MAXIM Series Controllers INSTALLATION INSTRUCTIONS
Proprietary No part of this technical manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of Mass Electronics Pty Ltd. Trademark The term ‘Innotech’ used in this manual is a trademark of Mass Electronics Pty Ltd trading as Innotech Control Systems Australia.
Document Management Document Title: Maxim Installation Instructions Revision History Version Number Date Summary of Changes 1.0 June 2011 First release of Installation Instructions for Innotech MAXIM Series Controllers. 2.0 November 2013 Contact Details Update, Style Update. Edition 2.
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Contents Chapter 1 - Preliminary Information................................................................9 1-1 Scope......................................................................................................................... 10 1-1.1 Systems Covered by this Manual.............................................................................10 1-1.2 Terminology used in this manual............................................................................11 1-1.3 Document layout...............
Chapter 4 - Network Installation...................................................................41 4-1 Overview................................................................................................................... 42 Chapter 5 - Commissioning...........................................................................43 5-1 Overview................................................................................................................... 44 5-2 Inspect the Installation ................
List of Illustrations Figure 2-1: Typical Enclosure Installation.................................................................................16 Figure 2-2: MAXIM I and MAXIM II Controller Dimensions.........................................................17 Figure 2-3: MAXIM III and MAXIM 1010 Controller Dimensions.................................................18 Figure 2-4: MiniMAX, MicroMAX, VAVMax and IG01 Controller Dimensions.............................19 Figure 2-5: LCD Optimum Viewing Angle...
List of Tables Table 1-1: Document Structure................................................................................................11 Table 1-2: Features of MAXIM Series Controllers......................................................................12 Table 3-1: MAXIM I, II, III and 1010 Power Source Specifications............................................28 Table 3-2: MAXIM I, II, III and 1010 Controller Power Input Terminals....................................
MAXIM Series Controllers INSTALLATION INSTRUCTIONS Chapter 1 - Preliminary Information
MAXIM Installation Instructions 1-1 Scope This manual is intended to provide qualified technical personnel with complete and easy-to-follow instructions for installing, testing, and commissioning the MAXIM Series Controllers. Although every effort has been made to simplify the installation process, it is assumed that qualified personnel installing the MAXIM Series Controllers are familiar with local regulations, codes, and safety requirements.
MAXIM Installation Instructions 1-1.2 Terminology used in this manual In order to simplify the instructions, common terminology and references to other Innotech products are used throughout this manual. A brief description of some of the terminology is provided in this section. Net comms communication is the primary means of communication between Innotech hardware and iComm software.
MAXIM Installation Instructions 1-2 Overview of MAXIM Series Controllers This section of the manual provides general information for the MAXIM Series Controllers. The subsequent sections include information on controllers that are installed on the primary network, and those that are installed on the subsystem network. Information is also provided for the Subsystem Gateway (IG01).
MAXIM Installation Instructions These controllers can operate in standalone applications, using the respective universal inputs, universal outputs, analogue outputs, and digital outputs to transmit and receive information and control external equipment, or as part of a network of Innotech devices that support Net and Global comms communication. However the MiniMAX (MM01) when installed in standalone applications does not provide Real Time Clock (RTC) synchronization functionality. 1-2.
MAXIM Installation Instructions 1-2.4 MAXIM I Controller The MAXIM I Controller is unique in that it only operates in standalone applications, using the built in universal inputs, analogue outputs, and digital outputs to transmit and receive information and control external equipment. The MAXIM I controller cannot be installed on a network.
MAXIM Series Controllers INSTALLATION INSTRUCTIONS Chapter 2 - Mechanical Installation
MAXIM Installation Instructions 2-1 Overview This section of the manual provides information to allow for the mechanical installation of the MAXIM Series controllers. Physical descriptions and dimension diagrams are provided for all controllers, followed by general installation instructions that include installing the MAXIM Series controllers on industry standard DIN rail. Innotech recognises that the installation examples described in this manual may not suit the requirements of all customers.
MAXIM Installation Instructions 2-2 Physical Description and Dimension Diagrams 2-2.1 Overview This section of the manual provides information on the general physical characteristics of the MAXIM Series controllers, followed by dimension diagrams to help with the mechanical installation. NOTE Please note that ALL physical dimensions illustrated in this section are in millimetres. 2-2.
MAXIM Installation Instructions Figure 2-3: MAXIM III and MAXIM 1010 Controller Dimensions 2-2.3 MiniMAX, MicroMAX, VAVMax, and IG01 These controllers are housed in a compact DIN case and are suitable to be mounted on DIN rail. And since these controllers are housed in a common case, the dimensions therefore for each controller are the same, as illustrated in Figure 2-4 on the next page. Edition 2.
MAXIM Installation Instructions Figure 2-4: MiniMAX, MicroMAX, VAVMax and IG01 Controller Dimensions 2-2.3.1 VAVMax Differential Pressure Input The Differential Pressure Input is only available on the VAVMax (VM01) controllers. It is used to measure and respond to changes in air velocity pressure, which is determined by how the VAVMax controller has been configured. The pressure sensor is factory calibrated for optimum performance and is an extremely sensitive electromechanical device.
MAXIM Installation Instructions 2-3 General Installation Information 2-3.1 Overview This section of the manual provides general installation guidelines to assist you with the mechanical installation of the MAXIM Series controllers. 2-3.
MAXIM Installation Instructions 2-3.3 Installing on DIN Rail As mentioned earlier the MAXIM Series controllers are designed to be mounted on DIN rail. The DIN rail is a set of different standardized rails widely used for mounting industrial control equipment inside equipment racks. Mounting Slot 18 x 5.2 * All dimensions are in millimetres. Figure 2-6: DIN Rail Dimensions To install a MAXIM Series controller on a DIN rail, align the DIN rail clip on the top edge of the DIN rail.
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MAXIM Series Controllers INSTALLATION INSTRUCTIONS Chapter 3 - Electrical Installation
MAXIM Installation Instructions 3-1 Overview This section of the manual provides information to assist in the electrical installation of the MAXIM Series controllers, which can be installed in a wide variety of configurations to suit your requirements. Innotech recognises that the installation examples described in this manual may not suit the requirements of all customers.
MAXIM Installation Instructions Innotech MAXIM Series III Controller (v6.
MAXIM Installation Instructions 3-3.1 MAXIM I, II, III, and 1010 Controllers This section of the manual provides wiring information for MAXIM Series I, II, III, and 1010 controllers. Information is provided on wiring a power source, and all associated inputs and outputs. The general layout of the input and output terminals for each of these controllers is illustrated in Figure 3-2 through Figure 3-5 below and on the next page.
MAXIM Installation Instructions POWER UNIVERSAL INPUTS DIGITAL RELAY OUTPUTS ANALOGUE OUTPUTS OPTIONAL ETHERNET PORT NET & GLOBAL COMMS (RS485) Figure 3-4: MAXIM III controller terminal connection layout Power Universal Inputs Universal Outputs Global & Optional Net Comms Ethernet RS485 Port Figure 3-5: MAXIM 1010 controller terminal connection layout Chapter 3 – Electrical Installation Page 27 © Mass Electronics Pty Ltd 2011
MAXIM Installation Instructions 3-3.1.1 Power Input The MAXIM I, II, III, and 1010 controllers may by powered by either an AC or a DC power source. The operating voltage must meet the requirements of Safety Extra Low Voltage (SELV) to EN60730. The transformer used must be a safety transformer in compliance with EN60742 and be designed for 100% duty. It must also be sized and fused in compliance with local safety regulations. Power input specifications for these controllers are detailed in Table 3-1 below.
MAXIM Installation Instructions 3-3.1.2 Universal Inputs The MAXIM I, II, III, and 1010 controllers are equipped with Universal Inputs that can be configured to suit a wide range of applications as described in Table 3-3 below. Each Universal Input has a signal terminal (+) and a reference terminal (–).
MAXIM Installation Instructions 3-3.1.3 Analogue Outputs The analogue outputs can be configured with MAXCon software to either heat valve mode or variable mode to suit your requirements. Each analogue output has a signal terminal (+) and a shared Com terminal (–). As illustrated in the connection details in Figure 3-1, the + terminal is the active signal, and the Com terminal is the signal reference of 0 V, which also can be referred to as ground.
MAXIM Installation Instructions 3-3.1.4 Digital Relay Outputs The digital relay outputs have two terminals assigned to each channel representing the Normally Open (NO) and Common (COM) contacts of the associated relay. It is good practice to use pilot relays for the actual switching functions, particularly when it applies to inductive loads such as coils, solenoids, and motors.
MAXIM Installation Instructions 3-3.2 MiniMAX Controllers (MM01 / MM02) This section of the manual provides wiring information for the MiniMAX MM01 and MM02 controllers. Information is provided on wiring a power source and all associated inputs and outputs. The general layout of the input and output terminals for each of these controllers is illustrated in Figure 3-7 below. Figure 3-7: MiniMAX (MM01 & MM02) Controller Terminal Connection Layout 3-3.2.
MAXIM Installation Instructions A single transformer may be used to supply voltage to more than one controller, but you must ensure that the planned load is well within the rating of the transformer. The transformer output terminal designated as AC Neutral must be solidly earthed to the main earth link of the enclosure panel. The dedicated power input terminals are Terminals 1 and 2 and are detailed in Table 3-6 below.
MAXIM Installation Instructions 3-3.2.3 TRIAC Outputs The MiniMAX controllers are equipped with four TRIAC outputs used for switching the 24 V AC power supply through to the outputs of the controller. There are four 24 V terminals for each TRIAC output, and two 0 V terminals that are shared by the four TRIAC outputs. The TRIAC outputs are rated at a minimum current of 20 m A and maximum current of 250 m A. The TRIAC outputs can operate in two modes: Pulse Width Modulation (PWM) or Digital (ON/OFF).
MAXIM Installation Instructions 3-3.3.1 Power Input The VAVMax and MicroMAX controllers are powered by a 24 V AC power source. The operating voltage must meet the requirements of Safety Extra Low Voltage (SELV) to EN60730. The transformer used must be a Class 2 safety transformer in compliance with EN60742 and be designed for 100% duty. It must also be sized and fused in compliance with local safety regulations.
MAXIM Installation Instructions 3-3.3.2 Universal Inputs / Outputs The VAVMax and MicroMAX controllers are equipped with two Universal Inputs/Outputs which can be configured with MAXCon software to be used as inputs or outputs. Each Universal Input/Output has a signal terminal (+) and a reference terminal (–). The types of inputs and outputs that can be configured and the respective range for each is shown are Table 3-11 below.
MAXIM Installation Instructions 3-3.3.3 TRIAC Outputs The VAVMax and MicroMAX controllers are equipped with four TRIAC outputs used for switching the 24 V AC power supply through to the outputs of the controller. There are four 24 V terminals for each TRIAC output, and two 0 V terminals that are shared by the four TRIAC outputs. The TRIAC outputs are rated at a minimum current of 20mA, and maximum current of 250mA.
MAXIM Installation Instructions 3-3.4 IG01 Sub System Gateway This section of the manual provides wiring information for the IG01 Sub System Gateway. Information is provided on wiring a power source and all associated inputs and outputs. The general layout of the input and output terminals for each of these controllers is illustrated in Figure 3-9 below. POWER ETHERNET SSG COMMS (RS485) NET & GLOBAL COMMS (RS485) Figure 3-9: IG01 Sub System Gateway Terminal Connection Layout 3-3.4.
MAXIM Installation Instructions A single transformer may be used to supply voltage to more than one controller, but you must ensure that the planned load is well within the rating of the transformer. The transformer output terminal designated as AC Neutral must be solidly earthed to the main earth link of the enclosure panel. The dedicated power input terminals are Terminals 1 and 2 and are detailed in Table 3-14 below.
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MAXIM Series Controllers INSTALLATION INSTRUCTIONS Chapter 4 - Network Installation
MAXIM Installation Instructions 4-1 Overview As mentioned in the Preliminary Information chapter, with the exception of the MAXIM I controller, all other MAXIM Series controllers can be installed on a primary or a sub system network depending on your specific model. Installing a MAXIM Series controller on a network provides the ability to share data among all controllers and devices on that network.
MAXIM Series Controllers INSTALLATION INSTRUCTIONS Chapter 5 Commissioning
MAXIM Installation Instructions 5-1 Overview The commissioning process of the MAXIM Series controllers can only be performed once the mechanical and electrical installation has been completed, and is intended to ready the controllers for full operation. The subsequent sections provide detailed information and steps for the commissioning process. CAUTION To prevent injury to personnel and damage to equipment, all electrical power must be turned OFF before starting the commissioning process.
MAXIM Installation Instructions 5-2.2 Electrical Inspection The electrical inspection of the installation process involves verifying all electrical connections are completed properly, and that there are no external voltages present on any of the inputs and outputs. The subsequent sections provide detailed information to perform a thorough electrical inspection of all wiring connections completed during the electrical installation process.
MAXIM Installation Instructions 5-2.2.1 Checking Power Inputs The power inputs must be inspected to ensure that the supplied voltage is within the specifications of the particular controller, as illustrated in Figure 5-1 below. In cases where a DC power source is utilised, correct polarity must be verified, and the 0 V terminal must be connected to ground.
MAXIM Installation Instructions 5-2.2.2 Checking Universal Inputs Before any Universal Inputs are connected to a MAXIM Series controller, you MUST follow the steps listed below to verify that 0 V A C is measured across these inputs. Please note that the voltage will be measured directly at the Universal Input wiring, and NOT at the controller, as illustrated in Figure 5-2 below. These steps do not apply if a DC source is connected to the Universal Inputs.
MAXIM Installation Instructions 5-2.2.3 Checking Digital Relay Outputs The Digital Relay Outputs on MAXIM Series controllers are interfaced through relays, each with Single Pole Single Throw (SPST) contacts. Before checking the Digital Relay Outputs, it is important to verify that there are no short circuits in the external wiring, which can cause the contact current to exceed the maximum rating. Excess current through the relay contacts can result in permanent damage to the controller.
MAXIM Installation Instructions The steps below provide further details to check and verify proper operation of the Digital Relay Outputs on MAXIM Series controllers, as illustrated in Figure 5-3 on the previous page. 1. Verify that the MAXIM controller on which the Digital Relay Outputs will be checked is powered OFF. You must also verify that power is turned OFF to all of the digital output circuits to be checked. 2.
MAXIM Installation Instructions 5-2.2.4 Checking Analogue Outputs The Analogue Output wiring on MAXIM Series controllers should be checked to verify that the output terminals are free of any external voltage, to verify continuity through the external analogue circuit, and to verify that the resistance of the external analogue voltage is sufficient to avoid overloading the analogue output circuit.
MAXIM Installation Instructions CHECKING ANALOGUE OUTPUT RESISTANCE Connected to equipment or device 2000 V V AC DC + Figure 5-5: Checking Analogue Output Resistance 5-2.2.5 TRIAC Outputs The following items should be checked and verified for proper operation of the TRIAC Outputs on applicable controllers: • Verify correct polarity of the wiring connected to the TRIAC outputs. • Inspect the controlling device for any defects or problems.
MAXIM Installation Instructions 5-2.2.6 End-of-Line Jumpers The End-of-Line (EOL) jumpers are required for MAXIM Series controllers that are installed on a subsystem network. There are certain rules that must be followed for proper installation of End-ofLine jumpers. If only one cable is connected into an RS485 Comms connector on a MAXIM controller installed on a subsystem network, you must place the EOL jumper on that controller.
MAXIM Series Controllers INSTALLATION INSTRUCTIONS Appendix A - Using the CT01 Commissioning Tool
MAXIM Installation Instructions A-1 Overview The Commissioning Tool – Subsystem Network (CT01) is a Human Machine Interface (HMI) that allows you to configure controllers on a Subsystem network. It provides full access and navigation through the menu structure of the Subsystem controllers. You can use the CT01 to commission the controllers as an alternative to the software method.
MAXIM Installation Instructions A-2.2 Connecting to Sub System Gateway (IG01) When you connect the CT01 to the Innotech Sub System Gateway (IG01) using the provided adaptor cable, the CT01 can communicate with all subsystem controllers on that network that are connected to the IG01, as illustrated in Figure A-2 below. Figure A-2: Connecting the CT01 to a Sub System Gateway IG01 NOTE The subsystem network must be reconnected as it was before once the commissioning process is complete.
MAXIM Installation Instructions A-2.3 Connecting to sub system network When you connect the CT01 to the subsystem network at any point using the provided adaptor cable, the CT01 can communicate with all controllers on the sub system network that are connected to the IG01, EXCEPT for the controller that is directly connected to the CT01. The IG01 will need to be unplugged from the subsystem network to allow this type of connection to work, as illustrated in Figure A-3 below.
MAXIM Installation Instructions A-2.4 CT01 Menus and Navigation The interface of the CT01 is relatively easy to navigate. To access the Menu page press the Exit button. To select how the CT01 is connected to the controller, select Setup and press the Enter button. Use the Up and Down navigation buttons to select between Network or Standalone. If the CT01 is connected directly to a controller as illustrated in Figure A-1 preivously, you will need to select Standalone.
MAXIM Installation Instructions A-4 VAVMax Settings Configuring a VAVMax controller requires a number of parameters that have to be calibrated. You can use the CT01 to calibrate the following parameters on a VAVMax controller to suit your requirements: • Zone temperature set point. • Minimum Flow rate (L/s) – The minimum design air flow for that particular VAVMax controller. • Maximum Flow rate (L/s) – The maximum design air flow for that particular VAVMax controller.
MAXIM Installation Instructions A-5.2 Configuring the K-Factor The K factor value is required to be calibrated to allow the VAVMax controller to correctly read the pressure and calculate the airflow. The VAVMax does not need to know the duct size because it is contained within the K factor. The K factor can be set manually, or the VAVMax can calculate it automatically by following the steps below: 1. Log onto a VAVMax controller as per the instructions in the previous section. 2.
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