"service manual"
Contents
1. ate dat 7 7 9 COMMUNICATIONS DISPLAY 9 AUTO CYCLE WIS 9 ANALOG OFFSET DISPLAY cisessicisvessccsisviysocssevniastnsetvscdvesascssivesvhocayvidesnnsanvercuvsaiessesvaphisoubvivesshasveesecesaeeteatsseerbensvibenenavavescthoaseite 9 HOW THE MICROPROCESSOR WORKS SUMMARY ccsccssssesscsssssesssssssessssssssescssssetsssssssseccssssutessssssessssssuuessssssuecssnsutesssaneess 10 MULTIPLE COMPRESSOR SEQUENCING 11 MICROPROCESSOR OUTPUT DATA 220 11 MICROPROCESSOR TELECOMMUNICATIONS scs scsssessssasssscociessvssscasscsscasdsesdosasvssestdoyedecscnseeonsssiveeersasvuesebdoastenscdbecsinanseesereaseas 11 COMMUNICATIONS PROTOCOL SPECIFICATIONS 11 TROUBLESHOOTING THE RXF 144 1040 14 GENERAL INFORMATIONL ccsccssssscssssssescsssssescssssseesssssssscssssssessssssuessssssssscsssssusssssssussssssssessssssuseesssssuesssssnutessssssusssssnuueesssaseese 14 TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM sssssssssssssssssssessssssessssssssessssssseesssssssesssssseessssssneiessssseesen 14 EPROM MEMORY I C CHIP2. REMOTE UNLOAD LIQ INJ PRESS REG 13 16 NOTE LN 39 IF ADDING OIL PUMP 777579 ONLY ON BOOSTERS WITH LIQ INJ OIL PUMP AUX 14 lt APPLICABLE COMPR AUX REMOVE OIL PUMP REQ D 16 l COMPR RUN TIME METER 17 i AUX 1 SEE NOTE B 18 19 AUX 2 SEE NOTE B 20 21 22 23 EMERGENCY SOF 2 COMPRESSOR START RUN 24 o OOO 2 SLIDE VALVE LOAD 25 SHOWN WITH SOL ON COMPR lt a gt COIL WITH SOL ON BASE YY SLIDE VALVE UNLOAD 2 gt SHOWN WITH SOL ON COMPR 26 ee lt b gt COIL WITH SOL ON BASE 27 DECREASE 3 5 Vi 28 DECREASE TO 2 2 Vi 29 LIQUID INJECTION IF 30 LIQUID HI Vi LIQ INJ 31 OIL HEATER 03 32 i 33 RELAY OR LAMP 34 35 WIRING IF ISOLATED 36 2CR CONTACT IS USED JUMP TO 6 2CR SEE NOTE A COMPR MOTOR STARTER IF REQ D Y YY IF STARTER CONTAINS MULTIPLE 37 SEE NOTE A JUMPER CONTACTORS RELAYS 8 TIMERS SEENOTEB 42 18 2218 ADD SUPPRESSORS OR VARISTORS AT EACH COIL SEE NOTE C 38 NOTE IF OIL PUMP IS REQ D WIRE OIL PUMP STARTER AS SHOWN 1 OIL PUMP AUX amp COMPR AUX MUST WIRED
3. 22 2 2 2 nccnnsansdarodssoncansiosecanasytnsonousiovansotelscassanSunseasns 16 SBC BOARD an 16 MICROPROCESSOR DISPLAY REPLACEMENT 16 FUSE REPLACEMENT 16 MICROPANEL ASSEMBLY WIRING 18 MINI MICROPROCESSOR CONTROL 570 400 OM JUN 99 Frick OPERATION Page 3 MINI MICROPROCESSOR CONTROL PANEL SETPO STEP DB 51 EMERGENCY STOP RXFMICRO THE FOLLOWING MUST BE READ AAWARNING AND UNDERSTOOD IN ADDITION TO THE OPERATING AND START UP INSTRUCTIONS 570 200 IOM BEFORE ATTEMPT ING TO START OR OPERATE THE UNIT The RXF compressor is controlled by a state of the art microprocessor control system The microprocessor continu ously monitors the compressor unit s condition and operation The microprocessor also directs instructions to the various compressor unit subsystems The microprocessor has a membrane switch keyboard Pressing the keyboard in the area outlined as a key will cause that function to be recognized by the microprocessor The keyboard has 32 membrane type keys In addition to the keyboard there is an emergency stop but ton Pushing the emergency stop will bypass the comp
4. RECYCLE A Recycle Delay message indicates that the compressor has started and has shut down within the time delay setpoint period The Recycle Delay will prevent the compressor from starting until the delay time expires and is intended to prevent damage to the compressor motor from successive restarts During Recycle Delay the micro processor will alternatively flash RECYCLE DELAY and the remaining delay time in minutes The RECYCLE message appears only when the compressor is in the recycle mode NOTE Consult Motor Manufacturer for the recom mended duration of the Recycle Delay If the RUN key is pushed while A CAUTION the unit is in Recycle Delay the compressor will start at the end of the delay period SETPOINTS DISPLAY SETPOINTS DISPLAY Adjustable Page 1 CCSP G LPCO G LPA G The information furnished by the Adjustable Setpoints of the Setpoints display is as follows CCSP The Capacity Control Setpoint reported in pounds per square inch gauge G or inches of mercury HG con trols the loading and unloading of the compressor when S V is in the automatic AUTO mode LPCO The Low Suction Pressure Cutout reported in pounds per square inch gauge G or inches of mercury H will shut down the compressor if the suction pressure drops to this limit or lower for 90 seconds or longer LPA The Low Suction Pressure Alarm reported in pounds per square inch gauge G or in
5. 2CR Check Wire 28 before fuse If fuse ok then possible bad output The Compressor Starter Auxiliary Contacts turn on Input 5 when they are closed These contacts are located on the Compressor Starter Check terminal 20 for voltage input OIL HEATERS DO NOT OPERATE separator sump is cold The oil heaters should operate only when the compressor is NOT running and the oil in the If the oil heaters do not work check between wires 25 and 2 for voltage If none check fuse FU1 15 amp If the fuse is not blown check between Wires 11 and 2 If 120VAC is not found check output 8 to ensure it is energized Check fuse FU8 if output is on If there is voltage check between Wires 26 and 2 If no voltage then replace CR1 SLIDE VALVE DOES NOT LOAD and or UNLOAD Verify that the Slide Valve is in the AUTO mode and that capacity control is calling for loading or unloading AUTO L or AUTO U will appear on the Operating display If 120VAC is not found when the LED for Output 2 is on check the fuse FU2 Output 2 controls the Slide Valve Load Solenoid If 120VAC is found across Wires 17 and 2 the Slide Valve Load Solenoid should be energized If not the solenoid is defective or neutral wiring from coil is loose SS S55 Frick RXF MINI MICROPROCESSOR CONTROL MAINTENANCE 70 400 OM JUN 99 Page 15 TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM Continued PROBABLE CAUSES and CORRECTIONS SLIDE VALVE DOES NOT LOAD a
6. CHANGE key to toggle between G and HG 4 In the event that an incorrect setpoint is keyed in press the CLEAR key to restore the original setpoint Pressing the CLEAR key a second time will eliminate the flashing characters 5 Having keyed in the desired setpoint press the ENTER key The new setpoint will be entered and the next adjustable setpoint will begin flashing NOTE A setpoint entry outside the parameters of the Adjustable Setpoint display will be refused HOW TO DETERMINE ADJUSTABLE SETPOINTS Adjustable Setpoints should reflect values compatible with normal system operation Too high a Low Suction Pressure Alarm setpoint may cause nuisance prealarms Similarly cutout setpoints should not fall within what are considered normal plant operation As a rule of thumb set the Low Suc tion Pressure Alarm 5 PSIG lower than the lowest normal suction pressure The Low Suction Pressure Cutout should be 5 to 10 PSIG lower than the Low Suction Pressure Alarm setpoint Display for illustrative purposes only SS S55 Frick The High Discharge Pressure Cutout should be set at 90 of the setting of the lowest high side relief valve The High Discharge Pressure Alarm should be set 10 PSIG lower than the Cutout The Capacity Control setpoint should be the equivalent of the normal suction condition SETPOINTS DISPLAY Fixed Page 1 HDTC 212 167 HDTA 194 159 HDTC The High Discharge Temp
7. CUSTOMER SUPPLIED 115 OR 230 VAC CONTROL TRANSFORMER POWER SOURCE 18 REQUIRED ALL POWER SOURCES SHALL BE GROUNDED ON ONE SIDE HOT ISOLATED AND SEPARATED FROM OTHER INDUCTIVE LOADS SUCH AS LIGHTING CIRCUITS NEUTRAL POWER SOURCE FROM FRICK SUPPLIED OR SPECIFIED STARTER USE MINIMUM 12 AWG FOR FEED ALL NEUTRALS ENTERING THIS ENCLOSURE SHALL BE TIED TOGETHER AT HOT IF SEPARATE FEED OR VOLTAGE FOR HEATER CIRCUIT IS DESIRED NEUTRAL SOURCE NOT IN THIS 8 REMOVE JUMPERS 1 1 amp 2 2 8 i A SEPARATE 115 OR 230 VAC SOURCE TO 1A amp 2A ENCLOSURE FOR 2 115V 1KW HTR S MOVE TIE NEUTRAL TO GROUND 1 WIRE TO 1A FU amp NUMBER 25A AT SOURCE 1CR 15 9 4 _ GROUND BAR IN MICRO 2A 2 ih SEPARATOR OIL HEATERS 04 15 1 KW OPTIONAL 2nd HEATER WHEN REQUIRED ALL HEATER WIRING TO BE 14 AWG ALL NEUTRAL EXP 2 amp 2A DIGITAL WIRING TO BE WHITE 07 EXCEPT WHERE NOTED 1151 SAFE A N O HELD CLOSED l 02 05 06 09 REMOTE START RUN STOP 10 REMOTE START RUN STOP REMOTE LOAD i E REMOTE LOAD 45
8. OR 37 36 18 COMPR STARTER ISOLATED CONTACT IF REQ D IF REQ D 19 17 14 15 5 20 12 5 21 11 5 22 10 5 23 3 4 AUX 2 IF AUX 1 IF OIL PUMP AUX IN SERIES W COMPR AUX IF COMPRESSOR AUX REMOTE UNLOAD REMOTE LOAD REMOTE START RUN STOP CURRENT TRANSFORMER 5 29 5 30 IF IF IF REQ D RXFMIWD2 Q NET network technology Make the Connection with QUANTUM Take full advantage of Q NET technology with all Frick products Quantum Cond Vesse Quantum AcuAir Remote PC Quantum Evaporator Air Unit System integration is what we do Q NET supports open protocols for your SCADA system i e Allen Bradley DF1 and Modbus ASCII connects for local or remote access Q NET can be applied to both new and existing systems Q NET means precise control 24 hours a day seven days a week Q NET distributed architecture means faster easier economical installations Q NET delivers increased operating efficiency and lowers energy costs Now available on Frick s AcuAire hygienic air handlers condensers screw compressors evaporators and refrigerant vessels too Take Control Form 570 400 600 Supersedes NOTHING 100 CV Avenue P O Box 997 Subject to change wit
9. SERIES OIL PUMP STARTER 39 IF FRICK STARTER IS SUPPLIED MODIFY STARTER AUX S SUPPRESSOR VARISTOR 5 SWITCH IS NOT SUPPLIED 8 INSTALLED AT OIL PUMP STARTER COIL SEE NOTE C RXFMIWD1 SSS Frick RXF MINI MICROPROCESSOR CONTROL MAINTENANCE 570 400 OM JUN 99 Page 19 MICROPANEL ASSEMBLY WIRING DIAGRAM continued C T MOUNTED IN STARTER OR MOTOR JUNCT BOX BY OTHERS 0 5 AMP SECONDARY ONE PHASE OF MOTOR TE 4 CABLE 2 CABLE 3 BLACK CABLE 4 BLACK WHITE RED CABLE 5 BLACK WHITE RED CABLE 6 BLACK WHITE RED CABLE 7 RED SLIDE VALVE POSITION POTENTIOMETER WHITE BLACK CABLE 8 PORT 1 RS 422 FRONT PANEL PSPL ES RXF SBC 14 COND RIBBON CABLE P7 KEY 1 12 COND RIBBON CABLE GREEN WIRE GND NO CONNECTION ON 230 FOR GROUNDED CIRCUITS CHANNEL 1 0 5 AMP AC COMPR MOTOR AMPS SEE IOM MANUAL FOR C T WIRE SIZING CHANNEL 2 SEP TEMP CHANNEL 3 DISCH TEMP CHANNEL 4 OIL TEMP CHANNEL 5 1 5 SUCTION PRESS CHANNEL 6 1 5 VDC DISCH PRESS CHANNEL 7 1 5 VDC OIL PRESS CHANNEL 8 SLIDE VALVE ALL ANALOG LOW VOLTAGE WIRING TO BE RUN IN SEPARATE CONDUIT FROM ALL OTHER WIRING TEMPERATURE WIRING SPECIFICAT
10. power is first applied to the control panel the unit will be in the Operating display mode To change to a different display mode press the CHANGE key The display modes in their order of rotation are RXF MINI MICROPROCESSOR CONTROL Page 4 OPERATION SSS Frick 1 Operating display 5 Pages 2 Setpoints display 7 Pages 3 Annunciator display 22 Pages P 4 Communications displ F2 Security display F4 Auto Cycle display OPERATING DISPLAY OPERATING DISPLAY Page 1 SUCT DISH OIL mode The Operating display is continuously updated and provides a variety of information in regard to the current status of the compressor s condition and performance The information furnished by the Operating display is as follows SUCT Suction Pressure is measured at the compressor inlet and is displayed in pounds per square inch gauge G or in inches of mercury DISH Discharge Pressure is measured at the compressor outlet and is displayed in pounds per square inch gauge G OIL Oil Pressure is measured prior to entering the compres sor and is displayed in pounds per square inch gauge G mode mode displays the status of the compressor unit The mode of operation will be indicated as either manual MAN when the RUN key has been pressed automatic AUTO when Auto Cycle has been activated remote RMT when the RMT key has been pressed or off OFF MODE s
11. the operator of the fault SS S55 Frick MULTIPLE COMPRESSOR SEQUENCING FOR RXF COMPRESSOR UNITS WITH MI CROPROCESSOR CONTROLS A The standard microprocessor panel includes 1 Remote Run Input 2 Remote Load Input 3 Remote Unload Input The remote run input is only recognized when the remote run mode has been selected by pressing the remote start key on the front panel of the microprocessor The remote load and unload inputs can only be recognized when the remote key in the slide valve column on the front panel of the microprocessor has been pressed A master sequence controller must be installed to provide the signals to remote start and stop the compressors and remote load and unload the compressors based on the common suction pressure or other parameter The customer may supply his own master sequencer panel usually a pro grammable controller or Frick can supply this sequencer if desired contact Frick for pricing RUN COMPRESSOR LOAD COMPRESSOR UNLOAD COMPRESSOR INPUTS A SPARE _ SLNdLNO HOVA WOIldAL HETIOWLNOO RXF COMPRESSOR WITH MICROPROCESSOR ATIVNSN HATIOULNOOD JONANODAS YALSVN TYPICAL FOR EACH COMPRESSOR OUTPUTS COMPRESSOR ALARM y MICROPROCESSOR OUTPUT DATA CODE A 3 5 OHM 10 watt resistor RES must be field installed as shown below when the
12. 120 VAC outputs of the RXF are driving 120 VAC solid state input devices such as program mable controllers NEUTRAL KOSS a RXF OUTPUT MASTER SEQUENCE 2 CONTROLLER OUTPUT RXF MINI MICROPROCESSOR CONTROL OPERATION MAINTENANCE Page 11 70 400 OM JUN 99 MICROPROCESSOR TELECOMMUNICATIONS The Frick RXF Microprocessor comes with an onboard telecommunications interface The telecommunications fea ture permits interfacing the microprocessor with a modem remote data communications terminal or master computer via RS 422 protocol In the case of a modem telephone lines are used for the actual transmission of data permitting communications from a remote location The components necessary to utilize the telecommunications feature will vary with the application Information concerning these items may be obtained from Frick Waynesboro Pa COMMUNICATIONS PROTOCOL SPECIFICATIONS All commands must be in ASCII CAPS to be recognized A compressor with an ID code of 00 is considered disabled ID Codes from 01 thru 99 are valid and are recognized by the microprocessor The following is a complete list of available command types COMMAND CODE and DESCRIPTION Returns compressor status information Compressor start command Compressor stop command Compressor capacity control command Return Pressures information Return Temperatures information Return full load amps information Enter Chan
13. A OR EQUAL FOR 230 VOLTS INDICATES FURNISHED OR REQUIRED WITH OIL PUMP ONLY INDICATES DEVICES SUPPLIED ONLY WHEN OPTIONAL OR REQUIRED WIRING BY OTHERS ALL WIRING ENTERING CONTROL CENTER INCLUDING GROUND amp NEUTRAL TO BE 14 AWG STRANDED WIRES UNLESS SPECIFIED OTHERWISE TERMINALS IN CONTROL CENTER NO THREE PHASE WIRING SHALL ENTER OR LEAVE MICRO PANEL OR BE RUN IN SAME CONDUIT AS ANY MICRO CONTROL WIRING ENTERING OR LEAVING MICRO PANEL NO SINGLE PHASE OVER 300 VOLTS SHALL ENTER OR LEAVE MICRO PANEL FOR PROPER INSTALLATION OF ELECTRONIC EQUIPMENT SEE FRICK PUBLICATION S90 400 SB SERVICE MANUAL ALL CONTROL CENTER WIRING TO BE 16 AWG STRANDED WIRE UNLESS SPECIFIED OTHERWISE FOR RXF PACKAGE MICROPROCESSOR TEST PROCEDURE SEE MMIB NO 4 11 10 9 FOR INSTALLATION OF MICROPROCESSOR BOARD AND EPROMS SEE MMIB NO 4 11 10 11 FOR HIGH POT TEST PROCEDURE SEE MMIB NO 4 11 10 7 SEE 640D0029 FOR STANDARD CONTROL CENTER ASSEMBLY STUD F2 SUPPL F1 SET SW 1 TO CORRECT VOLTAGE WRAP WIRES THROUGH TOROID TWO 2 TIMES ALL IN THE SAME DIRECTION Pt 230 U 2 GREEN TOROID FERRITE RING CUSTOMER S CONNECTIONS TO CONTROL CIRCUIT LINE NO TERM CIRCUIT DESCRIPTION 3 1 2 CONTROL POWER 3 1A 2A GND OIL HEATER POWER 37 18 2 OIL PUMP STARTER SEE NOTE A OR 37 36 18 OIL PUMP STARTER ISOLATED CONTACT 37 18 2 COMPR STARTER SEE NOTE A
14. COMPRESSOR SLIDE VALVE 01VLXX CONTROL COMMANDS 01VUXX 01VS 01VP Start command sequence Compressor ID code Compressor control command Load Slide valve command Unload slide valve command XX 00 Turns selected output off XX 01 to 15 Turns selected output on for XX seconds XX 99 Turns selected output on S Return slide valve position value Return slide stop position value If the command was 01 100 then the load slide valve output on compressor 1 would be turned off If the command was 01 105 then the load slide valve output on compressor 1 would be turned on for 5 seconds and would then automatically turn off NOTE the slide valve must be in the remote mode for this command to be executed RETURNED ANSWER for L or U commands 01 Character Description Position of returned data Acknowledge of command sent 2 3 ID code of compressor Carriage return line feed RETURNED ANSWER for S command ie 090 1 2 3 Slide valve position RETURNED ANSWER for P command ie 2 2 Carriage return line feed CHANGE SLIDE VALVE MODE 01MVR Start command sequence 01 Compressor ID Code MV Change slide valve mode ID X A Auto mode X R Remote mode If the command 01MVRID was sent the slide valve mode would change to Remote and the returned answer would be A01 followed by carriage return line feed RETURN PRESSURES COMMAND 01PX Start command sequence Compressor ID code Return pressures
15. E UNLD The Motor Load Control Force Unload MLFU reported as a percentage of the motor full load amps FLA will force the compressor to unload until the motor full load amps FLA falls to less than the stop load setpoint MLFU will show on display when active NOTE Consult mo tor manufacturer for recommended setpoint TO CHANGE THE ADJUSTABLE SETPOINTS Adjustable Setpoints are stored in memory and are easily changed in the field Although the Adjustable Setpoints A CAUTION are nol igei if power is interrupted we suggest that a list of Adjustable Setpoints be affixed to one end of the microprocessor cabinet for reference NOTE The following procedure also applies to the chang ing of the Security and Auto Cycle display setpoints 1 Press the CHANGE key to rotate the display to any of the Adjustable Setpoints displays Pages 1 2 3 4 or 5 2 Press the STEP key to move or step through the various setpoints A setpoint is selected for change or update when it is flashing 3 Having selected the setpoint to be changed the NU MERIC KEYPAD may be used to enter the new setpoint NOTE All digits must be entered including zeros For example 01 0 NOTE The AUX 1 and AUX 2 setpoints once selected are changed or updated by pressing the CHANGE key NOTE Certain setpoints may be reported in either pounds per square inch gauge G or inches of mercury HG Having selected the setpoint press the
16. Form 570 400 JUN 1999 aS Sa SERVICE MANUAL Section 70 Replaces NOTHING New Information Dist 3 3a 3b 3c RXF ROTARY SCREW COMPRESSOR UNITS MINI MICROPROCESSOR CONTROL THIS MANUAL CONTAINS OPERATION AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION OF THE UNIT Please check www frickcold com for the latest version of this publication 570 400 OM JUN 99 MINI MICROPROCESSOR CONTROL Page 2 OPERATION MAINTENANCE Prick Contents MINI MICROPROCESSOR CONTROL 3 KEYS AND KEY FUNCTIONS 4 OPERATING 15 4 SAONA N 5 TO CHANGE THE ADJUSTABLE SETPOINTS cssssssssssssssssesssssssesssssssessssssssesssssssessssssusessssssssesssssusssssnsussssssssesssssuesssessnsssessnees 6 HOW TO DETERMINE ADJUSTABLE 5 6 SETPOINTS DISPLAY Fixed Page 1 scsscsssssssssssssessssssssessssssssesssssssssssssssessssssssssssnssssssssuessssssuuessssssusssssnuuissssssesessanensssssssusess 7 SETPOINTS DISPLAY Fixed
17. IONS TEMPERATURE SENSOR WIRING TO BE 8760 BELDEN CABLE OR EQUAL GROUND DRAIN WIRE AT PANEL ONLY ON 4 SENSORS GROUND AT SENSOR END ONLY ON 1 SENSORS INSULATE DRAIN WIRE AT OPPOSITE END 2000 FT MAX DISTANCE NOTE A IF COMPR MOTOR STARTER IS A FRICK SUPPLIED STARTER OR CONFORMS TO FRICK STARTER SPECS WIRE AS SHOWN ON LINE 37 ONLY JUMP 6 TO 36 IF 2CR IS USED AS A ISOLATED CONTACT WIRE AS SHOWN BETWEEN THE HOT amp NEUTRAL LINES ON LINE 37 NOTE B FOR OPTIONAL ALARMS amp SHUTDOWNS HIGH LEVEL SHUTDOWN ETC WHEN REFERENCING MICRO POWER TO OPERATE COMPR MOTOR STARTER PARAGRAPH 1 NOTE A REMOVE JUMPER 36 TO 42 amp INSERT ISOLATED CONTACT S JUMP 42 TO STUD 04 EITHER 29 OR 30 AUX 1 OR AUX 2 PROGRAM AUX TO SHUTDOWN NORMALLY CLOSED WHEN USING 2CR AS A ISOLATED CONTACT PARAGRAPH 2 NOTE A REMOVE JUMPER 36 TO 42 amp INSERT ISOLATED CONTACT S A SEPARATE ISOLATED CONTACT SHOULD BE INSERTED BETWEEN 5 amp 29 OR 30 PROGRAM AUX AS AUX 1 amp AUX 2 BE PROGRAMMED TO ALARM OR SHUTDOWN NOR OPEN OR NOR CLOSED NOTE A SURGE SUPPRESSOR OR MOV TO BE INSTALLED ACROSS ALL INDUCTIVE LOADS IN CONTROL CENTER a SURGE SUPPRESSOR SUPPRESSOR SPECIFICATIONS RC NETWORK CONSISTING OF A 1 CAPACITOR 600 VDC IN SERIES WITH A 47 OHM RESISTOR USE ELECTROCUBE RG2031 3 6 OR EQUAL VARISTOR METAL OXIDE VARISTOR MOV SPECIFICATIONS GE V130LA10A OR EQUAL FOR 115 VOLTS GE V250LA10
18. M JUN 99 ANNUNCIATOR DISPLAY MULTIPLE FAILURES ANNUNCIATOR USE STEP HIGH PRESS ALARM The remaining screens show additional fail ure messages that may appear ANNUNCIATOR DISPLAY ANNUNCIATOR LOW PRESS CUTOUT ANNUNCIATOR DISPLAY ANNUNCIATOR LOW PRESS ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR OIL PRESS CUTOUT ANNUNCIATOR DISPLAY ANNUNCIATOR OIL PRESS ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR HI OIL TEMP CUTOUT ANNUNCIATOR DISPLAY ANNUNCIATOR HI OIL TEMP ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR LO OIL TEMP CUTOUT ANNUNCIATOR DISPLAY ANNUNCIATOR LO OIL TEMP ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR DISCH TEMP CUTOUT RXF MINI MICROPROCESSOR CONTROL Page 8 OPERATION SSS BSS Frick ANNUNCIATOR DISPLAY ANNUNCIATOR DISCH TEMP ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR COMPRESSOR AUXILIARY ANNUNCIATOR DISPLAY ANNUNCIATOR LEVEL ANNUNCIATOR DISPLAY ANNUNCIATOR COMP DIFFERENTIAL ANNUNCIATOR DISPLAY ANNUNCIATOR AUX 1 ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR AUX 1 SHUTDOWN ANNUNCIATOR DISPLAY ANNUNCIATOR AUX 2 ALARM ANNUNCIATOR DISPLAY ANNUNCIATOR AUX 2 SHUTDOWN ANNUNCIATOR DISPLAY ANNUNCIATOR BAD E2PROM CHIP ANNUNCIATOR DISPLAY ANNUNCIATOR SENSOR FAULT Display for illustrative purposes only SS SS Frick SECURITY DISPLAY KEYBD ENTRY ENABLED ENTER CODE The F2 function key will call up the Security display The Securi
19. NO0 9M SHAWOLSNO 4sno Frick Al NOLLOANNOO 5 1500 NOAY IWNOILdO NAHM Gal IddNS SADIAAC SALVOIGNI WVHOVIC 8 HOS 9 8200009 335 288 Id Ld39X3 288 OL SHIM OV X EL LNO ONIMS lee sindino 6 5 SINdNIZ 6Ns LN4 6110 8 6 2104 Ld 5001 2 0 9012 O 10d STANNVHO HOS woud ir lOd AVIdSIG OL gt HQ ide OLIN 9H9 LNO ONIMS 5 40 2 0334 ZH WASSV ld 2929 Zd 19 2 g KINO WSO Yt 285 21 SHIM 16 HLIM 31970 34035 TANVd LNOYS 570 400 OM JUN 99 RXF MINI MICROPROCESSOR CONTROL Page 18 MAINTENANCE Frick MICROPANEL ASSEMBLY WIRING DIAGRAM
20. Pressure Cutout Setpoint 03 Change Low Pressure Alarm Setpoint 04xxx Change High Pressure Cutout Setpoint 05 Change High Pressure Alarm Setpoint 06 Change MLC Stop Load Setpoint 07xxx Change MLC Force Unload Setpoint 08 Change Recycle Delay Setpoint 09 Change CTF Setpoint 01 Compressor ID code RETURNED ANSWER new setpoint which was sent followed by a carriage return line feed If the command was sent 01 01300901 the capacity control setpoint would be changed to 30 00 and the returned answer is 000 followed by a carriage return line feed If the command sent was 01C0711001 the MLC force unload setpoint would be changed to 110 and the returned answer is A110 fol lowed by a carriage return line feed If the command sent was 01 0520002 the returned answer is BAD followed by the ID number and a carriage return line feed gorh be lower case exception to All commands must be caps statement at beginning of section READ INPUT OUTPUT COMMAND 01X Start command sequence 01 Compressor ID Code X Read Input Output s command Returned Answer 1000001 100000000 Character Description Position Oil Level Input 1 Remote Run Input 2 Remote Load Input 3 Remote Unload Input 4 Compressor Aux Input 5 Aux 1 Input 6 Aux 2 Input 7 Compressor Run Output 1 Slide Valve Load Output 2 Slide Valve Unload Output 3 Slide Stop Increase Output 4 Sli
21. ches of mercury HG will trigger a prealarm if the suction pressure drops to this limit or lower SETPOINTS DISPLAY Adjustable Page 2 PB DB CT 15 1 0 10 PB The Proportional Band PB is used to determine the amount of time the load unload solenoid is energized ac cording to how far away from the setpoint the actual control pressure or temperature is The smaller the number the more load unload will be sent A PB of 10 is default It is adjustable to 2 5 10 15 20 or 25 percent DB The Dead Band DB is a plus or minus value above or below the setpoint at which the compressor will neither load nor unload It is adjustable between 5 and 5 0 psig or degrees in increments of 5 units 570 400 OM JUN 99 The Cycle Time CT setpoint is the amount of time between the beginning of each load unload response It is adjustable to 5 10 15 20 25 or 30 seconds Use the STEP key to step to the desired setpoint then press the CHANGE key to change the CC PB DB and CT values Enter the desired value for the remaining setpoints and press ENTER when complete SETPOINTS DISPLAY Adjustable Page 3 HPCO G AUX1 A NC HPA lt 0 2 5 HPCO The High Discharge Pressure Cutout reported in pounds per square inch gauge G will shut down the compressor if the discharge pressure equals or exceeds this setpoint HPA The High Discharge Pressure Alarm reported in pounds per square inc
22. ck the fuse FU4 Outputs 4 and 5 control the Slide Stop 2 2 Vi Solenoid If 120VAC is found across Wires 14 and 2 the Slide Stop 2 2 Vi Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 14 and 2 when the LED for Output 5 is on check the fuse FU5 Verify that the Liquid Injection TXV is modulating properly and not feeding excessive liquid to the compressor When oil temperature drops too low the microprocessor SHOULD deenergize this solenoid Output 6 controls the Liquid Injection Solenoid If 120VAC is found across Wires 13 and 2 the Liquid Injection Solenoid should be energized If not the solenoid is defective If 120VAC is not found when the LED for Output 6 is on check the fuse FU6 Output 7 controls the Hi Vi Liquid Injection Port solenoid If 120VAC is found across Wires 12 and 2 the Hi Vi Liquid Injection Port Solenoid should be energized If not the solenoid is defective If 120VAC is not found when the LED for output 7 is on check the fuse FU7 NOTE This output should only be on when the Vi is at 5 0 Output 9 controls the Alarm Circuit The Alarm should turn on only when there is a prealarm or shutdown If the Alarm does not sound when these conditions are found check for 120VAC across Wires 10 and 2 If 120VAC is not found check the fuse FU9 Inputs 2 through 4 can be used to operate the compressor from a remote location NOTE Check the Operating display to ver
23. command Return suction pressure PSIA Return discharge pressure g hg Return oil pressure g Return all pressures If the command was 01PS then the micro processor would dump the suction pressure RETURNED ANSWER XXX 3 characters followed by a carriage return line feed If using the A command then the returned data would be XXXXXXXXX 9 characters followed by a carriage return line feed RETURN TEMPERATURES COMMAND 01TX Start command sequence Compressor ID code Return temperature command Return discharge temperature Return oil temperature Return separator temperature Return all temperatures as a string of data If the command was 01TS then the micro processor would dump the suction temperature RETURNED ANSWER XXXX 4 characters followed by a carriage return line feed for suction XXX 3 characters followed by a carriage return line feed for discharge oil and separator If using the A command then the returned data would be XXXXXXXXX 9 characters followed by carriage return line feed COMPRESSOR DISPLAY SCREENS COMMAND 01DX Start command sequence Compressor ID code Compressor control command 0 Operating display Page 1 2 3 4 amp 5 will be dumped consecutively Adjustable Setpoints display Page 1 through 5 Fixed Setpoints display Page 1 amp 2 Autocycle display Security display If the command was 01D0 then the micropro cesso
24. de Stop Decrease Output 5 Liquid Injection Output 6 High Vi Liquid Injection Output 7 Oil Heated Output 8 Alarm Output 9 Example If the answer returned was 1000001100000000 the inputs outputs on compressor 1 which are energized are Oil Level Input 1 Aux 2 Input 7 Compressor Run Output 1 RETURN FAIL LIST 01L 01 L Return Fail List Will return a descriptive comment for each fail that is currently active each line is terminated by a carriage return line feed if there are no failures active No response is given CHANGE COMPRESSOR MODE 01MCR Start command sequence 01 Compressor ID Code MC Change compressor mode ID O Off mode Auto mode R Remote mode If the command 01MCRID was sent the com pressor mode would change to Remote and the returned answer would be 01 followed by carriage return line feed CLEAR FAILURE COMMAND 01KF Start command sequence 01 Compressor ID Code K Clear command ID X F Clear fails X R Clear recycle delay If the command 01KFID was sent the compressor cutout would clear and the returned answer would be A01 followed by carriage return line feed 570 400 JUN 99 TROUBLESHOOTING THE RXF MICROPROCESSOR This section contains information on troubleshooting and making corrections to the microprocessor and control circuits of the RXF unit This section is composed of four parts a general information section a tro
25. erature Cutout reported in degrees Fahrenheit will shut down the compressor if the discharge temperature equals or exceeds this setpoint HDTA The High Discharge Temperature Alarm reported in degrees Fahrenheit will shut down the compressor if the oil temperature equals or exceeds this setpoint HOTC The High Oil Temperature Cutout reported in de grees Fahrenheit will shut down the compressor if the oil temperature equals or exceeds this setpoint HOTA The High Oil Temperature Alarm reported in de grees Fahrenheit will trigger a prealarm if the oil temperature equals or exceeds this setpoint SETPOINTS DISPLAY Fixed Page 2 LOTC 49 HON 113 LOTA 58 HOFF 122 LOTC The Low Oil Temperature Cutout reported in de grees Fahrenheit will shut down the compressor if the oil temperature equals or falls below this setpoint LOTA The Low Oil Temperature Alarm reported in degrees Fahrenheit will trigger a prealarm if the oil temperature equals or falls below this setpoint HON The setpoint in degrees Fahrenheit to turn on the oil heater when the oil temperature in the oil separator equals or falls below this setpoint HOFF The setpoint in degrees Fahrenheit to turn off the oil heater when the oil temperature in the oil separator equals this setpoint Compressor Differential Cutout between Suction and Discharge The differential cutout has been lowered from 55 Ib to 25 Ib Cutout will occur after five minu
26. ge setpoints mode I R 5 T A The following is detailed description of each commana RETURN COMPRESSOR STATUS INFORMATION 011 Start of command sequence 01 Compressor ID code I Return Status information command RETURNED ANSWER ie O90RRRN340 Character Description Position of returned data 1 2 3 Capacity control position Remote Auto Manual Cap control Delay recycle Running Off Rem Man Off Auto Compressor mode Cutout Alarm Normal Suction in PSIA Carriage return line feed COMPRESSOR START COMMAND 01801 Start command sequence 01 Compressor ID code R Start compressor command 01 ID code repeated for verification NOTE The compressor must be in the remote start mode for this command to be executed Returned answer 01 Character Description Position of returned data Acknowledge of command sent 2 3 ID code of compressor Carriage return line feed 570 400 JUN 99 RXF MINI MICROPROCESSOR CONTROL Page 12 OPERATION MAINTENANCE Frick COMPRESSOR STOP COMMAND 01S01 Start command sequence Compressor ID code Stop compressor command ID code repeated for verification NOTE The compressor must be in the remote start mode for this command to be executed RETURNED ANSWER 01 Character Description Position of returned data Acknowledge of command sent 2 3 ID code of compressor Carriage return line feed
27. h gauge G will trigger a prealarm if the discharge pressure equals or exceeds this setpoint AUX 1 and AUX 2 May be configured for either an alarm or shutdown and with either a normally closed NC or normally open NO contact SETPOINTS DISPLAY Adjustable Page 4 RECYCLE DELAY 30 MIN C T FACTOR RECYCLE DELAY The Recycle Delay displays the current recycle delay setpoint in minutes NOTE Consult motor manufacturer for recommended setpoint CT FACTOR The Current Transformer Factor records the proper current transformer factor to match the compressor motor FLA rating to the current transformer primary amp rating The CTF factor is programmable and its correct value is determined by the following formula 1024 x FLA Full Load Amps 10x CT Current Transformer Primary Amps CTF See motor nameplate See CT located in starter panel EXAMPLE FLA 230 Amps CT 300 300 5 1024 x 230 19x 300 80 Round whole number SETPOINTS DISPLAY Adjustable 5 MLC STOP LOAD MLC FORCE UNLD MLC STOP LOAD The Motor Load Control Stop Load MLSL reported as a percentage of the motor full load amps FLA will prevent the compressor capacity control from loading when the setpoint is equaled or exceeded NOTE Consult motor manufacturer for recommended setpoint RXF MINI MICROPROCESSOR CONTROL Page 6 OPERATION SSS Frick MLC FORC
28. hen the system has failed for more than one condition USE STEP will appear in the upper right side of the display The appli cable failure displays will be individually rotated through by pressing the STEP key Continued pressing of the STEP key will result in the applicable failure displays repeating Pressing the CLEAR key while at the Annunciator display will clear all alarms and or cutouts In order to restore the Annunciator display and resume normal operation it will be necessary to go through the fol lowing steps 1 Correct the conditions causing the alarm 2 Press the ALARM SILENCE key This action may pre cede correcting the conditions causing the alarm 3 To clear or reset the Annunciator pages press the CLEAR key This will also clear the ALARM SHUTD or CUTOUT indicator from the Operating display 4 Press F1 to call up the Operating display If the conditions causing the alarm have not been corrected or a new fault has occurred the ALARM SHUTD or CUTOUT message will appear NOTE Use of the Emergency Stop Button may trip or more alarm setpoints 5 After all failures have been corrected and the CLEAR key has been pressed and if there are no failures the An nunciator display will show NO FAILURES ANNUNCIATOR DISPLAY NO FAILURES ANNUNCIATOR NO FAILURES ANNUNCIATOR DISPLAY 1 FAILURE ANNUNCIATOR HIGH PRESSURE CUTOUT Display for illustrative purposes only 570 400 O
29. hen the oil temperature reached 50 F the microprocessor would allow the Low Oil Temperature Cutout to be cleared and the compressor unit could now be started Assume that the RUN key has been pressed and that the compressor has now started The low oil temperature alarm would still be engaged and cannot be cleared until oil temperature exceeds 58 F The oil heater s shut off on compressor start AT 113 F The microprocessor instructs the liquid injection solenoid output to deenergize the liquid injection solenoid AT 122 F The microprocessor instructs liquid injection solenoid output to energize and the oil heater s output to deenergize This is a fail safe The heater s should already be deenergized due to compressor running AT 50 TO 157 F Normal operating range The microprocessor continues monitoring oil temperature and reporting this information on the Operating display 158 F The microprocessor triggers the High Oil Temperature Alarm and displays the alarm on the Operating display and the Annunciator display AT 167 F The microprocessor instructs the compressor motor to shut down and displays a SHUTD indication on the Operating display Information regarding the cutout will also be retained by the Annunciator display s NOTE If the operator makes an error by attempting to start the compressor under conditions outside safe normal operating conditions the microprocessor will prevent start up and advise
30. hout notice Waynesboro PA USA 17268 0997 Printed in USA GUI 100 806 2 00 Phone 717 762 2121 FAX 717 762 8624 2006 Johnson Controls Inc ALL RIGHTS RESERVED JOHNSON CONTROLS COMPANY www frickcold com
31. ify that the compressor and the Slide Valve are in the REMOTE MODE If 120VAC is found across Wires 21 and 2 22 and 2 and 23 and 2 and the input does not turn on and after checking for bad input and loose wires consult Frick The current transducer is used to convert the AC motor amps to a DC voltage signal for the microprocessor If the FLA reading from the Operating display is incorrect consult Frick Co TEST 1 Shut down the compressor and allow pressures to equalize Discharge pressure and oil pressure should have the same reading TEST 2 If either oil pressure or discharge pressure read different pressures or both transducers are at fault Valve off the suction transducer from the unit and open the vent valve on transducer manifold to atmosphere If the suction transducer reads atmospheric pressure then the suction transducer is correct NOTE A 1 tolerance is allowed for all transducers Verify that the AUTO key has been pressed and AUTO appears under SV Pos on the Operating display 4 If the problem persists see the Troubleshooting section SLIDE VALVE DOES NOT LOAD and or UNLOAD A loose or improper connection between the displays and the SBC is indicated Remove fuse 2FU 10 amp for 15 seconds then restore to reset the displays E2PROM chip malfunction or bad The system may still be run by resetting all Adjustable Setpoints and clearing Annunciator Display If condition repeats replace E2PROM i
32. in the auto matic AUTO manual MAN or remote RMT mode The microprocessor will control this function in the automatic mode To the right of the mode indicator three other mes sages may appear L indicates Slide Valve loading U indicates Slide Valve unloading FU indicates Slide Valve forced unloading A Forced Unload FU message indicates that the percentage of motor full load amps has exceeded the maximum limit and the microprocessor is unloading the compressor until the percentage FLA falls back to normal limits CAP CON The Capacity Control setpoint reported in pounds per square inch gauge G or inches of mercury HG controls the loading and unloading of the compressor when S V is in the automatic AUTO mode SUCT P Suction Pressure is measured at the compressor inlet and is displayed in pounds per square inch gauge G or in inches of mercury HG This is the same value as shown on Operating Display Page 1 OPERATING DISPLAY Page 5 VOLUME RATIO AUTO RECYCLE 30 MIN VOLUME RATIO Volume Ratio is the ratio selected by the microprocessor to provide the highest efficiency at any given suction and discharge pressure condition Immediately below Display for illustrative purposes only RXF MINI MICROPROCESSOR CONTROL OPERATION Page 5 570 400 OM JUN 99 this an information space has been provided to indicate whether V ratio is in the automatic AUTO or the manual MAN mode
33. mal operating condition has been reached or is present it will generate one or more of the following instructions 1 If a subsystem the compressor unit such as the heater s or liquid injection can correct the problem the microprocessor will energize or deenergize this system 2 If an alarm setpoint has been reached the microprocessor will trigger the alarm and display this information on the Operating display and the Annunciator display 3 If a cutout setpoint has been reached the microprocessor will trigger the cutout and shut down the compressor The microprocessor will indicate CUTOUT on the Operating dis play Information will be available through the Annunciator display RXF MINI MICROPROCESSOR CONTROL Page 10 OPERATION MAINTENANCE SSS 4 Frick A typical example of how the microprocessor responds can be illustrated by the responses generated by the micropro cessor as oil temperature increases Assume that the ambi ent temperature and compressor unit temperature is 45 F liquid injection R 22 refrigerant and you have just pressed the RUN key to start the compressor unit AT 45 F Microprocessor receives information that the oil tempera ture is below 49 F the low oil temperature cutout setpoint and triggers a cutout The microprocessor will prevent the compressor package from being started The microproces sor also instructs the oil heater s output to energize the oil heater s AT 50 F W
34. n slot U6 570 400 JUN 99 EPROM MEMORY I C CHIP REPLACEMENT Microprocessor EPROM memory chip is located inside the microprocessor console on the SBC board A special tool is required to remove this chip to prevent damaging it See Troubleshooting The Microprocessor The procedure to replace the EPROM memory chip is outlined below 1 Shut off control power 2 Open console cover 3 Using a chip extraction tool remove old and install new chip NOTE The chip must be inserted into socket U3 The notched end of the chip must A CAUTION be up when the chip is inserted to match the notch on the U3 chip socket SBC BOARD REPLACEMENT The procedure to replace SBC boards is outlined below 1 Shut off control power 2 Remove the old board from the machine and the new board from its packing and place both on an antistatic surface 3 Remove the program chip s from the defective board and install them in the replacement board RXF MINI MICROPROCESSOR CONTROL Page 16 MAINTENANCE SSS SST Frick Pay particular attention to the A CAUTION orientation of the notch es on the end of the chip s Install the chip s on the replacement board in exactly the same position as they were on the defective board 4 Then install the modified replacement board in the panel MICROPROCESSOR DISPLAY REPLACEMENT The procedure to replace the microprocessor display is outlined below 1 Shu
35. nd or UNLOAD Continued SLIDE STOP DOES NOT INCREASE and or DECREASE LIQUID INJECTION SOLENOID DOES NOT ENERGIZE LICO ONLY HI Vi LIQUID INJECTION PORT SOLENOID DOES NOT ENERGIZE ALARM CIRCUIT DOES NOT ENERGIZE CONTROL PANEL DOES NOT RESPOND TO REMOTE CONTROL SIGNALS MOTOR LOAD CONTROL FORCED UNLOAD OCCURS PRESSURES ON THE OPERATING DISPLAY DO NOT APPEAR CORRECT COMPRESSOR DOES NOT AUTOMATICALLY LOAD OR UNLOAD DISPLAY SCREENS DISPLAY SCRAMBLED PATTERN OR LIST ALPHABET ANNUNCIATOR DISPLAY MESSAGE BAD E2PROM CHIP U6 Output 3 controls the Slide Valve Unload Solenoid If 120VAC is found across Wires 16 and 2 the Slide Valve Unload Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 16 and 2 when the LED for Output 3 is on check the fuse FU3 Check for Motor Load Control Stop Load MLSL and Motor Load Control Forced Unload MLFL Check Autocycle minimum Slide Valve position manually cycle to check for bad pot or that rod is hung If all ok Hydraulic System Troubleshooting NOTE Verify that the proper setpoint has been programmed into C C Capacity Control on theAdjustable Setpoints display Output 4 controls the Slide Stop 3 5 Vi Solenoid If 120VAC is found across Wires 15 and 2 the Slide Stop 3 5 Vi Solenoid should be energized If not the solenoid is defective If 120VAC is not found across Wires 15 and 2 when the LED for Output 4 is on che
36. oint limit NOTE This limit must be set higher than Low Suction Pressure Cutout and the Low Suction Pressure Alarm setpoints MIN SV Minimum Slide Valve Position shown as a per centage will limit the slide valve position to the displayed setpoint ENABLE Indicates whether Auto Cycle is active YES or not active NO Press the CHANGE key while at this setpoint to change the status Upon deactivation the com pressor will return to the previous mode of operation The Analog Offset Display is accessed by pressing key ANALOG OFFSET DISPLAY PAGE 1 SUCT DISCH OIL TEMP 0 1 1 ANALOG OFFSET DISPLAY PAGE 2 DISCH OIL SEP TEMP 0 0 2 All analog values can be offset or 5 units depending on which value is being adjusted Use the STEP key to step through the desired setpoint Press the CHANGE key to change the value of the offset by 1 The actual analog value will be displayed under the word PRESS or TEMP 570 400 OM JUN 99 HOW THE MICROPROCESSOR WORKS SUMMARY The Frick microprocessor has 3 major components and a va riety of sensors The major components are the SBC single board computer 1 display screen and the keyboard The SBC can be considered the brain of the microprocessor control console The SBC contains the logic center which provides the rules by which the microprocessor will oper ate the integrated circuit chips which store the burned in memory of how the compress
37. operates the computer and its various sensors The microprocessor console contains the SBC single board computer and one display screen When working within the micropro AWARNING cessor console 120 VOLTS CAN CAUSE INJURY OR DEATH To troubleshoot the low voltage side of the RXF control cir cuits it is necessary to have the following tools Accurate digital multimeter Small wire stripper Small screwdriver Small snip nose pliers 15 watt soldering iron no larger 032 60 40 rosin core solder IC chip extraction and insertion tools Grounding strap Static free grounded work surface Available from Frick Order kit 451862 P N 111Q0451862 TROUBLESHOOTING FRICK SBC MICROPROCESSOR SYSTEM Refer to wiring diagrams NOTE Before proceeding check all wiring connections wire nuts terminal strips etc Also make sure operating condi tions are calling for change PROBABLE CAUSES and CORRECTIONS DISPLAY IS INOPERATIVE Check F1 on SBC F2 if 230 VAC Check the 10 amp fuse 2FU which controls all voltage going to the microprocessor Shut off power to the microprocessor and confirm that all cable and wire connections are made COMPRESSOR AUXILIARY SHUTDOWN Output 1 controls the Compressor Start Relay 2CR If the compressor does not start and the LED for Output 1 is on check the fuse FU1 5 amp If the problem persists check the interposing relay
38. or unit is to behave an analog input to convert Volts DC from the various sensors into com puter binary language and RAM random access memory integrated circuit chips to store information which can be readily changed by the microprocessor or as in the case of adjustable setpoints by the operator The SBC collects information processes the information and delivers instruc tions to the displays and to the output modules The SBC gathers information from several sources on the compressor unit Pressure transducers sense changes in pressure and return a variable DC voltage of 1 to 5 VDC to the SBC The signals are converted into binary code which the microprocessor understands The microprocessor scans the incoming data many times per second and compares the information it receives with the instructions programmed in the PROM chips information stored in the RAM chips and instructions it has received from the console keyboard As operating conditions change the microprocessor also for wards the information it is receiving to the display screen When an operating condition or conditions develop which the microprocessor program identifies as requiring a specific action the microprocessor generates an instruction which is forwarded to the output modules The instruction triggers a solid state output device capable of handling control voltage and the instruction is executed If the microprocessor receives information that indicates an abnor
39. r would dump the operating display RETURN FULL LOAD AMPS COMMAND 01A Start command sequence 01 Compressor ID code A Return full load amps command If the command was 01A then the micro processor would dump the full load amps value RETURNED ANSWER XXX 3 characters followed by a carriage return line feed MINI MICROPROCESSOR CONTROL 570 400 OM JUN 99 Frick OPERATION MAINTENANCE Page 13 READ FAILURES COMMAND 01F Start command sequence 01 Compressor ID Code F Read Failures command Returned Answer 00000000000000000000000 Character Description Position High Press Cutout High Press Alarm Low Press Cutout Low Press Alarm 011 Press Cutout Oil Press Alarm Hi Oil Temp Cutout Hi Oil Temp Alarm Lo 011 Temp Cutout Lo Oil Temp Alarm Disch Temp Cutout Disch Temp Alarm Comp Auxiliary Pump Auxiliary Oil Level Comp Differential Aux 1 Alarm Aux 1 Shutdown Aux 2 Alarm Aux 2 Shutdown Bad E2Prom Chip U6 Sensor Fault 2 2 2 32 00ND RON Example If the answer returned was 00000100000000000000000 compressor 2 has an Oil Press Alarm CHANGE SETPOINTS COMMAND 01C Start command sequence Compressor ID code Change setpoint command New setpoint New setpoint g or h for gauge or inches following is the complete list of the setpoints that may be changed while in the change setpoints command 01 Capacity Control Setpoint 02 Change Low
40. t off control power 2 Remove the defective display s 3 Install the new display s FUSE REPLACEMENT 1 Shut off control power 2 Open console cover 3 Identify faulty fuse 4 Use voltmeter to verify that no voltage is present on either side of the fuse 5 Remove faulty fuse using fuse puller 6 Install new plug type fuse 17 570 400 OM JUN 99 8601 X SZH L TANVd WOLLOS lt pe i 9 lt E ae 2 92 S lt a 3 8 5 S 4 2 lt 9 z om 1 088 8 40 6 GNLS OL 893 9 888 jg 049 2 SOA OZI SLOAN A E LO T JOHLNOO 1 062 4 1 f J041
41. tate state displays the current condition of the compressor unit The display will indicate if the unit is running RUNG off OFF shutdown because of some compres sor or system condition or alarm ALARM when there is an alarm condition OPERATING DISPLAY Page 2 DISCH OIL SEPARATOR DISCH Discharge Temperature degrees Fahrenheit is displayed OIL Oil Temperature is displayed in degrees Fahrenheit SEPARATOR Separator displays the oil separator temper ature in degrees Fahrenheit Display for illustrative purposes only SS SSS Frick OPERATING DISPLAY Page 3 COMP mode FLA HEATER state 11 OFF COMP Compressor mode indicates whether the compres sor is in automatic AUTO remote RMT or manual MAN operating mode STATE state indicates the unit operating condition when run ning RUNG off OFF shutdown SHUTD or ALARM FLA Percent Full Load Amps displays the percentage of the drive motor full load amperage rating that the motor is currently using HEATER Heater displays the condition of the oil separator heater s indicating ON or OFF OPERATING DISPLAY Page 4 S V Slide valve position is displayed as a percentage This percentage reflects the mechanical position of the slide valve and does not reflect the percentage of full load operation Immediately below this information space has been provided to indicate whether the S V is
42. tes To allow operation at low differential pressures the micro will take the following steps A Force unload the compressor to 50 and display an F Unload when the oil pressure is within 10 Ib of the main oil injection port pressure and the slide valve position is greater than 50 B Prohibit the compressor from loading and display a Ld Inhib message when the differential is within 15 Ib of the main oil injection port pressure Oil Pressure Alarm and cutout Logic has been revised to same logic as currently used on RXB RXF The new logic is as follows RXF MINI MICROPROCESSOR CONTROL OPERATION Page 7 570 400 OM JUN 99 Alarm will occur if oil pressure is 25 lb below discharge pres sure or within 10 Ib of suction pressure for 30 seconds Cutout occurs if oil pressure is 30 below discharge pressure or if oil pressure is within 7 Ib of suction pressure for 10 seconds and alarm has already been set ANNUNCIATOR DISPLAY When a prealarm or cutout occurs a flashing ALARM or SHUTD shutdown indicator will appear in the lower right hand corner of the Operating Display Page 1 and in the lower left hand corner of Operating Display Page 3 To determine the fault rotate to the Annunciator display by pressing the CHANGE key The Annunciator display will show all failures individually If there is only one failure the annunciator display will appear as shown on the following Annunciator Display s W
43. the new five digit access code and press ENTER NOTE Power loss will not affect the Security display NOTE IF NO ACCESS CODE WAS ENTERED AND THE DISABLED COMMAND WAS SELECTED THE ACCESS CODE IS 1000001 LOST OR FORGOTTEN ACCESS CODE Consult Frick for assistance COMMUNICATIONS DISPLAY COMMUNICATIONS ID 33 BAUD 9600 ID The ID number is a programmable identification code used in telecommunications to access a specific compres sor BAUD Shows the baud rate of the RS 422 communication port Both ports are configured as follows word 8 bit par ity none or even stop 1 bit The communications port is programmable from 300 to 19200 baud Display for illustrative purposes only RXF MINI MICROPROCESSOR CONTROL OPERATION Page 9 70 400 OM JUN 99 AUTO CYCLE DISPLAY START G MIN SV STOP G ENABLE YES The Auto Cycle display is accessed by pressing F4 The Auto Cycle display provides for independently adjustable setpoints to turn the compressor on and off in response to the suction pressure or as an adjustable setpoint to limit the minimum slide valve position NOTE To change the Auto Cycle setpoints refer to TO CHANGE THE ADJUSTABLE SETPOINTS START Compressor Start up will bring the compressor back on line when the suction pressure rises to the displayed setpoint STOP Compressor Stop will shut down the unit if the suc tion pressure drops to or below the displayed setp
44. ts The CLEAR key will reset an alarm or cutout indication on the annunciator screen s and will clear the microprocessor to allow continued operation or restarting if all conditions have returned to normal and no other control lockouts are in force The NUMERIC KEYPAD is used to introduce new setpoint limits The key will call up the Analog Offset display page 1 then page 2 The RUN STOP and REMOTE START keys control the starting and stopping of the compressor unit The ALARM SILENCE key will de energize the alarm horn output The AUTO REMOTE and MANUAL keys control the operation of the compressor slide valve The AUTO MANUAL 2 2 MANUAL 3 5 and MANUAL 5 0 keys control the operation of the compressor slide stop The F1 function key will return the operator to the main operating display This function may be invoked at any time even during setpoint entry The F2 function key will call up the Security display NOTE Press the F2 key as prompted by the display to return to the previously selected display The F3 function key is nonoperational The F4 function key will call up the Auto Cycle display NOTE To exit the Auto Cycle display press the F1 key as prompted by the display The microprocessor has a liquid crystal display in a 2 line by 20 character format for a total of 40 characters There are 6 different display modes with a total of 36 possible displays When
45. ty display allows the operator to either enable or dis able the microprocessor s keyboard to prevent unauthorized tampering with the various adjustable setpoints When en abled the microprocessor keyboard is fully operative and the security lockout is not in effect When disabled the keyboard is rendered partially nonfunctional All displays will still be accessible through the keyboard If any attempt is made to enter new adjustable setpoints however the microprocessor will default to the Security display TO ENABLE THE KEYBOARD press the STEP key so that the Enter Access Code asterisks flash key the proper five digit access code and press ENTER The Setpoints Access will toggle from disabled to enabled and adjustable setpoint entry is now possible TO DISABLE THE KEYBOARD press the F2 function key to call up the Security display Press the STEP key until the Enter Access Code asterisks flash key the proper five digit access code and press ENTER Now press the STEP key until ENABLED DISABLED beside KEYBD ENTRY flash and press the CHANGE key to toggle from enabled to disabled TO CHANGE THE ACCESS CODE press the F2 function key to call up the Security display Press the STEP key until the Enter Access Code asterisks flash key the proper five digit access code and press ENTER Now select the Enter Access Code a second time by pressing the STEP key until the asterisks flash key in
46. ubleshooting guide a repair procedure guide and a section with illustrative schematics and data GENERAL INFORMATION THE COMPONENTS WITHIN THE CAUTION MICROPROCESSOR CONSOLE CAN BE INADVERTENTLY DAM AGED BY STATIC ELECTRICITY OR MISHANDLING ONLY QUALIFIED TECHNICIANS SHOULD DIRECTLY HANDLE THESE COMPONENTS 1 DO NOT REMOVE the microprocessor console cover or attempt to make corrections to the microprocessor power supply without shutting off the control power Accidental shorts can irreparably damage the SBC single board com puter or the display screen 2 DO NOT HANDLE the SBC or the display screen board when their cables are disconnected without first attaching a ground strap to prevent static electrical discharge from your body RXF MINI MICROPROCESSOR CONTROL Page 14 MAINTENANCE Frick Most problems encountered with the microprocessor and control circuits will be the result of a wiring fault blown fuse or failure of a peripheral control such as a solenoid coil or a pressure transducer Faults in the computer while possible are unlikely If a fault develops in the computer the prob ability is that all functions will cease and the display screen will go blank The control system of the RXF compressor consists of a 120 volt AC high voltage side and a DC low voltage side The 120 volt side actuates solenoids relays alarms and other electromechanical functions The DC side
47. uter and remove all power from the outputs This will shut down the compressor motor and all control power 120v to the compressor auxiliary systems such as the oil pump and liq uid injection solenoid THE EMERGENCY STOP BUTTON IS FOR EMERGENCY SHUTDOWN SITUATIONS ONLY AND MUST NOT BE USED TO ROUTINELY SHUT OFF THE COMPRESSOR The microprocessor hardware contains an internal watchdog circuit If the microprocessor should fail this circuit will dis able turn off all outputs 570 400 OM JUN 99 KEYS AND KEY FUNCTIONS The CHANGE key rotates the display through the different display screens The CHANGE key is also used to change the status of various setpoints This key when pressed will cause the existing settings to be replaced with symbol for each number of the setting To change from pounds per square inch G to inches of mercury HG press the CHANGE key when the G or HG is flashing The STEP key steps or moves a set of flashing characters through the Adjustable setpoints on the Setpoints displays the Auto cycle display and the Security display The set point replaced by the flashing symbol may be changed or updated The STEP key is also used when the Annun ciator display is selected to step through the annunciator s information displays NOTE The key is used to step or move to previous screens described above one at a time The ENTER key is used to change or enter new setpoin
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