FläktGroup Semco NEUTON User manual

PROACTIVE CONTROL
1ST COST SAVINGS
ENERGY SAVINGS
OWNER’S MANUAL
CONTROLLED CHILLED BEAM PUMP MODULE

2
OWNER’S MANUAL
NEUTON™PUMP MODULE
TABLE OF CONTENTS
Introduction ..................................3
Configurations ................................3
Principle of Operation ..........................4
Sequence of Operation .........................5
Component Parts..............................6
Dimensions ..................................8
Receiving & Inspecting ........................10
Installation & Wiring ..........................10
Controls .................................... 14
Keypad.....................................19
Points List ..................................19
Troubleshooting ..............................25
© SEMCO LLC 2015. All rights reserved.
The information in this owner’s manual is furnished for informational use only, is subject to change without notice, and should not be construed as
a commitment by SEMCO LLC. SEMCO LLC assumes no responsibility for any errors that may appear in this owner’s manual.
No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical,
recording, or otherwise, without the prior written permission of SEMCO LLC.
Patent pending.
SEMCO and the SEMCO logo are registered trademarks of SEMCO LLC. All other trademarks are registered to their respective companies. ZS Pro
is owned by OEMCtrl.
WARNING
To prevent injury or death, or property damage, read and follow all instructions and warnings.
Improper installation, adjustment, alteration, service maintenance, or use can cause explosion, fire,
electrical shock, or other conditions which may cause personal injury or property damage. Consult
a qualified installer or service agency for information or assistance. The qualified installer or agency
must use factory-authorized accessories when modifying this product.
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or
maintenance, turn the electrical power to unit to OFF at disconnect switch(es). Unit may have
multiple power supplies. Follow lock out-tag out procedures when servicing.
!

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OWNER’S MANUAL
NEUTON™
TO BEAMS
FROM
BEAMS
This manual describes the installation and maintenance of the NEUTON™ controlled chilled beam pump module.
The descriptions include all optional equipment and devices for the unit currently available from SEMCO. If optional
equipment is required after receiving the unit, please contact:
SEMCO LLC
1800 East Pointe Drive Columbia, MO 65201
573 443 1481 main 573 886 5408 fax
Email: [email protected]
Before proceeding with handling and installing the NEUTON™, review the important features and devices on the unit as
described and explained in the following pages of this manual.
INTRODUCTION
CONFIGURATIONS
NEUTON4, Dual Valve Pump Module NEUTON2, Single Valve Pump Module
CLOSED CLOSED
TO BEAMS
FROM
BEAMS
• Utilized as only cooling or only heating
• 2 pipe primary system (supply/return) - requires
primary system to have a summer/winter switch
over
• 4 pipe primary system (cold supply/ cold return,
hot supply/ hot return) - requires one NEUTON2per
circuit (one for cooling, one for heating)
• Utilized as dynamic zone operation with simultaneous
heating and cooling demand
• 2 pipe primary system – return water from pump
module is returned to same loop downstream from
supply, on both cooling and heating loops. Requires
only one NEUTON4for both cooling and heating.
• 4 pipe primary system – return water is piped to
dedicated return line, one for cold water and one
for hot water. Requires only one NEUTON4for both
cooling and heating.

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OWNER’S MANUAL
NEUTON™PUMP MODULE
PRINCIPLE OF OPERATION
NEUTON™ is the HVAC industry’s first smart, plug-and-
play controlled chilled beam pump module (CCBPM)
for reducing chilled beam system installation and
operational costs.
NEUTON™ is a factory-built and pre-tested CCBPM
package complete with its own powered integrated direct
digital controller, chilled and hot water connections,
valves, variable-speed electronically commutated motor
(ECM) pumps, zone sensors, and other unique features.
The device provides active condensation control
effectively addressing one of the key design concerns
regarding active chilled beams.
The intuitiveness of NEUTON™ eliminates the expense
of a separate chiller, boiler and secondary water
distribution system associated with conventional chilled
beam HVAC designs. Instead of expensive secondary
piping loops, each NEUTON™ blends and re-circulates
return water within its zone to convert typical 42°F and
140°F primary loop water temperatures to optimal 58°F
or 100°F chilled beam discharge temperatures, which
prevents cooling mode condensation and heating season
heat stratification.
Each NEUTON™ can control up to 10 chilled beams,
depending upon the water flow rate required.
Numerous important design advantages are provided by
the combination of Pinnacle systems with active chilled
beams including:
• Very high energy efficiency
• Very low primary airflow requirements
• Low noise levels
• Reduced filter maintenance – central location not
room by room
• Ideal air distribution
• Improved indoor air quality – excellent outdoor air
delivery
• Ideal humidity control
• Active condensation control
62˚F
62
˚
F
58˚F
62˚F
Knob In
Closed
Mode
Knob in
Partial Open
(modulating)
Mode
CWR CWS HWS
(Closed)
Note: Only one of
multiple beams in
zone shown.
Cooling Mode
(4 pipe primary loop shown)
HWR
(Closed) 42˚FChilled Water
Supply
Chilled Water Return
120˚F
90
˚
F
100˚F
90˚F
Knob in
Partial
Open
(modulating)
Mode HWR
CWR
(Closed)
CWS
(Closed) HWS
Hot Water Supply
Hot Water Return
Note: Only one of
multiple beams in
zone shown.
Heating Mode
(4 pipe primary loop shown)
Knob in
Closed
Mode

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OWNER’S MANUAL
NEUTON™
SEQUENCE OF OPERATION
NEUTON™ receives space conditions and setpoints from either a communicating wall mount ZS Pro Zone Sensor or
from the Building Automation System (BAS). The sequence begins when power is applied to the controller. The BAS
can override the controller operation with a stop command.
The controller modulates the chilled and hot water valves to maintain the desired supply water temperature to the
chilled beams. The water flow is modulated to maintain the desired space temperature setpoint. The controller
accepts occupied and unoccupied setpoints, which may be entered either at the zone sensor, or through the BAS.
Occupied mode is initiated either by a digital input, a call from the BAS, by space CO2exceeding the “CO2force occupied
mode setpoint,” or by the override button on the thermostat.
On call for cooling, the chilled water valve modulates to produce the “cooling beginning water temperature” setpoint.
On continued call for cooling, the pump operates at the default mid-range pump speed for a short duration and the
control valves modulate, as required, to achieve the desired beam supply water temperature setpoint.
After a default time delay, if the space cooling setpoint is not achieved or if it is exceeded beyond the deadband
parameters set, the pump speed is modulated between the “Cooling Minimum Pump Output %” and the “Max Pump
Demand” setpoint until space conditions are achieved.
If after reaching maximum pump speed the space cooling setpoint is not achieved, after a time delay, and on continued
call for cooling the water temperature delivered to the beams will be gradually reset until it is equal to the space
dewpoint plus the “water offset above dew-point” setpoint.
On call for heating, the hot water valve modulates to produce the “Heating Beginning Water Temperature” setpoint. On
continued call for heating the water temperature delivered to the beams will be gradually reset until it reaches 100°F.
The pump is running at the “heating minimum pump output %” setpoint while the water temperature is being reset.
When the water temperature reaches 100°F (adj.), and if the space heating setpoint is not reached, the pump demand
will modulate from its heating minimum pump output % setpoint up to the “max pump demand” (if needed) to reach the
space heating setpoint temperature.
58˚F
62˚F
Manual air vent
Beam Zone

6
OWNER’S MANUAL
NEUTON™PUMP MODULE
1
2
3
4
5
6
7
8
9
10
11
12
1) Integrated electrical, DDC controls panel
2) Electronically Commutated Motor (ECM)
high efficiency, variable speed pump
3) Hot water control valve
4) Chilled water control valve
5) Chilled water return
6) Hot water supply
7) Zone loop return connection
8) Chilled water supply
9) Hot water return
10) Zone supply water connection
11) Pete’s plugs for pressure and flow
measurement
12) Zone supply water thermistor
13) Pump Isolation Valves
14) Optional Main Power Penetration
and Bushing
COMPONENT PARTS
ZS Pro Sensor Zone Controller.
Temperature and Humidity standard,
CO2optional
Optional BACview6Keypad
14
13

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OWNER’S MANUAL
NEUTON™
• The pump, water temperature sensor, control valves, associated electrical and controls are all factory wired
and tested
• Only field connections required are main power (208/230/1Ph), zone sensor, and BAS (if used)
• On-board controls specifically developed and optimized for chilled beam zone control (plug and play)
• All pipe connections use swivel half-union adapters with face gasket designed to easily connect to standard
1” male fittings
BAS
Communications Link
(field wiring by contractor)
18-4 Plenum
Cable
(field wiring by
contractor)
Main Power Connection
(field wiring by contractor)

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OWNER’S MANUAL
NEUTON™PUMP MODULE
DIMENSIONS: NEUTON4DUAL VALVE PUMP MODULE
7-5/16" 10-1/2"
10-1/2"
21-9/16"
7-11/16"
4-1/8" 3-13/16"
21-3/8"
1A. FRONT
1C. SIDE 1D. BACK
1B. TOP
FIGURE 1. Dimensions of the NEUTON 4 Dual Valve Pump Module from the front (A), top (B), side (C), and back (D).

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OWNER’S MANUAL
NEUTON™
DIMENSIONS: NEUTON2SINGLE VALVE PUMP MODULE
FIGURE 2. Dimensions of the NEUTON 2 Single Valve Pump Module from the front (A), top (B), side (C), and back (D).
20-3/4"
17-1/2"
4-1/8" 7-11/16" 3-13/16"
10-1/2"
10-1/2"
7-5/16"
2A. FRONT
2C. SIDE 2D. BACK
2B. TOP

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OWNER’S MANUAL
NEUTON™PUMP MODULE
1) A control panel penetration/bushing will need to
be inserted to accommodate the BAS and/or zone
sensor wiring. Installer should determine optimal
positioning per final installation orientation. The
use of a knockout punch is recommended for
penetration(s). Install bushing.
NOTE: Take care to keep the inside of the control
panel free of metal shavings when installing hole.
2) Mount unit to an appropriate bracing system. The
pump module can be mounted in any position that
allows the pump shaft to be oriented horizontally
while not allowing the terminal box be oriented
in a downward position (See Figure 3). See the
dimensional drawings in Figures 1D and 2D for the
dimensions between the four (4) mounting holes
for each configuration. At a minimum, 12” should
be added to the width and 8” to the depth shown
to allow reasonable service access to the pump
and the valves and to allow for a full swing of the
electrical panel door.
3) Disconnect the o-rings that are attached to the unit
and place on each pipe connection (See FIgure 4).
INSTALLATION & WIRING
RECEIVING & INSPECTION
Upon delivery, confirm that the quantity and model(s) received matches the Bill of Lading. If there is any discrepancy,
immediately notify SEMCO LLC.
Inspect the packages for signs of damage. If damage is suspected, contact SEMCO immediately. If no visible damage
is apparent, the unit should be properly stored until installation.
FIGURE 3. Acceptable (A, B, E) and unacceptable (C, D) mounting orientations. Note that orientation C can be utilized provided that
the pump motor is field rotated to an acceptable position (E).
A B C D
4) Make pipe connections. See the dimensional
drawings in Figures 1A and 2A for the dimensions
between pipes. All piping connection ports on
NEUTON are 1” female National Pipe Tapered
(NPT) swivel half-union adapters with face gasket
designed to connect to standard 1” male National
Pipe Tapered fittings (NFT) to be provided by the
installing contractor. Tighten the swivel nut by hand
and then gently snug with pliers (1/8 to ¼ turn) for a
leak-free joint. Do not over-tighten or you may cut
the gasket and cause a leak.
5) WARNING! Air in the system will damage the pump:
air must be completely eliminated from the pump
module and chilled beam loop using a vent at the
high point. The actuator control valves must be
manually opened to facilitate filling the system (See
Figure 5). After the system is filled, the valve should
be returned to automatic operation. Be sure the
knob has “popped” out to the engaged position to
return to automatic mode. See Figure 6 for position
of valve knob and rotation direction switch after
E