United CoolAir Marvel Plus Installation, Operation And Maintenance Manual

Marvel Plus
DISCONTINUED
For Reference Only
MICROPROCESSOR CONTROLLER
Installation, Operation and Maintenance Manual
Effective October 2018
***Interactive PDF***

Contents

Marvel Plus
Contents ������������������������������������������������������������������������������2
Use of Symbols �������������������������������������������������������������������3
ELECTRICAL HAZARD �������������������������������������������������������3
WARNING ���������������������������������������������������������������������������3
CAUTION ����������������������������������������������������������������������������3
INFORMATION ��������������������������������������������������������������������3
Display Mounting Location ��������������������������������������������4
Connecting Cable ����������������������������������������������������������4
OPERATING THE CONTROLLER ��������������������������������������5
Unoccupied Mode ���������������������������������������������������������6
Unoccupied Override Mode �������������������������������������������6
System Operation ����������������������������������������������������������6
Supply Air Temperature Control ������������������������������������6
Return Air Temperature Control (Option) �����������������������6
Sequence of Operation �������������������������������������������������6
Humidication (Option) ��������������������������������������������������7
Dehumidication (Option) ����������������������������������������������7
Reheat Mode (Option) ���������������������������������������������������7
Air Side Economizer (Option) ����������������������������������������7
Air Side Economizer - Compressor Assist Mode �����������7
Water Side Economizer (Option) �����������������������������������7
Water Side Economizer - Compressor Assist Mode ������7
STATIC PRESSURE TRANSDUCER (DUCT MOUNT) WITH VAV OPTION ���������������������������������8
MOUNTING �������������������������������������������������������������������8
WIRING �������������������������������������������������������������������������8
Chilled Water Coil (Option) ��������������������������������������������9
Freezestat (Option) �������������������������������������������������������9
Marvel Plus Display Screen Information �����������������������9
System Status ���������������������������������������������������������������9
Blower / Motor Screen ���������������������������������������������������9
Compressor Discharge Pressure Screen ��������������������10
System Status Screen �������������������������������������������������10
Water Status Screen ���������������������������������������������������10
Compressor Status Screen �����������������������������������������10
Compressor Minimum On Status Screen �������������������� 11
Compressor Minimum Off Status Screen ��������������������11
Analog Outputs Status Screen ������������������������������������ 11
Occupied / Unoccupied Override Screen �������������������� 11
Menu and Sub-Menu Areas �����������������������������������������12
Enables �����������������������������������������������������������������������12
System Enables ����������������������������������������������������������12
Constant or Variable Air Flow Enables ������������������������12
Set Points ��������������������������������������������������������������������������12
Set Points (continued) �������������������������������������������������13
Cooling Mode ��������������������������������������������������������������13
Heating Mode ��������������������������������������������������������������13
Set Points (continued) �������������������������������������������������14
Morning Warm-up ��������������������������������������������������������14
Warm-Up Set Points ����������������������������������������������������14
Morning Cool Down �����������������������������������������������������14
Cool Down Set Points �������������������������������������������������14
Set Points (continued) �������������������������������������������������15
Alarm Set Points ����������������������������������������������������������15
Run Hours �������������������������������������������������������������������15
Day Min/Max Screen ���������������������������������������������������16
Alarm History Screen ��������������������������������������������������16
Set Day, Time, Date and Daylight Savings Screen �����16
Schedule ���������������������������������������������������������������������16
Morning Warm-up Time �����������������������������������������������17
Unoccupied Humidity Control Screen �������������������������17
BMS Setup Screen ������������������������������������������������������18
BMS Reset Function Screen ���������������������������������������18
Change Password Screen �������������������������������������������18
Technicians Menu ��������������������������������������������������������18
Temperature Unit Screen ��������������������������������������������18
Manual Analog & Digital Control ����������������������������������19
Sensor Calibration �������������������������������������������������������20
Digital Inputs ����������������������������������������������������������������22
Alarm Logic Manual Reset Screen ������������������������������22
Economizer Setup Screen �������������������������������������������22
BMS Economizer Interface Screen �����������������������������23
Water Flush Mode Screen �������������������������������������������23
Water Valve Position Screen ���������������������������������������23
Duct Static Pressure Screen ���������������������������������������23
High Duct Static Pressure Screen �������������������������������24
Change Passwords Screen �����������������������������������������24
Software Version Screen ���������������������������������������������24
Control Board Screen ��������������������������������������������������24
LIMITED WARRANTY �������������������������������������������������25
FACTORY TESTED ����������������������������������������������������25
Subject to change without notice. 120.5-IM (1018)
2
Marvel Plus

Use of Symbols

This publication includes warnings, cautions and information icons that point out safety related issues or conditions as well as other pertinent information relative to a safe installation, service or maintenance situation� The following icons should be interpreted as follows:

ELECTRICAL HAZARD

WARNING

CAUTION

INFORMATION

The electrical hazard icon indicates the presence of an electrical hazard which could result in electrical shock or death�
The warning icon indicates a potentially hazardous situation which could result in death or serious bodily injury if not avoided�
The caution icon indicates a potentially hazardous situation which may result in minor or moderate injury if not avoided�
The information icon indicates a situation that may result in equipment or property damage� The information provided alerts the reader to relevant facts and/or conditions�
Subject to change without notice. 120.5-IM (1018)
3
ELECTRICAL HAZARD
Only a qualied licensed electrician or other individual that
is properly trained in handling live electrical components should perform the wiring installation� Failure to follow all electrical safety precautions and industry accepted practices when exposed to live electrical components could result in death or serious injury�
INFORMATION
All electrical wiring must be in accordance with NEC (National Electrical Code), NFPA (National Fire Protection Agency) most current versions as well as any applicable state or local codes�
INFORMATION
Unit wiring and components have been designed for the
specic unit application and factory assigned controls.
Do not use the unit transformers or alter the unit wiring to
interface any eld supplied accessories or controls.
Marvel Plus
ash memory (4 Megabytes). An on-board real time clock
maintains programming during a loss of power� All critical control points such as system set points, system schedules, alarm set points, and alarm history are stored in non-volatile memory� Each Marvel Plus controller has the ability to record up to 50 alarms/faults under an alarm history page to allow technicians to scroll through alarm history to view critical operating data temperatures and optional discharge refrigerant pressure (units with head pressure control option) at the time of failure�
The Marvel Plus wall mount terminal is used to interface with the Marvel Plus Main Board microprocessor through the on-board display and keypad� The software stored in the
ash memory of the Marvel Plus Main Board microprocessor
was designed with menu/sub-menu driven dis- play screens allowing customers to easily navigate through the menus and sub-menus for setup of their systems�
Marvel Plus Main Board microprocessors allow for connection to some of the more widely used Building Management Systems without requiring a Gateway to interface� For optional communications with BACnet™, Modbus, or Lonworks®, an add-on Serial or IP based communications card is required�

Display Mounting Location

The wall display does not provide any temperature or humidity sensing functions� Therefore, the display can be mounted either in the space being conditioned or in a remote location�

Connecting Cable

The Marvel Plus is supplied with a factory provided
WARNING
Moving fan drives and high horsepower blowers/motors can cause injuries� Before applying power to the unit, make sure all service access panels/doors are closed and fastened/ latched to prevent injuries from the moving drives or from blowing open� Connect power to the unit at the main power
supply. Next, apply power at the eld in- stalled service
disconnect switch�
The Marvel Plus controller is designed to control United
CoolAir Variable Air Volume congured units. The Marvel
Plus controller package consists of a double microprocessor design control system made up of a Marvel Plus main control board and a Marvel Plus wall mount terminal “display and
keypad” (standard conguration).
The Marvel Plus microprocessor main board is a 16 bit microprocessor programmable controller with on-board
Subject to change without notice. 120.5-IM (1018)
communications cable� A factory supplied cable MUST be used when connecting the Marvel Plus display to the Marvel Plus control board�
The standard cable length provided is 100 feet� Any excess length can be placed where practical� It should be noted that any excess cable should not be coiled up as this may generate EMF that could affect the control operation� As always, care must be taken not to place this control cable in proximity to any high voltage power wiring�
The maximum length of cable in the standard conguration
will be 500 feet� Beyond 500 feet a different type of cable and cable gauge must be used�
If a longer length of cable (i�e� more than 100 feet) is required, please contact a United CoolAir Distributor�
4
Marvel Plus
Please note that if at the time of installation or start-up it is
found that the 100 feet is not sufcient, the system can still
be started and set up� The required length of cable can then be ordered as necessary from United CoolAir�
1. The display can be located next to the unit or other suitable location temporarily�
2. The display is required for monitoring the system or for making changes to the set points and also to have the audible alarm function�

OPERATING THE CONTROLLER

To operate the control system, there are six basic buttons on the Marvel Plus wall mount terminal which are used to change settings, time schedules, system setup, and view alarms critical and non-critical alarms� (Refer to Figure 1)
Some alarms are just simple faults known as indicators which are not harmful to the operation of the unit but may
require attention in the near future� Pressing the will reveal what alarm caused the system to shut down�
To reset an alarm, press the displays “NO MORE ALARMS, Press ENTER to RESET”� Simply pressing the button will reset the alarm when on the NO MORE ALARMS screen�
button until the screen
button
PROGRAM BUTTON
The Prg button is used to program the system’s set points, alarm thresholds, view alarm history, adjust sensor calibration, enable system operation, view run hours, set occupied/unoccupied schedules, and much more� A complete listing is under the section called menus�
ESCAPE BUTTON
The escape button is used to go back to the previous menu screen�
UP BUTTON
The up button is used to scroll upward through the screens and menus, increase the value of a setting, or to toggle a component ON/OFF�
Figure 1 - Wall Display / Keypad
An explanation of each button is as follows:
ALARM BUTTON
The button is used for viewing the present alarms with the system� There is a built in watch-dog alarm constantly monitoring for alarm conditions with each of the system
safeties. It will constantly ash on and off to show that the
watch-dog alarm is operating� During an alarm condition, the button illuminates a continuous Red� Depending on the type of alarm, the system may shut down or continue to operate�
ENTER BUTTON
The enter button is used to conrm temperature, humidity, or pressure settings, and conrm selected components. It is
also used to clear alarms once the alarm is viewed�
DOWN BUTTON
The down button is used to scroll downward through the screens and menus, decrease the value of a setting, or to toggle a component ON/OFF�
Subject to change without notice. 120.5-IM (1018)
5
Marvel Plus

Unoccupied Mode

When the unit is in the Unoccupied Mode, the supply air blower will ramp back to minimum speed and the unit will maintain the return air temperature between the High and Low Temperature Night Set Back Temperature Set Points� Any optional Outdoor Air Dampers and Airside Economizer Dampers connected to the system are closed� When the unit is in the Occupied Mode, the system will be fully operational� Any interlocked fresh outdoor air dampers shall be open and airside economizer dampers shall be modulated based on economizer availability status demand�

Unoccupied Override Mode

Unoccupied Override is available to override the Unoccupied Mode of operation during after hours tenant occupancy� When activated, the system returns to the Occupied mode
for the specied adjustable (1 hour increments) time period.

System Operation

There are two methods of control depending on the application, options ordered, and functions of the system� The two methods of control are Supply Temperature Control and Return Temperature Control� Please refer to each
specic method of control for details of operation of each
function within the system� The method of control is preset
at United CoolAir specic to customer ordered application.

Supply Air Temperature Control

Supply Temperature Control monitors the supply temperature to determine if the supply air temperature is above the supply air temperature set point� If the supply air temperature is above the supply temperature set point plus Band set point, mechanical cooling, optional waterside economizer, or optional airside economizer is sequenced to maintain the supply air temperature based on a percentage of cooling demand required� The amount of cooling demand is determined by how far the supply air temperature is above the supply air temperature set point�
If the system has the Morning Warm Up Option, morning Warm Up is sequenced based on return air temperature and morning Warm Up set points�
If the system has the Morning Cool Down Option, morning Cool Down is sequenced based on the return air temperature and morning cool down set points�
sensor is factory provided but must be eld installed. The
return air sensor will be used to determine the mode of operation Cooling, Heating, Humidication, Dehumidication and/or Reheat�

Sequence of Operation

After power is applied to the system from the main power supply, the unit must be started through the Marvel Plus wall mount terminal� To start the unit, press and hold the ENTER button for 5 seconds� To stop the unit, press the ENTER button again and hold for 5 seconds�
Once the system is started through the Marvel Plus Wall Control, the supply air blower will start after the factory
default 15 second time delay (eld adjustable) times out.
When the unit is in the occupied mode, the supply air blower will start at the minimum blower speed to supply the
minimum required amount of air ow. Once at the minimum
speed, the controller will verify that the blower is operating by
checking the airow proving switch. The high duct pressure safety switch is also veried for possible high duct pressure
conditions� If both safety switches are closed, the controller will ramp the VFD to maintain the supply air blower at the static pressure set point�
If the pressure in the ducting increases above the high duct static pressure switch setting, the system will shut down all modes of operation� The supply air blower will be shut down and an audible alarm will be generated and displayed in text
on the Marvel Plus wall mount terminal under the The bottom line of the opening screen for System Status will also display “Off by High Press AL” before entering the
button�
At any time, if the Marvel Plus controller monitors that there
is a loss of air ow, the controller will shut down all modes
of operation to protect the system� The supply air blower will shut down and an audible alarm is generated and displayed
in text on the Marvel Plus wall mount terminal under the button� The bottom line of the opening screen for System
Status will also display “Off by Airow Alarm” before entering
the button�
If both switches are veried and no alarms exist, the controller
will continue with the cooling or optional modes of operation
heating, humidication, dehumidication, morning warm up
or morning cool down�
button�

Return Air Temperature Control (Option)

If the application requires both cooling and heating or
requires humidication or dehumidication, a return air
Subject to change without notice. 120.5-IM (1018)
6
Marvel Plus
Humidication (Option)
If the system has the Humidication Option, humidication
will operate based on return air humidity� When the return air humidity is less then the return air humidity set point minus
the Band set point, humidication is enabled. Humidication
is then sequenced ON and OFF based on the return
air humidity requirement or humidication demand. The percentage of humidication demand is determined by how
far the return air humidity is below the return air humidity set point�
Dehumidication (Option)
If the system has the Dehumidication Option, dehumidication is sequenced based on return air humidity.
When the return air humidity is greater than the return air
humidity set point plus the Band set point, dehumidication mode is enabled. Dehumidication is then sequenced /
staged ON and OFF by cycling compressors based on the
dehumidication requirement or dehumidication demand. The percentage of dehumidication demand is determined
by how far the return air humidity is above the return air humidity set point�

Reheat Mode (Option)

If the system has the Dehumidication Option and the
optional factory provided heaters or hot gas reheat coil and valve, the heaters/hot gas reheat coils are available for the Reheat Mode Option� The heater(s) will be activated for the
Reheat Function during the Dehumidication Mode. Reheat
function is based on both Return Air Temperature and Supply Air Temperature and their respective set point� If the return air temperature falls below the return air temperature set point or the supply air temperature falls below the supply air temperature set point, the reheat is brought on and applied based on whichever demand for heating is greater� The reheat demand is based on how far the temperature is from the set point and whichever demand is greater (reheat demand based on supply air temperature or reheat demand based on return air temperature)� For systems with multiple stages of heater, the quantity of heaters for Reheat Mode is determined by the heating demand based on return air temperature�

Air Side Economizer (Option)

If the system has the Airside Economizer Option, the system will utilize the airside economizer when the outdoor air enthalpy is less than return air enthalpy and the outdoor
air temperature is less than the outdoor air temperature set point minus the Band set point� Once the outdoor air enthalpy
is veried, the Marvel Plus controller sends a modulating signal (0-10vdc) to the eld interlock terminal strip as shown
on the electrical diagram provided with the unit� The signal provided will maintain the supply air temperature as close to the supply air temperature set point as possible until the
return air temperature (cooling requirement) is satised.
INFORMATION
The minimum position damper setting may in some instances affect system operation if too much outdoor air is continuously introduced to the space being controlled�

Air Side Economizer - Compressor Assist Mode

Mechanical Cooling Assist is a function available for applications where the outdoor air temperature cannot meet the cooling demand requirements� The Mechanical Cooling Assist function has an adjustable time delay (minutes) before mechanical cooling compressor stages are energized to assist with the Airside Economizer option�

Water Side Economizer (Option)

The Water Side Economizer Option provides an economical method of cooling when a free-cool coil can be utilized� If the system has a free-cool coil and a cooling tower available, the system will use free cooling when the water temperature is below the free-cool temperature setting� If the water temperature is above the free-cool setting, the system will use mechanical cooling� If the water temperature is below the free-cool setting, the water valve for free-cool mode will modulate open to satisfy the cooling requirement�

Water Side Economizer - Compressor Assist Mode

Mechanical Cooling Assist is a function available for applications where the waterside economizer function cannot meet the cooling demand requirements� The Mechanical Cooling Assist function has an adjustable time delay (minutes) before mechanical cooling compressor stages are energized to assist with the Water Side Economizer option�
Subject to change without notice. 120.5-IM (1018)
7
Marvel Plus

STATIC PRESSURE TRANSDUCER (DUCT MOUNT) WITH VAV OPTION

MOUNTING

The static pressure transducer shown in Figure 3 – Pressure Transducer must be installed in the main supply air ducting at a location approximately two-thirds of the distance down the straightest duct run from the supply air outlet of the unit�
The location must be a non-turbulent area of supply air ow.
Mount the pressure transducer as follows:
1. Remove the pressure transducer’s cover plate screws using a Phillips head screw driver�
2. Select the mounting location� Install the sensor at the approximate mid-point/center of the vertical plane of the ducting�
3. The sensor must be mounted vertically with the electrical entrance/strain relief facing downward�
4. Drill a 1/2” hole through the face of the duct�
5. Before installing the duct pressure transducer, make
sure the gasket at the base where the duct probe
meets the transducer housing is intact and sealed to the sensor (so that it will seal the perimeter of the hole drilled)�
6. Insert the probe into the duct and mount the pressure
transducer using two (2) eld provided #8 sheet metal
screws�

WIRING

Using a minimum 18-20 AWG 300 volt rated two conductor shielded cable with drain wire make the following electrical connections�
IMPORTANT: Please observe polarity of this sensor� The “+” is +24 vdc and the “–“ is the output (4-20 mA) to the Analog Input of the controller�
7. Connect from the positive terminal “+” inside the pressure transducer to the unit’s electrical terminal block TB-DMPT +�
8. Connect from the negative terminal “–” inside the pressure transducer to the unit’s electrical terminal block TB-DMPT –�
9. Connect the drain wire to ground at the unit end only�
FIGURE 1 – PRESSURE TRANSDUCER
Subject to change without notice. 120.5-IM (1018)
8
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