HEAT (24 VAC to D6)

PLUG D CONNECTOR

Pin 1 S1 (LED)Pin 2 S2 (LED)Pin 3 HUM (LED)Pin 4 DEHUM (LED)Pin 5 COOL (LED)Pin 6 HEAT (LED)

TS CONNECTOR

Pin 1 COMMON (24 VAC)Pin 2 CLOSED TO HTG (24 VAC)Pin 4 COMMON (24 VAC)Pin 6 OPEN TO COOLG (24 VAC)

6 HTR2 (Line Volts)7 RHS2 (Line Volts)8 RHS1 (Line Volts)9 HUMIDIFIER (Line Volts)

10 HUMIDIFIER (Line Volts)11 DRAIN VALVE (Line Volts)12 DRAIN VALVE (Line Volts)13 MANUAL DRAIN (Line Volts)14 FILL VALVE (Line Volts)15 L1 INPUT (Line Volts)16 L2 INPUT (Line Volts)17 L2 INPUT (Line Volts)18 1DHR INPUT (24 VAC)1920 MANUAL DRAIN (Line Volts)21 RH JUMPER (24 VAC)22 L1 INPUT (Line Volts)23 L1 INPUT (Line Volts)24 GND (24 VAC)25 REMOTE CONDENSER (GND)26 CB (24 VAC)27 RH JUMPER (GND)28 TS6 (24 VAC)29 TS2 (24 VAC)30 TS4 (24 VAC)31 TS1 (24 VAC)32 CB (24 VAC)33 CB (24 VAC)34 GND (24 VAC)

Datamate Control Board Connections


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Datamate Relay Sockets

REHEAT (PINS OUT)

1 – NC to 9 8 – NO to 122 – NC to 10 9 – NC 13 – NC to 11 10 – NC to 24 – NC to 12 11 – NC to 35 – No to 9 12 – NC to 46 – NO to 10 13 – 24 VAC to Coil7 – NO to 11 14 – 24 VAC to Coil

HUMIDITY, FAN, HI/LO, DEHUMIDIFY (PINS OUT)

1 – NC to 52 – NC to 63 – NO to 54 – NO to 65 – NC to 16 – NC to 27 – 24 VAC to Coil8 – 24 VAC to Coil

Datamate Relay Connections

4 3 2 1

8 7 6 5

12 11 10 9

14 13

2 1

4 3

6 5

8 7


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ELECTRO-MECHANICAL OPERATION

The Datamate system uses basic electro-mechanical control. In its simplest form these aredevices that react mechanically to a change in the environment (such as, a rise or drop intemperature or humidity). Electrical contacts that work with the mechanical devices theneither open or close a control circuit to a system component.

The following text describes the electro-mechanical operation of the Datamate. Thenomenclature of the electrical schematics is given in parenthesis. For example, theschematic designation for the Dehumidification Stat is DHS. The first occurrence of theterm is written Dehumidification Stat (DHS). Subsequent occurrences may be writtensimply DHS.

POWER UP

Utility power is supplied to Lugs L1 and L2. Factory wiring connections are from Lugs L1and L2 to Terminals L1 and L2 respectively on the control board. Power travels via theprinted circuit track L2 to Terminal A3 (feeds one side of the evaporator and its capacitor)to Reheat Relay (RH) contacts 4RM and 3RM, to Terminal 9 (feeds one electrode ofoptional steam generator) and to Terminal 14 (feeds the fill valve of the steam generator).A second wire from L2 is connected to either a 208V or 230V lug for primary feed to thetransformer. Power from Terminal L1 travels via printed circuit track to contacts 1RM and2RM (feed reheats), to contact H (feeds optional steam generator circuit) and to Terminal15. A jumper wire connects Terminal 15 to Terminal 22. Voltage continues via printedcircuit track to Motor Relay (MR) contacts (feeds evaporator fan speed contacts) and toTerminal 23 (feeds control transformer). Secondary voltage from the transformer powersthe control board through an unnumbered terminal connection on the control board. Thehot side of the transformer travels through printed circuit track to Terminal 32 where aconnection is made to the circuit breaker. Power returns to the control board at Terminal33 where it travels to Lug 3. Either a remote shutdown device or a jumper wire connectspower to Lug 4. A wire from Lug 4 to Terminal 26 returns power to the printed circuittrack on the control board where it tracks to Terminal C1. A wire connects the powercircuit from the control board (C1) to the display board Terminal D1. Power then travelsthrough the display board printed circuit track to the unit start switch. The ground side ofthe transformer secondary is connected to the control board at Terminal 24. A ground wirefrom the frame to Terminal 34 ties this circuit to safety ground. A wire from Terminal C8on the control board to Terminal D8 on the display board completes the display boardcircuit. Refer to Schematic 1C16377 for more information.


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START CIRCUIT

When the Start switch is closed, power is supplied via printed circuit track to the unit ONlight and to the HI/LO switch (S2), which in the LOW position lights the LOW lightterminal or in the HIGH position lights the HIGH fan speed light and sends voltage via theHIGH/LOW Relay (HLR) to the HIGH position. A wire from Terminal D2 or C2 carriesvoltage from the display board to the control board. Power travels via printed circuit trackto the Evaporator Motor Relay (MR) and to contacts 1DHR, the temperature stats, thedehumidistats, and through contact 1DHR to the humidistats.

COOLING

The Temperature Stat for cooling closes, carrying power from Terminal 4 to Terminal 6.A jumper wire from Terminal 6 to Terminal 28 on the control board carries voltage viaprinted circuit track to Terminal 18. A jumper wire connects this to Lug 2 for heatrejection interlock. The printed circuit track carries power to Terminal C5. A jumper wirefrom C5 to D5 powers to COOLING LED on the Control/Display Board.

HEATING

The Temperature Stat (TS) for heating closes carrying power from Terminal 1 to Terminal2. A jumper wire from Terminal 2 to Terminal 29 carries voltage via printed circuit trackto Terminal 21. A jumper connects to Terminal 27. Printed circuit track carries power tothe Reheat (RM) contactor closing contacts 2RM and 3RM and allowing operating voltageto flow through the safeties to the reheat rod. A jumper wire from Terminal C6 to D6powers the HEATING LED on the Control/Display Board.

DEHUMIDIFICATION

The Dehumidistat (DMS) closes completing voltage to Terminal B4 on the control board.Printed circuit track carries voltage that energizes the Dehumidification Relay (DMH)closing contacts 1DMR of the cooling circuit, energizing heat rejection and the COOLINGLED. Contacts DMR of the humidification circuit and contact 2DMR of the evaporatorHigh Fan Speed open. Contacts 2DHR close and bring voltage to the low speed fancircuit. Printed circuit track carries voltage to Terminal C4. A jumper wire connects C4 toD4 on the Control/Display Board and the DEHUMIDIFY LED is lit.


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HUMIDIFICATION

The humidifier uses current to operate the controls. This type of control activationoperates on the principle that electricity follows the path of least resistance.

On startup the H contactor closes completing the humidifier circuit. Power from L1 travelsthrough the H contactor contacts and then branches to the drain valve and overloads. Thepath of least resistance causes current to follow a path through the overload and manualdrain to the humidifier electrodes and fill valve. Since there is no water across theelectrodes, there is no current flow, thus the only operating device at this time is the fillvalve. As water begins to fill the canister and cover the electrodes, current flow across theelectrodes (through the water) begins, creating steam. The fill valve shuts off when thecurrent flow begins (path of least resistance is through the electrodes). After boilingcauses the water level in the canister to drop below the electrodes, current flow across theelectrodes no longer exists, causing the fill valve to energize, filling the canister again.This cycle repeats itself when necessary to maintain water in the canister.

If the current across the electrodes rises above the overload limit (5.5 amps), the overloadopens, leaving a path through the drain valve as the only way for current flow. This causesthe drain valve to open, draining water out of the canister. As the water drains out of thecanister, the overloads cool and close again allowing the cycle of fill and boil to continue.

The Humidistat closes sending power to Terminal B1. Power travels via printed circuittrack to the Humidifier Relay and to Terminal C3 to send power via a jumper wire andprinted circuit track to the HUMIDIFY LED. The Humidifier Relay energizes thehumidifier contactor (H) powering the steam generator.


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226


227

Datamate Electrical Schematic


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Datamate Outdoor 1ph Condensing Module


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232

Datamate Outdoor 3ph Condensing Module


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Datamate Indoor 1ph Piggyback Condensing ModuleTROUBLESHOOTING GUIDELINES

Unit will not start No power to unit Check voltage at input terminal block.

Control voltage circuitbreaker open

Locate short and reset circuit breaker.

Float switch relay hasopened due to high wateror high head pressure

Reset unit by switching STOP/RUNswitch to STOP, then to RUN. Referto section below.

SYMPTOM

Turn off power to unit at disconnect switch unless you are performing tests that requirepower. With power and controls energized, unit could begin operating automatically atany time.

POSSIBLE CAUSE CHECK OR REMEDY

Hazardous voltage is still present at evaporator, condenser, reheat, and humidifier, evenwith the unit turned off at the control panel. To isolate unit for maintenance, turn offpower at disconnect switch.


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No cooling Compressor high headpressure

1. Call for cooling.2. Jumper high head pressure statmomentarily. If compressor runs,high head stat is open. Refer tocompressor section.

Low refrigerant charge. Check pressure with gauges.

Compressor contactornot pulling in

Check for 24 VAC ±2 VAC atterminals 18 and 25. If no voltage,replace solid state board.

Compressor willnot operate

Poor jumperconnection

Outside air condenseronly: Temperaturebelow 30°F; lowambient stat incondenser fan sectionopen

Check continuity with OHM meter.

Check outside temperature. Makesure low ambient stat is turnedcompletely clockwise.


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Compressor highhead pressure

Water/ Glycol cooled units: No fluid flow through condenser

Check fluid supply to adjust water-regulating valve.

Air Cooled units:Condenser fan notoperating

Check fan operation.

Insufficient air flowacross condenser coil

Remove debris from coil and airinlets.

Humidifier does notoperate

No water flow Check canister water level forpossible boil-off. Check nylonoverflow line if canister is full.

Canister fill rate is notkeeping up with steamoutput

Check fill valve screen openingand capillary tube for obstructions.

Reheat will notoperate

Defective solid stateboard

Check voltage for 24 VAC ±2VAC at 24 and 29 on solid stateboard.

Reheat safety open Jumper high temp stat. If reheatfunctions, stat is open.

Element is burned out Turn off power. Check elementcontinuity with OHM meter.

Continuous Heating Open sensor circuit Find open circuit and repair.Check sensor out of circuit.

Continuous Cooling Shorted sensor circuit Find short and repair.

ContinuousHumidification

Open sensor circuit Find open circuit and repair.

ContinuousDehumidification

Shorted sensor circuit Find short and repair.

Condensate pump Open or short circuit Find open or short circuit and repair does not operate in wiring power

Not drawing Check drain line and connections for

leaks.

SYMPTOM POSSIBLE CAUSE CHECK OR REMEDY


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Chapter 11

Static Control

• Introduction

• ESD Susceptibility

• Identification

• Static-Controlled Work Station

• Table Mats and Wrist Straps

• Floor Considerations

• Environmental Considerations

• Work Station Maintenance

• Unit Installation

• Customer Service


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IntroductionWith the increased use of high-speed digital and microelectronic devices on Liebertcomputer support systems, the incidence of component damage from ElectroStaticDischarge (ESD) is increasing. Damage caused by static electricity occurs in a random,intermittent, invisible pattern in manufacturing plants, between shipping points and in thecomputer room. Components sensitive to ESD include microelectronic andsemiconductor devices, film resistors, diodes and piezoelectric crystals. Additionally,any other equipment containing these parts and not having adequate protection circuitryare also ESD-sensitive. Although people are the single greatest threat to static sensitivedevices, materials are also prime generators of electrostatic voltages. Commonly usedmaterials that can generate charges include common plastics such as polyethylene, vinyl,foam, polyurethane, synthetic textiles, fiberglass, glass and rubber. Sliding rubber orseparating action between these and other materials generates electrostatic voltage(frequently up to 15,000 volts).

ESD damage to electronic components can adversely affect computer room operations.Environmental and power control failure can ultimately result in critical and costlycomputer downtime. Some units may continue to operate, but with less than optimumperformance due to non-catastrophic ESD damage. An ESD-altered part can cause amicroprocessor to occasionally lose data or get out of sequence resulting in loss ofutilization.

ESD damage to electronic circuits causes hidden or delayed effects in addition to thereadily detected failures. Degraded performance is the most common effect of ESDdamage to circuits. Components continue to function but with reduced or alteredcharacteristics. Units containing these parts may pass normal bench tests of thecompleted assembly but may not operate properly in actual use. Curve tracer analyses ofcomponents have shown marginal thresholds or switching times caused by non-catastrophic ESD damage. The ESD damage often occurs after the components havepassed their quality assurance test (for example, Integrated Circuit (IC) Burn-In).

EDS SusceptibilityData on the exact cost of the problem is difficult to obtain, but the experiences of severalmanufacturers show the benefits of implementing ESD protective measures. Somecomputer manufacturers report that 70% of all field service (warranty) calls are staticrelated. Others indicate that ESD-induced production line failures are typically between8%-11% of the failures experienced. A reported 50% of the CMOS devices returned totwo manufactures surveyed had catastrophic ESD damage. In another case, a supplierhad shipped 50 replacement PCBs in anti-static bags with shut bars on the boards, butcushioned them with static-generating bubble plastic. Upon receipt, 45 of the 50 boards


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had blown devices. One display terminal manufacturer reports a 90% decrease inwarranty repairs after incorporation of plant-wide ESD controls.

Reported Susceptibility Ranges for Various Devices Exposed to ElectrostaticDischarge from a Person or Electronic Equivalent

Device Type Susceptibility Range

MOSFET 100V – 200V

JFET 140V – 10,000V

CMOS 250V – 2,000V

Schottky Diodes TTL 300V – 2,500V

Bipolar Transistors 380V – 7,000V

ECL (Hybrid use PC–Board Level) 500V – 3,500V

SCR 680V – 1,000V

Identification

Not all electronic devices and component assemblies are susceptible to the effects ofESD. Likewise not all electronic devices and assemblies require the special protectivepackaging and handling procedures specified in this document. Therefore, to save costand time, devices and assemblies sensitive to ESD should be clearly identified andlabeled.

Caution labels and decals are used to identify electrostatic sensitive parts, packages,packs, assemblies and equipment that contain these parts. These labels are a visualreminder that serve to alert trained personnel that special handling is required.

Since there is no consensus among user companies and government agencies, there arecurrently three label designs that serve to indicate the presence of an ESD-sensitivedevice. Although all three labels are acceptable for use by electronic component vendorsand suppliers, Liebert Corporation prefers the Electronic Industries Association (RS 471)identification label for our devices and component assemblies.


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Static - Controlled Work StationLiebert recommends that static-controlled work stations be established wherever youhandle, test, or repair ESD-sensitive components. Setting up an approved static-controlled work station requires analysis of many details. Some items are basicrequirements. In general a static-free work area can be set up by accomplishing thefollowing:

1. Provide a conductive or static-dissipative path to ground. Groundedconductive or static-dissipative table mats, grounded test equipment,conductive packaging and conductive totes are regarded as minimum.Topical anti-static treatment of the remaining static-generatingmaterials or replacement with anti-static items is also stronglyrecommended.

2. Ground all personnel at the work station to earth-ground with anapproved soft-ground wrist strap.

3. Identify and remove all static-generating items from the work station.

4. Place an ESD caution sign at or above the work station to alertapproaching personnel to observe ESD protection procedures.

5. Set up a regular program to re-certify and evaluate the effectivenessof the static-controlled work station.

Table Mats and Wrist StrapsQuite simply, static discharge can be thought of as the pouring of a container of waterthrough a funnel and into a sink. The sink is the equivalent of an electrical ground. Thevolume of the container represents the charged object's capacitance. The water simulatesthe charge (the number of excess or deficient electrons), and the funnel provides aresistance to the flow of that charge. By providing paths to ground capable of conductingthe required electron flow, static charge accumulations on personnel and other conductorsin the work area can be effectively controlled.

For this reason it is important to define earth-ground. The static dissipative path to earth-ground should be periodically checked and maintained to ensure the effectiveness of thestatic-controlled work station. It should be noted that the 1 meg ohm series resistor is aprotective measure to prevent harmful electrical shock. The series resistor ensures thecurrent is limited to less than 5 ma.The purpose of the conductive or static dissipative table mat is not only to provide astatic-free surface on which to work but also to remove the static charge from any


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conductive item placed on it. The primary technical consideration in selecting andmaintaining the proper table mat for use in a static-control work station is its surfaceresistivity. This value, measured in ohms per square inch, should not be greater than 104

nor less that 109. Some other considerations include determining the correct applicationfor the hard versus soft table mat, as well as the product's durability and cleanability.Cleanliness is an important factor in maintaining the protective properties of any worksurface. Contaminated work surfaces can put an insulating static barrier between thedevice or assembly and the protective top.

The purpose of the grounded wrist strap is to provide an effective means by which todischarge personnel working at the station. The wrist strap should be worn at all timeswhen handling ESD-sensitive devices or assemblies. Wrist straps should also be testeddaily. This can be done relatively easily using a wrist strap system tester (VoyagerTechnologies, Inc. WSST-300 or equivalent). Since many different types of straps arenow available on the market, due consideration should be given for the comfortable feeland fit as well as the durability of the wrist strap.

Floor ConsiderationsThe triboelectric effect makes the floor is the single greatest contributor to staticgenerated by personnel, carts and sliding materials. Regardless of the type of floorcovering, cleanliness is essential for proper electrostatic control.

The three basic floor types are described below:

1. Concrete (Sealed and Unsealed) - Unsealed concrete floors withregular maintenance are generally not a concern in relation to staticcontrol. On the other hand, sealed concrete floors pose a major staticcontrol problem. This type of floor requires conductive floor mats ateach work station.

2. Tiled (Conductive and Nonconductive) - Vinyl or nonconductivefloors generate substantial static. This type of floor covering requiresconductive floor mats or the periodic application of a conductive oranti-static wax. Treated floors also require periodic testing using asurface resistivity meter (Voyager, Inc. SRM-110 or equivalent). Thelength of time between treatments and between tests varies with usageand floor wear. Conductive floor tile is the preferred floor covering.

3. Carpeted - Never use carpeting on or around the work station.


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Environmental ConsiderationsAlthough not a complete remedy, humidity is an important factor in controlling staticgeneration. High relative humidity will not stop generation of charge even though it isimportant in controlling the accumulation of static charge. Relative humidity of at least40%-60% is best to keep surfaces moist, thereby improving surface conductivity. Inareas where the relative humidity cannot be controlled within this range, otherprecautions must be taken. These include the use of air ionizers and restricting the use ofnonconductive materials.

Eating or drinking should not be allowed at or near the work station. Food wrappers andstyrofoam cups generate excessive static. Also, most foods and drinks encouragebacterial or fungal growth and contaminate computer boards and assemblies.

Work Station MaintenancePeriodic checks of the work station should be conducted to ensure all ESD protectionelements are in good working order. These consist of checking the ground connections,cords, limiting resistors and work mats. This work station re-certification should beperformed at least three times a year or every four months.

The common point for each work station ground system should be checked and verifiedfor its integrity. Faulty connections should be repaired.

Wrist straps and table mats should be checked and cleaned. Most wrist straps can becleaned using ordinary laundry soap and water. Table mats should be cleaned only by themanufacturer's recommended method.

Static controlled work stations should be periodically surveyed with a static meter (TrekInc. Model 510A or equivalent) to identify sources of static potential. Any item oractivity in the work area that registers significantly on the meter should be corrected.

Note: Generally the static meter is not for accurate measurement but rather for anindication of the presence of static potential.Wherever ESD-sensitive component assemblies are installed, there is the need forsafeguards. There are three significant protective measures that must be implemented toensure ESD safeguards.

1. Proper use of the special static-shielding shipping container (Thisspecial container provides complete ESD and strenuous shippingprotection. The containers are reusable and are to be returned to theelectronics stockroom at the Columbus facility.)


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2. A proper earth-ground to the unit (The unit to which the ESD-sensitive device or component assembly is installed must begrounded. This eliminates the potential for static charge build up,while at the same time providing a proper connection point for therequired wrist strap.)

3. Proper use of the soft-ground wrist strap (The wrist strap provides aneffective means by which to discharge personnel handling ESD-sensitive devices and component assemblies. The wrist strap mustproperly connect to an unpainted segment of the unit frame that hasbeen grounded.

Other safeguards include the elimination of nonconductive and static-generatingmaterials (for example, styrofoam cups, plastics, smoke) in and around the unitinstallation area, removing the assembly from the protective container only when ready toinstall and handling the assembly with extreme care.

Customer ServiceESD awareness training is included along with the standard training for customer servicetechnicians. Training video tapes, instructions for utilizing the special static-shieldingshipping container and a copy of this document should be included in the training.


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GlossaryAC—Alternating Current; current that reverses its direction X times per second (Thereversing action is called Hertz.)

Address—A pattern of characters that identifies a unique storage location

Algorithm—A set of procedures to obtain a given result

Ampere—The amount of current required to flow through a resistance of one ohm with apressure of one volt

Analog—Refers to circuitry; also called linear circuitry; circuitry that varies certainproperties or electricity continuously and smoothly over a range

Anti-Static Material—A slightly conductive material that allows the net charge to bedrained off through a path; an electrostatic protective material having a surface resistivitygreater than 104 but not greater 109 Ohms per square inch (does not generate staticelectricity)

Atom—The smallest part of an element that can be identified

Binary Number System or Binary Code—A method of writing numbers by using twodigits, 0 and 1

Bit—The smallest possible piece of information; a specification of one of two possibleconditions (Bits are written as 1 for yes and 0 for no.)

Bus—Large trace or foil extending around the edge of a PCB to provide conduction forseveral sources

Byte—A set of adjacent binary digits operated upon as a unit (usually 8 bits)

Charge—The product of capacitance times voltage

Circuit—The path that electric current takes from the source to the load

CMOS—Complimentary Metal Oxide Substrate semiconductor

Compressor—The device used in mechanical refrigeration to compress the refrigerant

Computer—At least one CPU together with input, output, control switch buttons andmemory units


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Condensing Unit—The portion of a split air conditioning system that contains thecompressor, condenser, condenser fan motor, and controls for these components

Conductive Material—Material that conducts electrical charge (Because it conductscharge, there is no potential difference across or storage of a static charge.); electrostaticprotective material having a maximum surface resistivity of 10 Ohms per square unit, ora maximum volume resistivity of 10 Ohms/cm.

Contactor—A device that opens and closes a set of electric contacts by the action of asolenoid coil

Control Buttons—Push buttons on the display bezels to operate the increase/decrease,advance, or silence functions

Control Switches—Sometimes called dip switches and used for additional programmingfeatures on all levels

CPU—Central Processing Unit; the part of a computer system that contains the mainstorage, arithmetic unit and special register groups (It performs arithmetic operations,controls instruction processing and provides timing signals.)

Current—The flow of electrons to a load (measured in amperes)

Data—Another name for information

Data Bus—One method of input/output for a system where data is moved by way of agroup of wires forming a common bus

DC—Direct Current; current that flows from a negative pole source to a positive poletarget (The current flows in one direction.)

Decrease Button—Control button used to decrease values

Digital—Information in discrete or quantized form, not continuous

DIP—Dual Inline Package; a type of Integrated Circuit (IC)

Earthground—The portion of an electrical circuit that is at zero potential with respect tothe earth

Edge Card—PCB with multiple terminal contacts on one end

Edge Card Connector—Hardware that connects the Edge Card to the system circuitry

Electron—A stable particle that has a negative charge and orbits the nucleus of an atom(also refer to free electron)


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Electrostatic Field—The field around an electrostatically charged object

Electrostatic Voltage—Voltage generated by the sliding, rubbing or separating actionbetween materials

EPROM—Erasable and Programmable Read-Only Memory; an integrated circuitmemory chip whose stored data can be read at random (Data can be erased and new datacan be stored.)

ESDS—ElectroStatic Discharge Sensitive; sensitive to electrostatic voltage of 4000 voltsor less as determined by the human test circuit

Factory-Installed Wiring—Wiring installed in a piece of equipment at the factory,usually connections between components (also refer to Field Wiring)

Field Wiring—Wiring installed in the field by the installation mechanic (also refer toFactory-Installed Wiring)

Firmware—Software stored in EPROM or PROM

Free Electrons—Electrons that are easily dislodged from the outer orbits of atoms (Freeelectrons carry current.)

Hard Ground—A direct connection to earthground (also refer to soft ground)

Hardware—The PCB, cable, switches and associated devices

Hertz (Hz)—The frequency at which AC reversing takes place (United States 60 Hz,foreign 50 Hz)

Humidistat—A moisture-sensitive device used to control humidity (The humidistatcontrols a mechanical linkage that opens and closes an electric switch.)

IC—Integrated Circuit; an assembly that consists of all the necessary parts of anelectronic circuit

Input—An incoming information signal

Insulator—A material that impedes the flow of electrons

Junction—A boundary between two semiconductor regions with differing electricalproperties

LED—Light Emitting Diode; a semiconductor that emits light when electric current ispassed through it by way of two terminalsLine Voltage—Voltage supplied to the equipment as the power supply


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Load—Devices that consume electricity to do work

Manual Override—A means of bypassing triac switches at all levels for manualoperation of system components for test or emergency

Memory—In a digital system, the part of the system where information is stored

Microprocessor—An Integrated Circuit (IC, or set of a few ICs) that can beprogrammed with stored instructions to perform a wide variety of functions (Amicroprocessor consists of at least a controller, some registers and some sort ofArithmetic Logic Unit (ALU).)

Ohm—The unit of measure used to determine the resistance electrons encounter whenflowing to the load; the amount of resistance that allows one ampere to flow with apressure of one volt

Output—An outgoing information signal

Pad—A small round conductor to which component leads are soldered on a PCB

PCB—Printed Circuit Board; made of insulating material with conducting paths securedto one or both sides

Permeance Level—(Specific to vapor barriers) The rate at which moisture penetratesthe confines of a room.

Program—A set of instructions to achieve a certain result

PROM—Programmable Read-Only Memory; an Integrated Circuit (IC) memory chipwhose stored data can be read at random (The IC can be used only one time.)

RAM—Random-Access Memory where work can be written (stored) or read (recovered)in any order

Resistance—The opposition to the flow of electrons

ROM—Read-Only Memory containing data permanently stored when the unit ismanufactured

Schematic Drawing—A diagram that lays out a control system circuit by circuit and iscomposed of symbols representing components and lines representing inter-connectingwiring


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Semiconductor—A group of elements classified between conductors and insulators inrelation to ability to conduct current

Sensor—A device that reacts to a change in the conditions being measured, permittingthe condition to be controlled

Soft Ground—A connection to ground through an impedance sufficiently high to limitcurrent flow to safe levels for personnel (Impedance needed for a soft ground isdependent upon the voltage levels that can be contacted by personnel near the ground.)

Software—A set of computer programs, procedures and possible associateddocumentation concerned with the operation of a data processing system

Solenoid—A coil of wire wrapped around a hollow core (When the wire is energized, amagnetic field is created within the hollow core.)

Solid State—Electronic circuitry having no vacuum tubes

Static-Dissipative Material—Electrostatic protective material having surfaceresistiveness greater that 104 but not greater than 109 Ohms per square inch

Static-Shielding Material—Material that does not allow spark energy or electrostaticfields to pass through or penetrate it

Surface Resistivity—An inverse measure of the conductivity of a material and equal tothe ratio of the potential gradient to the current per unit width of the surface where thepotential gradient is measured in the direction of current flow in the material (Surfaceresistivity is numerically equal to the surface resistance between two electrodes formingopposite sides of a square. The size of the square is immaterial. Its value is measured inOhms per square inch.)

Thermistor—A resistor manufactured from semiconductor material and sensitive tothermal change

Trace or Foil—A very thin sheet metal path that connects two or more pads on a PCB

Triac—An electronic device used to control high voltage and high current loads

Triboelectric Effect—The generation of static electricity on an object by contact,separation or friction

Watt—The rate at which power is used; the product of volts X amperes

small systems #1 - hvac-talk

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