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Carrier HS070-160 User's Manual

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1. HEATING amp COOLING 30HR HS070 160 Flotronic Plus Reciprocating Liquid Chillers Controls Troubleshooting Guide All Model E Units Have Microprocessor Controls and Electronic Expansion Valves CONTENTS Page SAFETY CONSIDERATIONS 1 FLOTRONIC PLUS CONTROL SYSTEM 1 4 General dorina e ERE ru RE RUE 1 Features tect ead hated ea xe a a E 2 PROCESSOR MODULE 2 e LOW VOLTAGE RELAY MODULE 2 EXV ELECTRONIC EXPANSION VALVE DRIVER MODULE 2 KEYBOARD AND DISPLAY MODULE 2 ELECTRONIC EXPANSION VALVE 3 e THERMISTORS 0 00000 c cece eee ee 3 CAPACITY CONTROL 3 CONTROL SEQUENCE 4 5 Off Cycle ieee a ey he ee ie tn EUER 4 Start Up acarians isiad aaen a 4 Capacity Control Lseeese 4 SEQUENCE See hean AE ea ccc cece ee ees 4 Unit Shutdown cece eee eee eee 5 Complete Unit Stoppage Lees 5 Single Circuit Stoppage 5 Lag Compressor Stoppage 5 Restart Procedure 5 e GENERAL POWER FAILURE 5 e BLOWN FUSE IN POWER FEED DISCONNECT ix ei4eeREE EAMUS 5 e LOW WATER TEMPERATURE CUT OL T easiest dente a piston Nea uide 5 e AUXILIARY INTERLOCK 5 e OPEN CONTROL CIRCUIT FUSE 5 FREEZE PROTECTION 5 e HIGH PRESSURE SWITCH
2. Compressor motor defective Seized compressor erratic in action Power off restart i Pump binding free pump System Noises Incorrect wiring rewire i Pump motor burned out replace Check connections i Check wiring and i rewire i Check line voltage i determine location of i voltage drop and i remedy deficiency i Check motor winding Low refrigerant charge High pressure control erratic in action Compressor discharge valve partially closed i Air in system Condenser scaled i for open or short Compressor i Replace compressor loses oil if necessary Repiace compressor Repair leak recharge Replace control Add refrigerant Replace control 5 i Frosted pp MPen Valve Orre suction line i place if defective Purge Hot liquid line j Clean condenser Receiver not properly vented refrigerant backs up into evap condenser Condenser water pump jor fans not operating Repipe as required Frosted liquid providing adequate line venting Start pump repairor replace if defective Compressor will not unload Compressor will not load Low refrigerant charge REMEDY Add refrigerant Control contacts fused Replace control Air in system Purge Partially plugged or plugged expansion valve or filter drier Defective insulation Service load
3. Inefficient compressor Piping vibration Expansion valve hissing Clean or replace Replace or repair i Keep doors and i windows closed Check valves replace if necessary Support piping as required Check for loose pipe Connectors Add refrigerant Check for plugged liquid line filter drier Compressor noisy Check valve plates for valve noise i Replace compressor i worn bearings Check for loose i compressor hold down bolts Leak in system Mechanical damage i blown piston or broken gisch valve Repair leak Repair damage or replace compressor Oil trapped in line Crankcase heaters not energized during shutdown f Expansion valve admitting excess refrigerant Shortage of retrigerant due to leak Shutoff valve partially closed or restricted Restricted filter camer Hurned out cot Check piping for oil traps Replace heaters check wiring and crankcase heater relay contacts a Check cooler and i compressor thermistors test EXV Repair leak and recharge Open valve or remove restriction Remove restriction t or repiace filter drier t Hep ace coil Detective capacity control valve Miswired solenoid Weak broken or wrong valve body spring i Miswired solenoid Rep ace valve Rewire correctly Replace spring i Rewire correctly
4. 5 e LOSS OF CHARGE SWITCH 5 COMPRESSOR DISCHARGE TEMPERATURE SWITCH 5 OIL SAFETY SWITCH 5 CONTROLS OPERATION 5 11 Accessing Functions and Subfunctions j Display Functions 5 SUMMARY DISPLAY 5 STATUS FUNCTION 05 5 TEST FUNCTION eessee 10 Programming Functions 11 SERVICE FUNCTION ees ll e SET POINT FUNCTION Bi e SCHEDULE FUNCTION ll TROUBLESHOOTING 12 26 Checking Display Codes 12 e OPERATING MODE CODES 12 ALARM CODES ii aeiia aE PANEER 12 Quick Test 222 naure Ena Ena aA 14 Electronic Expansion Valves 19 e CHECKOUT PROCEDURE 19 e EXV OPERATION 00000 eee 21 Thermistors 5 7 lil II RE BIDS 22 e LOCATION ihe e 22 e SENSOR REPLACEMENT 22 Modules 2 221 REB ER IUE 23 SAFETY CONSIDERATIONS Installation start up and servicing of this equipment can be hazardous due to system pressures electrical components and equipment location Only trained qualified installers and service mechanics should install start up and service this equipment When working on the equipment observe precautions in the literature tags stickers and labels attached to the equipment a
5. Cooler leaving water temp Cooler entering water temp Saturated suction temp circuit A Compressor suction gas temperature circuit A Superheat temp circuit A Saturated suction temp circuit B Compressor suction gas temperature circuit B Superheat temp circuit B Reset temperature Systems pressures Circuit A loss of charge switch Circuit A oil pressure switch Circuit B loss of charge switch Circuit B oil pressure switch viel ANALOG 4 EXVA X LU EXVB X System analog values Circuit A EXV valve position Circuit B EXV valve position QUICK TEST DISPLAY INPUTS KEYBOARD ENTRY COMMENT DIM Factory field test of inputs LWT X Leaving water temperature EWT X Entering water temperature SSTA X Saturated suction temp circuit A CGTA X Compressor suction gas temp circuit A SSTB X Saturated suction temp circuit B i CGTB X Compressor suction gas temp circuit B i RST X Reset temperature LCSA X Loss of charge switch i circuit A LCSB X Loss of charge switch circuit B Oil pressure switch circuit A OILA x E Eel Ae RJ El Ee B El OILB X Oil pressure switch Circuit B OUTPUTS Factory field test of outputs L SLDA X Circuit A liquid line i solenoid test ES SLDB X Circuit B liquid line solenoid test UNLA X Unloader A test UNLB X Unloader B test ae E
6. In dual set point schedule this mode means the machine is operating to the unoccupied set point In single set point schedule this mode shuts down the unit in the same manner as Unit Standby If the schedule is holding the machine off when it is needed set the schedule for inactive mode until the schedule can be properly reprogrammed See the Sched ule Function section of the Installation Start Up and Service Instructions The override feature can also be used to temporarily place the unit in occupied mode Enter LU SCHO then the number of hours to override c 1 to 4 then press en If the unit is in override and you wish to cancel it enter zero hours in the same manner Run Mode 28 To enter the MODES subfunction depress and use the key to determine if more than one mode applies 4A WARNING Do not attempt to bypass short or modify the control circuit or electronic boards in any way to correct a problem This could result in component failures or a hazardous operating condition ALARM CODES The following is a detailed descrip tion of each alarm code error and the possible cause Manual reset of an alarm is accomplished by moving the RUN STANDBY switch to STANDBY then back to RUN Codes 5 1 54 Compressor Failure If the DSIO relay module relay or control relay feedback switch opens during operation of a compressor the microprocessor will detect this and will stop the compressor energize th
7. 29199 1 2439 5 3 90262 i 12 696 61 1 25786 1 2 6 3 85979 12 085 62 1 22454 1 1579 7 3 816 11 506 63 1 192 1 1175 a 3 77142 10 959 64 1 16014 1 0786 9 3 726 10 441 65 1 12916 1 0414 10 3 67969 9 9495 66 1 09887 1 0056 11 3 63271 9 485 67 1 06889 9707 12 3 58496 9 0445 68 1 04046 9384 13 3 53653 8 627 69 1 01238 90635 14 3 48742 3 231 10 984975 8758 15 3 43771 7 8555 5 Electronic Expansion Valves CHECKOUT PROCEDURE _ Follow steps below to diagnose and correct EX V problems For an explanation of EXV operation see page 2 Step 1 Check EXV Driver Outputs Check EXV output signals at appropriate terminals on the EXV driver module Fig 8 as follows Connect positive test lead to terminal 1 on EXV driver Set meter for approximately 20 vde Enter outputs sub function of test function by pressing then advance to EXVA Open Quick Test by pressing 5 times Press kem The driver should drive the EXV fully open During the next several seconds connect the nega tive test lead to pins 2 3 4 and 5 in succession Voltage should rise and fall at each pin If it remains constant at a voltage or at zero volts remove the connector to the valve and recheck Press 4 to reach the EXV A Close Quick Test If a problem still exists replace the EXV driver If the voltage reading is correct the expansion valve should be checked Next text EXV B Connect the positive test lead to pin 7 and the negati
8. 7 for specific control wiring Each module in a panel is numbered 1 2 3 4 Each terminal strip is labeled J2 J3 J4 The terminal strip on the machine schematic combines the module and strip numbers For example 2 3 is terminal strip J3 on module 2 The module numbers can be found on the com ponent arrangement label The subfunction checks the thermistor and switch inputs The thermistor tests display the tempera ture that the thermistor is reading If the display and the actual temperature do not match the thermistor and the input channel can each be checked To check the thermistor disconnect its leads from the PSIO terminal the entire connector can be pulled from the PSIO by pulling the connector to the left Read the resistance of the thermistor then find the corresponding temperature in Table 8 This temperature should match the actual temperature to which the thermistor is exposed The thermistor can be checked while connected to the processor by measuring the voltage across its terminals and finding the corresponding temperature in Table 8 This method can only be used if it is certain that the processor circuits are putting out the correct voltage If there is any doubt the thermistor should be checked by the resistance method The input channel can be tested by removing the thermistor from the terminals and attaching a fixed resistor with a value between 40 000 ohms and 400 ohms Refer to Table 8 and fi
9. Defective capacity contre valve Plugged strainer high side Hep ace valve 1 Clean or replace 1 strainer Stuck or damaged unloader piston or piston ring s Clean or replace i the necessary parts 26 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Bask 2 Ta b 55 PC111 Catalog No 533 030 Printed in U S A Form 30HR HS 1T Pg 28 1 89 Replaces New E
10. Enter appropriate EXV Quick Test step for EVXA or EXYVB in the outputs subfunction of the test function led Press ENTR to initiate test With cover lifted off the EXV valve body observe operation of valve motor and lead screw The motor should turn in the clockwise direction and the lead screw should move down into the motor hub until the valve is fully closed or fully open depending on whether you initiate the open or close test step for that valve Lead screw movement should be smooth and uniform from fully open to fully closed position or from fully closed to fully open If valve is properly connected to processor and receiv ing correct signals yet does not operate as described above the valve should be replaced The operation of the EXV valve can also be checked without removing the top cover This method depends on the operator s skill in determining whether or not the valve is moving To use this method initiate the Quick Test to open the valve Immediately grasp the EXV valve body with the hand As the valve drives open a soft smooth pulse will be felt for approximately 26 seconds as the valve travels from fully closed to fully open When the valve reaches the end of its opening stroke a hard pulse will be felt momentarily Drive the valve closed and a soft smooth pulse will be felt for the 26 seconds necessary for the valve to travel from fully open to fully closed When the valve reaches the end of its stroke a hard
11. drier becomes plugged it can result in not enough refrigerant being fed to the evaporator which results in a high super heat failure EXV Failure If the EXV fails to open enough to feed the proper amount of refrigerant the error will occur EXV Driver Module Failure li the DSIO module hardware that controls the EXVs fails the valve will not move LEAVING WATER CONNECTION THERMISTOR LEAVING WATER SENSOR Th COOLER WATER BAFFLE ENTERING WATER CONNECTION SUCTION CONNECTION THERMISTORS SATURATED COOLER SENSORS COOLER TUBE TYPICAL Fig 4 Thermistors mis located or out of Bad Thermistor calibration Code 68 and 69 Low Suction Superheat if the follow ing logic is satisfied then all the compressors on the circuit will be stopped Suction superheat is equal to 0 F 0 C or the satu rated suction is greater than 58 F 14 4 C and either condition has been true for more than 5 minutes Possible causes for this failure are a stuck electronic expansion valve or thermistors mis located or out of calibration To reset use the manual reset method Code 71 to 81 Thermistor Failure If the measured temperature of a thermistor is less than 60 F 51 C 363 000 ohms or greater than 240 F 116 C 2 16 ohms the appropriate sensor error code will be displayed and the unit will be stopped The thermistor failures will automatically rese
12. explained below Refer to Table 6 for all the elements in the subfunctions NOTE The Quick Test energizes the alarm light and alarm relay They will remain energized as long as the unit is in Quick Test To reach a particular test enter its subfunction number and then scroll to the desired test with the D key A test can be terminated by pressing c i r Pressing V after a test has started will advance the system to the next test whether the current one is operating or has timed out Once in the next step you may start the test by pressing A or advance past it by pressing VE c While the unit is in Quick Test you may access another display or function by depressing the appropriate keys however the unit will remain in the Quick Test func tion until fres is entered or if the keyboard is not used for 10 minutes the unit will automatically leave the Quick Test function See the following example i i KEYBOARD DISPLAY ENTRY RESPONSE COMMENTS COMP Factory field test of compressors subfunction of test function CA1 OFF Circuit A compressor 1 test CA1 ON Pressing ENTR starts the test when the compressor should be running the display shows CA1 on CA1 OFF If the test is allowed to time out the display will show CA1 off CA2 OFF Pressing the down arrow key advances the system to circuit A compressor 2 test END TEST If no other test is desired exit quick test Refer to Fig 5 6 and
13. fully open position is 760 steps The 7 Sri subfunction shows the EXV valve positions They should change constantly while the unit operates If a valve should stop moving for any reason mechanical or electrical other than a processor or thermistor failure the processor will continue to attempt to open or close the valve to correct the superheat Once the calculated valve position reaches 160 fully closed or 760 fully open it will remain there If the EXV posi tion reading remains at 160 or 760 and the cooler and compressor refrigerant thermistor displays are reading the measured temperature correctly the EXV is not moving Follow the EXV checkout procedure to deter mine the cause The EXV is also used to limit cooler suction tem perature to 55 F 13 C This makes it possible for the chiller to start at higher cooler water temperatures with out overloading compressor This is commonly referred to as MOP maximum operating pressure Thermistors All thermistors are identical in their temperature vs resistance performance Resistance at various temperatures are listed in Table 8 LOCATION General location of thermistor sensors are shown in Fig 9 Cooler Leaving Water Sensor T1 is located in the leav ing water nozzle The probe is immersed directly in the water All thermistor connections are made through a 1 4 in coupling Fig I I Actual location is shown in Fig 4 Cooler Entering Water Sensor T2 i
14. group To move to the other elements scroll up or down using the arrow keys When the last element in a subfunction has been displayed the first element wilt be repeated To move to the next subfunction it is not necessary to use the subfunction number pressing the function name key will advance the display through all subfunctions within a function and then back to the first DESCRIPTION Reset Set Points Reset Set Point Reset Limit Reset Ratio Reset Set Point DEMAND TIME SET POINT To move to another function either depress the function name key for the desired function display will show the first subfunction or Access a particular subfunction by using the subfunction number and the function name key Demand Limit Set Points Time of Day and Day of Week Display System Set Points X ALARMS STAGES X Alarms Detected Capacity Stages Table 6 Keyboard Directory STATUS DISPLAY X ALARMS KEYBOARD ENTRY COMMENT Current alarm displays ALARM Alarm 1 ALARM Alarm 2 ALARM Alarm 3 Current operating mode displays Mode 1 STAG ES Capacity stages X STAGE Stage number SET POINT Current operating set point CWS X Leaving chilled water set point If unit is in dual set point mode the set point currently in effect is displayed Leaving water temperature System temperatures
15. high cooler water temperatures This allows the unit to start with very warm water temperatures THERMISTORS The electronic control uses 7 ther mistors to sense temperatures used to control the opera tion of the chiller Sensors are listed in Table 3 CAPACITY CONTROL The control cycles com pressors and alternately loads and unloads cylinders to give capacity control steps as shown in Table 4 The unit controls leaving chilled water temperature Entering water temperature is used by the microprocessor in deter mining the optimum time to load and unload but is not a control set point The chilled water temperature set point can be auto matically reset by the return temperature reset or space and outside air temperature reset features Table 2 Function and Subfunctions SUBFUNCTION FUNCTIONS NUMBER Suus Tes T Sewe SetPoint Schedule 1 Alarm Displays Quick Test of inputs Log On and Log Off System Occupied Mode Chilled Water Override 2 Operating Mode Displays Quick Test of Outputs 3 Capacity Stages Quick Test of Factory Demand Limit Period 1 Compressors Configurations Software Version Schedule Type 4 Current Operating Terminate Quick Test Field Period 2 Set Points Configurations 5 System Temperatures Period 3 6 System Pressures i Period 4 7 EXV Position l Period 5 8 E I peris 9
16. location Use the temperature subfunction of the status function ds to determine if thermistors are reading correctly 2 Check thermistor calibration at known temperature by measuring actual resistance and comparing value measured with values listed in Table 8 3 Make sure that thermistor leads are connected to proper pin terminals at 157 terminal strip on processor module and that thermistor probes are located in proper position in refrigerant circuit Fig 9 When above checks have been completed actual operation of EXV can be checked by using procedures outlined in Step 5 Step 5 Check Operation of the EXV Use following procedure to check actual operation ofelectronic expan sion valves l Close liquid line service valve for circut to be checked and run through the Quick Test step in subfunction 3 of test function for the lead compressor in that circuit to pump down the low side of the system Repeat test step 3 times to ensure that all refrigerant has been pumped from low side NOTE Be sure to allow compressors to run full 10 seconds at each step 2 Turn OFF compressor circuit breaker s Close com pressor service valves and vent any remaining refrig erant from low side of system 20 3 Remove screws holding top cover of EXV Carefully remove top cover using caution to avoid damage to the motor leads If EXV plug was disconnected during this process reconnect it after the cover is removed 4
17. pulse will again be feit as the valve overdrives by 50 steps The valve should be driven through at least 2 complete cycles to be sure it is operating properly If a hard pulse is felt for the 26 second duration the valve is not moving and should be replaced Hii The EXV test can be repeated as required by pressing to start the test lf operating problems persist after reassembly they may be due to out of calibration thermistor s Or inter mittent connections between processor board terminals and EXV plug Recheck all wiring connections and voltage signals Other possible causes of improper refrigerant flow control could be restrictions in liquid line Check fer plugged filter drier s stuck liquid line solenoid valve s or restricted metering slots in the EXV Formation of ice or frost on lower body of electronic expansion valve is one symptom of restricted metering slots Clean or replace valve if necessary NOTE Frosting of valve is normal during compressor Quick Test steps and at initial start up Frost should dissipate after 5 to1 minutes operation of a system that is operating properly If valve is to be replaced wrap valve with a wet cloth to prevent excessive heat from damaging internal components EXV OPERATION These valves control the flow of liquid refrigerant into the cooler They are operated by the processor to maintain 20 degrees F of superheat between the cooler entering refrigerant thermistor an
18. 13 0 4 28472 5 96 0 3170 3 14 0 4 27623 8 97 0 3099 4 15 0 4 26803 7 98 0 3030 5 16 0 4 26011 2 99 0 2963 5 1 0 4 25245 1 100 0 2898 4 18 0 4 24504 6 101 0 2834 9 19 0 4 23788 7 102 0 2773 2 20 0 4 23096 4 103 0 2713 1 21 0 4 22426 9 104 0 2654 7 22 0 4 21779 3 105 0 2597 8 23 0 4 21152 8 106 0 2542 3 24 0 4 20546 7 107 0 2488 3 25 0 4 19960 2 108 0 2435 8 26 0 4 19392 5 109 0 2384 5 11 0 4 18843 0 110 0 2334 6 28 0 1831 0 111 0 2285 9 23 0 4 17795 8 112 0 2238 5 30 0 4 17297 0 113 0 2192 2 31 0 4 16813 8 114 0 2147 0 32 0 4 16345 7 115 0 2103 0 33 0 4 15892 2 116 0 2060 0 34 0 4 15452 7 117 0 2018 0 35 0 4 15026 7 118 0 1977 0 36 0 4 14613 9 119 0 1936 9 31 0 3 14213 6 120 0 1897 8 38 0 3 13825 5 121 0 1859 5 39 0 3 13449 2 122 0 1822 1 40 0 3 13084 2 123 0 1785 5 4 0 3 12730 1 124 0 1749 7 42 0 3 12386 6 125 0 1714 7 43 0 3 120533 126 0 1680 4 44 0 3 11730 0 127 0 1646 8 45 0 3 11416 1 128 0 1613 8 46 0 3 11111 5 129 0 1581 6 47 0 3 10815 8 130 0 1550 0 48 0 3 10528 7 131 0 1518 0 49 0 3 10250 0 132 0 1488 6 50 0 3 9979 3 133 0 1458 8 51 0 3 9716 5 134 0 1429 6 52 0 3 9461 3 135 0 1400 9 p 53 0 3 9213 4 136 0 1372 7 54 0 3 8972 6 137 0 1345 1 55 0 3 8738 6 138 0 1318 0 56 0 3 8511 4 138 0 1291 3 57 0 3 8290 6 140 0 1265 2 17 Table 8b Thermistor Temperature vs Resistance and Voltage Sij TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE ikon
19. E EXVAO X Circuit A EXV open test u EXVAC X Circuit A EXV close test EXVBO X Circuit B EXV open test Lt EXVBC X Circuit B EXV close test slm Factory field test of compressors Circuit A compressor 1 test Circuit A compressor 2 test EEr Circuit B compressor 1 test Circuit B compressor 2 test 4 WARNING During test of compressors each compressor will start and run for 10 seconds Compressor servicevalves and the liquid line valve must be open Energize compressor crankcase heaters for 24 hours prior to performing compressor tests a e END TEST Leave quick test Table 6 Keyboard Directory cont SERVICE CONFIGURATIONS SCHEDULE KEYBOARD ENTRY O OGON bcp E When finished with configurations Ing out as follows COMMENT Now enter password C see KEYBOARD ENTRY DISPLAY COMMENT Entering number of hours to extend LOGGED ON Schedule Type entry codes inactive 1 single set point 2 dual set point SCHTYP X LOGGED ON Shows that configura tions available LOGOFF PERIOD 1 Define time schedule EXIT LOG period 1 Contigurations now again password protected Start of occupied time OCC XX XX Return to unoccupied UNO XX XX R time Software version number VERSION MON X Monday flag entry codes 1 ye
20. E Period 7 Table 3 Thermistors CONTROL SEQUENCE The control power 115 1 60 for 60 Hz units 230 1 50 SENSOR ZEMECRATUME for 50 Hz units must be supplied directly from a separate TI Cooler Leaving Water source through a code approved fused disconnect to the T2 Seale Entering Water Ll and L2 terminals of unit power teminal block T5 i Cooler Saturated Suction Temperature Circuit A NOTE There is no switch or circuit breaker only fuses If the control power feed is live so is the circuit T6 Cooler Saturated Suction Temperature y Circuit B Crankcase heaters are wired into the control circuit T7 Compressor Suction Gas Temperature They are always operative as long as control circuit Circuit A power is on even though unit may be off because of T8 Compressor Suction Gas Temperature safety device action Heaters are wired so they are on only Circuit B when their respective compressors are cycled off T10 Reset Temperature Sensor Accessory WARNING The control circuit power must never be off except when unit is being serviced After a prolonged shutdown the crankcase heaters should be on for 24 hours before starting the unit When power is supplied to control circuit unit is ready for operation providing all safety devices are satisfied interlocks are closed and instructions on warning labels have been followed If schedule function is used refer to page 11 for details Table 4 Capaci
21. ENSOR COUPLING Fig 11 Thermistor Compressor and Cooler ae qq Modules Turn controller power off before servicing the controls This is to ensure safety and prevent damage to the controller PROCESSOR MODULE PSIO LOW VOLTAGE RELAY MODULE DSIO AND EXV DRIVER MODULE DSIO The PSIO and DSIO modules all perform continuous diagnostic evaluations of the condi tion of the hardware Proper operation of these modules is indicated by LEDs light emitting diodes on the front surface of the DSIOs and on the top horizontal surface of the PSIO Red LED Blinking continuously at a 3 to 5 second rate indicates proper operation Lit continuously indicates a problem requiring replace ment of the module Off continuously indicates the power should be checked If there is no input power check fuses If fuse is bad check for shorted secondary of transformer or for bad module Green LED On a PS1O this is the green LED closest to the COMM connectors The other green LED on the module indicates external communications when used DSIO ADDRESS SELECTOR The green LED should always be blinking when power is on it indicates that the modules are communicating properly f a green LED is not blinking check the red LED lf the red LED is normal check the module address switches See Fig 9 The proper addresses are PSIG Processor Module 00 DSIO Relay Module 32 DSIO EXV Drive
22. INPUTS 24 VAC o c Ww CHASSIS CHANNEL I J3 PINS 18 2 GROUND E 2 384 3 586 t 4 788 RED STATUS LIGHT sm i 2 4 6 amp 8ARE GROUND C j GREEN COMMUNICATION gt P LIGHT e n STEPPER MOTOR 2 M A MORE STEPPER MOTOR I ADDRESS ADJUST NOT SHOWN ON RDERSIDE Fig 16 EXV Driver Module DSIO 25 Keyboard Display Module HSIO Fig 17 The only function of the HSIO is to allow the operator 10 com municate with the processor It is used to enter configura tions and set points and to read data perform tests and set schedules laTaTeli POWER SENSOR BUS Q IE HOAR 4 5 AAO eG BEE Keyboard Display Module HSIO CLR m Fig 17 SYMPTOMS Compressor does not run Compressor cycles off on toss of charge Compressor shuts down on high pressure control Loss of charge control case 1 Power line open Control fuse open Safety thermostat tripped DGT Tripped power breaker TROUBLESHOOTING REMEDY SYMPTOMS Reset circuit breaker Check control circuit for ground or short Replace fuse Move RUN STANDBY Unit operates long or continuously switch to STANDBY then back to RUN Check the controls Find cause of trip and reset breaker Condenser circu lating pump not running Loose terminal i connection i Improperly wired controls Low line voltage
23. MS DETECTED STATUS FUNCTION The status function shows the current status of alarm diagnostic codes capacity stages operating modes chilled water set point all measured system temperatures superheat values pres sure switch positions and expansion valve positions These subfunctions are defined below Refer to Table 6 for additional information srr Alarms Alarms are messages that one or more faults have been detected Each fault is assigned a code number which is reported with the alarm See Table 7 for code definitions The codes indicate failures that cause the unit to shut down terminate an option such as reset or result in the use of a default value as set point Up to 3 alarm codes can be stored at once To view them in sequence press mnm stat to enter the alarm displays and then press key to move to the individ ual alarm displays Press mm after a code has been dis played and the meaning of code will scroll across the screen When a diagnostic alarm code is stored in the display and the machine automatically resets the code will be deleted Codes for safeties which do not automatically reset will not be deleted until the problem is corrected and the machine is switched to STANDBY then back to RUN continued on page 10 Table 5 Accessing Functions and Subfunctions OPERATION To access a function press the subfunction number and the function name key The display will show the subfunction
24. OR A ocooooos 100 cocooco SCOmAMIOD oooooon orwnuololo 0 0 0 0 2 3 4 5 6 110 NO BO eo ro OO amp m O 0 Bono pee ae DOAWA M Lija iE 120 160 ocoooocoon om i i Haan BNO o0 ncs i ooocooosal aa NONI AE Sarees 140 Cc o0Oo UG rnmo o coadsoorm 2 10o04 amp ocr j o 10ooronNx o0o0d amp GNMN 50 morr ijmomsmeom DAOADAL BAL NDEODAMHAA MAM AMADA MDAAAAMAAAI MHPOALAAMAMAHAL LAMAN NM OLOBORLA MADAM AADAIOAOELOAAHA ool ore ER qs POCO ON Ooo o ooOoooos DOOD When the second or lag refrigeration circuit is started the circuit will go through a lo second pumpout unless the circuit has been operating in the 15 minutes prior to this start Upon load reduction the control system will unload the unit in the reverse order of loading until the capacity nearly matches the load Each time the lead compressor is cycled off the liquid line solenoid valve and electronic expansion valve will be closed for 10 seconds prior to compressor shutdown to clear the cooler of liquid refrigerant Unit Shutdown To stop unit move the RUN STANDBY switch to the STANDBY position Any refrigeration circuit that is operating at this time will continue for 10 seconds to complete the pumpout cycle Lag compressors stop immediately lead compressors run for 10 seconds Complete Unit Stoppage can be caused by any of the following conditions a gen
25. a processor module PSIO low voltage relay module DSIO electronic expansion valve EXV EXV driver module DSIO keyboard and display module HSIO and thermistors to provide analog inputs to the microprocessor The soft ware resides in the PSIO Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 030 E PC 111 Tab 5c Printed in U S A Form 30HR HS 1T Pg1 1 89 Replaces New Features The 30HR HS control panel is shown in Fig 1 PROCESSOR MODULE This module contains the operating software and controls the operation of the machine It continuously monitors information received from the various temperature thermistors and communi cates with the relay module to increase or decrease the active stages of capacity The processor module also controls the EXV driver module commanding it to open or close each electronic expansion valve in order to main tain approximately 20 F of superheat entering the cylinders of each of the jead compressors Information is transmitted between the processor module and the relay module EXV driver module and keybuard display module through a 3 wire communications bus ane 1 Keyboard Display Module 2 Control Power ON Light 3 RUN STANDBY Switch 4 Discharge Pressure Gage Valves 5 e Suction Pressure Gage Valves 6 Suction Pressure Gages 7 m Discharg
26. andby 27 Unoccupied mode 28 Run mode ALARMS Action Display Description Lakon Py uda Probable Cause ontro 51 Al Al Failure Circuit A shut off High pressure switch trip or high discharge gas temp 52 Comp A2 A2 Failure Comp shut off switch trip on when it is not supposed to be on Wiring 53 Comp 81 B1 Failure Circuit B shut off error between electronic control and compressor relay 54 Comp B2 Failure Comp shut off 59 Loss of charge circuit A Circuit A shut off Low refrigerant charge or loss of charge pressure switch 60 Loss of charge circuit B Circuit B shut off failure 61 Low cooler flow Unit shut off No cooler flow or reverse cooler flow 63 Low oil pressure circuit A Circuit A shut off Oil pump failure or low oil level or switch failure 64 low oil pressure circuit B Circuit B shut off i 65 Freeze protection Unit shut off i Low cooler flow 66 High suction superheat circuit A Circuit A shut off i Low charge or EXV failure or plugged filter drier 67 High suction superheat circuit B Circuit B shut off 68 Low suction suoerheat circuit A Circuit A shut off j EXV failure or cooler thermistor error 69 Low suction superheat circuit B Circuit B shut off 71 Leaving water thermistor failure Unit shut off i Thermistor failure or wiring error or thermistor not 72 Entering water thermistor failure Use default value s connected to input terminals 75 Cooler thermistor failure circuit A Circuit A shut of
27. art upon a call for cooling approximately one minute after the chilled water pump is turned on The schedule function can be programmed for inactive single set point or dual set point operation When the schedule is configured for inactive the chilled water pump relay remains energized continuously but is not used since the chiller is usually controlled by remote chilled water pump interlock contacts When the schedule is set for single set point operation the chilled water pump relay will be energized whenever the chiller is in the occupied mode regardless of whether the chiller is running When the chiller is in unoccupied mode the chilled water pump relay wil not be energized When the schedule is set for dual set point the chilled water pump relay will be energized continuously in both occupied and unoccupied modes The occupied mode places the occupied chilled water set point into effect the unoccupied mode places the unoccupied chiller water set point into effect The schedule consists of from one to 8 occupied time periods set by the operator These time periods can be flagged to be in effect or not in effect on each day of the week The day begins at 00 00 and ends at 24 00 The machine will be in unoccupied mode unless a scheduled time period is in effect If an occupied period is to extend past midnight it must be programmed in the following manner Occupied period must end at 24 00 hours midnight a new occupied
28. d the lead compressor entering gas thermistor located between the compressor motor and the cylinders There is one EXV per circuit A cutaway drawing of valve is shown in Fig 10 A need NE NN es 4 STEPPER MOTOR 3 LEAD SCREW 2 PISTON ORIFICE ASSEMBLY UN Fig 10 Electronic Expansion Valve High pressure liquid refrigerant enters valve through bottom A series of calibrated slots have been machined in side of orifice assembly As refrigerant passes through orifice pressure drops and refrigerant changes to a 2 2 phase condition liquid and vapor To control refrig erant flow for different operating conditions piston moves up and down over orifice thereby changing orifice size Piston is moved by a linear stepper motor Stepper motor moves in increments and is controlled directly by processor module As stepper motor rotates motion is transferred into linear movement by lead screw Through stepper motor and lead screws 760 discrete steps of motion are obtained The large number of steps and long stroke results in very accurate control of refrigerant flow Control of valve is by microprocessor Two thermistor temperature sensors are used to determine superheat One thermistor is located in the cooler and the other is located in the passage between the compressor motor and cylinders The difference between the 2 temperatures controls superheat On a normal TXV system super heat leaving e
29. e Pressure Gages 8 Compressor ON Lights 9 Control Circuit Fuses 10 Alarm Light Fig 1 Control Panel LOW VOLTAGE RELAY MODULE This module closes contacts to energize compressors solenoid valves and unloaders It also senses the condition of the com pressor safeties and transmits this information to the processor module EXV ELECTRONIC EXPANSION VALVE DRIVER MODULE The EXV driver module operates the elec tronic expansion valves based on commands from the processor and monitors the status of the oil pressure switches and the refrigerant Ioss of charge switches If the loss of charge switch opens due to a low refrig erant charge the EXV driver module detects a zero voltage condition in the loss of charge switch electrical circuit and communicates this information to the pro cessor module The processor module immediately shuts down all compressors in the affected refrigeration circuit During operation if the EXV driver module detects zero voltage in the oil pressure switch electrical circuit for 45 consecutive seconds due to an open oil pressure switch it communicates this information to the pro cessor module The processor module immediatelv shuts down all compressors in the affected refrigeration circuit At start up if the oil pressure switch has not closed by the end of a 60 second time period the EXV driver module senses this and the processor module immediately shuts down all compressors in
30. e alarm light and display a code of 5 1 to 54 depending on the compressor The compressor will be locked off to reset use the manual reset method f the lead compressor in a circuit is shut down all the other compressors in the circuit will be stopped and locked off Only the alarm code for the lead compressor will be displayed The microprocessor has also been programmed to indicate a compressor failure if the feedback terminal on the 2J3 terminal strip receives voltage when the com pressor is not supposed to be on Following are possible causes for this failure High Pressure Switch Open The high pressure switch for each compressor is wired in series with the 24 volt power that energizes the compressor control relay If the high pressure switch opens during operation the com pressor will stop and this will be detected by the micro processor through the feedback terminals Discharge Gas Thermostat The discharge gas thermo stat switch in each compressor is also wired in series with the 24 volt power that energizes the control relay CR If the switch opens during operation of the compressor the compressor will be stopped and the failure will be detected through the feedback terminals DSIO Module Failure If a DSIO relay module relay fails open or closed the microprocessor will detect this and lock the compressor off and indicate an error Wiring Errors If a wiring error exists causing the CR or feedback switch not
31. e followed by the modified chilled water set point If single set point or inactive schedule has been selected in the schedule function then when depressed the display will show the modified chilled water set point c The modified chilled water set point is determined by the microprocessor as a result of the reset function and is displayed for reference only it cannot be set or changed by the operator If reset is not in effect the modified set point wii be the same as either the occu pied or unoccupied chilled water set point according to how the schedule function has been programmed Displays the reset reset Limits and reset ratio set points These set points are not accessible when reset type has been configured for NONE in the service funct ion 3 ___ Displays the demand limit set points Displays time of day and day of week SCHEDULE FUNCTION This function provides a means to automatically switch the chiller from an occupied mode to an unoccupied mode When using the schedule function the chilled water pump relay located in the unit control box must be used to switch the chilled water pump on and off The chilled water pump relay will start the chilled water pump but the compressors will not run until the remote chilled water pump interlock con tacts are closed and the leaving chilled water temperature is above set point If a remote chilled water pump inter lock is not used the first compressor will st
32. e leaving water tem perature may not equal the chilled water set point The modified chilled water set point will not be displayed in the status function To read the modified chilled water set point refer to the Set Point Function section page To enter the set point subfunction depress then use the n to display the leaving chilled water set point followed by the leaving water temperature 5 Temperature The temperature subfunction displays the readings at temperature sensing thermistors To read a temperature enter 5 then scroll to the desired temperature using 1 j key Table 6 shows c the order of the readouts s Pressure This subfunction displays the status of the oil pressure and loss of charge switches The display will show LOW or NRM for the oil pressure switch and LOW or SAFE for loss of charge switch Position The position subfunction displays the current position of the electronic expansion valves in steps Fully Open 760 Operating Position 160 Minimum Fully Closed Circuit Shut Down 0 TEST FUNCTION The test operates the Quick Test diagnostic program When the unit is in STANDBY mode the test subfunctions will energize the solenoid valves unloaders electronic expansion valves and com pressors The solenoids and unloaders will energize for 3 minutes The expansion valve will travel to fully open in one test and to fully closed in the next The compressors will energize f
33. eedback terminal on terminal strip 233 see Fig 7 When this occurs the display will switch from OFF to UN If the display changes but the compressor does not start check the control relay con tactor compressor circuit breaker interconnecting wiring and the compressor motor If the display does not change check the discharge gas thermostat high pressure switch condenser fan overload on 30HS if used continuity across the DSIO terminals and interconnecting wiring To protect the compressors from repeated cycling a delay of one minute is required before the same com pressor is retested The fest subfunctions take the unit out of the Quick mode Press 4 rest and the display will show END TEST press EU and the display blinks and c then shows END TEST again 24V 2 24V NEUTRAL TERMINAL FEED 245 TBi TBI ORNO QRO 2J3 TERM 3 6 9 TBI Oso 5 gt J3 TERM 5 HPS4 DGT4 COMPR B Sem ge edP O40 2 2J3 TERM 7 THE OCESSOR OPERATES THESE CONTACTS Fig 5 Compressor 24 V Control Circuit Wiring Simplified 24V FEED 24V NEUTRAL 24v 24v FEED DS NEUTRAL TERM INAL STRIP 3J3 UNLOADER CKT A A _ CHANNEL 4 CIL PRESSURE OPS3 i COMPR BI US a l UNLOADER CKT 8 A 4 d mS s i CHANNEL 3 OIL PRESSURE OPSI 2 i COMPR Ai f ox 5 LIQUID LINE SOLENOID CKT A LOSS OF LCS3 CHARGE CIRCUIT B l LIQUID LINE N CRG CHANNEL SOLENOID CKT B Ere E
34. eral power failure blown fuse in control power feed disconnect open control circuit fuse RUN STANDBY switch moved to STANDBY freeze protection trip low flow protection trip open contacts in chilled water flow switch optional BUG me 0 c open contacts in any auxiliary interlock Terminals TBI 13 and TBJ 14 jumpered from factory are in series with the control switch Opening the circuit between these terminals places the unit in STANDBY mode just as moving the control switch to STANDBY would Code26 will appear as the operating mode in the status function display The unit cannot start if these contacts are open and if they open while unit is running it will pump down and stop Single Circuit Stoppage can be caused by the following a open contacts in lead compressor discharge gas thermostat b open contacts in loss of charge switch c open contacts in oil safety switch d open contacts in lead compressor high pressure switch Stoppage of one circuit by a safety device action does not affect the other circuit Besides stopping com pressor s all devices listed will also close liquid line solenoid valve for that circuit Lag Compressor Stoppage can be caused by the following a open contacts in discharge gas thermostat b open contacts in high pressure switch A CAUTION If stoppage occurs more than once as a result of any of the above safety devices determine and correct the cause before attempting ano
35. f 76 Cooler thermostor failure circuit B Circuit B shut off 77 Comp thermistor failure circuit A Circuit A shut off 78 Comp thermistor failure circuit B f Circuit B shut off 79 Reset thermistor failure Stop reset NOTES 1 Freeze protection trips at 35 F 1 7 C for water and 6 degrees F 3 3 degrees C below set point for brine units Resets at 6 degrees above set point 2 All auto reset failures that cause the unit to stop will restart the unit when the error has been corrected 3 All manual reset errors must be reset by moving the control switch to STANDBY then to RUN 4 Valid resistance range for thermistors is 363 000 ohms to 216 ohms Modes The operating mode codes are dis played to indicate the operating status of the unit at a given time See Table 7 The modes are explained in the Troubleshooting sec tion on page 12 Stages This subfunction displays the capac ity stage number from to 8 See Table 4 for compressor loading sequence to enter the STAGES subfunction depress 3 srar and use the key to display the stage number 4 Set Point This subfunction displays the leaving water temperature and the Leaving chilled water set point If the unit is programmed for dual set point the chilled water set point currently in effect either occupied or unoccupied will be displayed If reset is in effect the unit will be operating to the modified chilled water set point This means that th
36. ffle space in close proximity to the cooler tubes as shown in Fig 4 When there is no cooler water flow and the compressors are operating the leaving water temperature thermistor wil indicate no temperature change But the temperature of the entering water will drop rapidly and the entering water thermistor will detect this When the entering water temperature drops to 5 F 2 8 C below the leaving water temperature all the compressors wili stop and code no 61 will be displayed To correct use manual reset method after cooler water Row is resumed The error will be caused either by no cooler flow or if the water is flowing in the wrong direction through the cooler or if the thermistors have been interchanged TRAN 24V enol 255 DGT _ HPSI od 0 o74C JUMPER 30 HR COND FAN OVERLOAD 30HS ONLY TO TERMINALS 4 6 8 ON 99 2J3 Fig 3 Compressor Al Control Wiring Typical Code 63 and 64 Low Oil Pressure A low oil pressure switch is installed on the lead compressor in each circuit If the switch opens during operation of the compressor all the compressors in the circuit will be shut off the alarm light will be energized and the appropriate display code shown The switch will be bypassed for one minute during start up and for 45 seconds during normal operation The manual reset method must be used to reset this safety Possible causes for failure are Loss of Oil Pressu
37. g gf the compressor Al feedback channel It is connected to the 24 volt ground Code 59 and 60 Loss of Refrigerant Charge A loss of charge switch Is connected to the high pressure side of the refrigerant system The microprocessor monitors this switch directly if it opens all the compressors in the circuit will be locked off the alarm will be energized and the display code will appear when the alarm display is accessed To reset use the manual reset method move the RUN STANDBY switch to STANDBY then back to RUN Following are some possible causes for this alarm Low Refrigerant Charge If the system refrigerant charge is very low the microprocessor will detect this through the switch and indicate the error Switch Failure If the switch fails open the micro processor will detect this and indicate an error Wiring Error If there is a wiring error that causes an open circuit the microprocessor will treat this as an open switch and indicate an error Processor Board Failure If the hardware in the pro cessor module fails in a manner that the switch cannot be read properly an error may be indicated Code 61 No Cooler Fiow The microprocessor con tains logic that protects the cooler against loss of cooler flow The cooler entering and leaving water temperature sensors are used for this purpose The leaving thermistor is located in the leaving water nozzle and the entering sensor is located in the first cooler ba
38. g zs TERMINAL CRCUITA STRIP 2u4 Fig 6 Pressure Feedback Circuit Wiring Fig 7 Auxiliary Components 24 V Control Simplified Circuit Wiring Simplified us xai 16 Table 8a Thermistor Temperature vs Resistance and Voltage English TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE F j DROP V OHMS F DROP V 25 0 4 98005 6 58 0 24 0 4 94707 1 58 0 7867 7 23 0 4 91521 5 60 0 1665 1 22 0 4 88448 9 61 0 7468 3 21 0 4 85485 5 620 7277 1 20 0 4 82627 2 63 0 7091 2 19 0 4 79870 6 544 0 69106 18 0 4 11212 0 65 0 6735 1 17 0 4 74647 9 66 0 6564 4 16 0 4 72175 1 67 0 6398 6 15 0 4 69790 3 68 0 6237 5 14 0 4 67490 4 69 0 6080 8 13 0 4 65272 4 70 0 5928 6 12 0 4 63133 3 710 5780 6 11 0 4 61070 3 72 0 5636 8 10 0 4 59080 6 n B 5497 0 9 0 4 57161 7 74 0 5361 2 8 0 4 55310 9 15 0 5229 1 1 0 4 53525 8 76 0 5100 8 6 0 4 51804 0 0 0 4916 0 5 0 4 50143 2 76 0 4854 8 4 0 4 48541 1 79 0 4736 9 3 0 4 46995 6 80 0 4622 4 2 0 4 45504 7 87 0 4511 1 1 0 4 44066 3 82 0 4402 9 0 0 4 42678 5 83 0 4297 1 1 0 4 41339 3 84 0 4195 5 2 0 4 40047 1 85 0 4096 3 0 4 38800 0 86 0 3999 6 4 0 4 37596 4 87 0 3905 7 5 0 4 36434 7 88 0 3814 4 6 0 4 35313 3 83 0 3725 8 7 0 4 34230 7 90 0 3639 5 8 0 4 33185 4 91 0 3555 7 9 0 4 32176 2 92 0 3474 2 10 0 4 31201 5 93 0 3395 0 11 0 4 30260 1 94 0 3318 0 12 0 4 29350 9 95 0 3243 1
39. he other modules terminals 2 and 3 are connected in the same manner See Fig 13 If a terminal 2 wire is con nected to terminal 1 the system will not work in the 30HR HS units the processor module low voltage relay module and keyboard display module are all powered from a common 21 yac power source which connects to terminals 1 and 2 on the power input strip of each module A separate source of 12 5 V C power is used to power the EXV driver module through terminals 1 and 2 on the power input strip RELAY Fig 13 EXV DRIVER Sensor Bus Wiring Processor Module PSIO Fig 14 Inputs Each input channel has 3 terminals only 2 of the 3 terminals are used The application of the machine determines which terminals are used Always refer to the individual unit wiring for terminal numbers Outputs Output is 24 vdc Again there are 3 terminals only 2 of which are used which 2 depends on the appli cation Refer to unit wiring diagram NOTE Both address switches must be set at zero CHASS IS GROUND REAR NETWORK CENNECTOR FORWARD SENSOR BUS CONNECTOR Je SLOAN Zi ADDRESS lt SW ITCHES O OF OO FONT ODOR cot tN eeoeeneceoeeteee se 060 PSIO o e c 4 D Ez 4j w e Fig 14 Processor Module PSIO 24 Low Voltage Relay Module DSIO Fig 15 Inputs Inputs on strip J3 arc discrete inputs ON OFF When 24 vac are applied across the 2 terminals in a chan
40. i ikon 3 38739 7 499 39 157 44 17 i 3 3366 1 161 38 147 41 18 3 2853 6 84 37 138 09 19 i 3 23369 6 5358 36 129 41 20 i 3 18154 6 246 35 121 33 21 3 12913 5 971 34 113 81 22 l 3 07641 5 7095 33 106 88 23 3 02348 5 461 32 100 26 24 l 2 97044 5 225 31 94 165 25 2 91715 30 88 48 26 2 86384 4 1861 29 83 17 27 81049 4 5825 28 78 125 28 75717 4 3887 27 73 58 29 70394 4 2042 26 69 25 30 65082 4 0284 25 65 205 31 59787 3 8609 24 61 42 32 54514 3 7013 23 57 875 33 4927 3 5492 22 54 555 34 44053 3 4041 21 51 45 35 38871 3 2657 20 48 536 36 33733 3 1338 19 45 807 37 2 28633 3 0078 18 43 247 38 2 23582 2 8876 1 40 845 39 2 18579 2 7728 16 38 592 40 2 1363 2 6632 15 4 55426 36 476 41 2 08738 2 5585 14 4 53099 34 489 42 f 2 03907 2 4585 63 4 50678 32 621 43 1 99135 2 3629 12 4 48165 1 30 866 44 1 94433 2 2716 11 4 45556 29 216 45 1 89792 2 1842 10 4 42794 21 633 46 1 85224 2 1007 9 4 40044 26 202 47 1 80726 2 0208 a 4 37141 24 827 48 1 76302 1 9444 7 4 34138 23 532 49 1 71947 1 8712 6 4 31036 22 313 50 1 67672 1 8012 5 4 27829 j 21 163 51 1 63474 1 7342 4 4 24521 20 079 52 1 59351 1 67 3 4 21115 19 058 53 1 55306 1 6085 2 4 17605 i 1 3 084 54 1 51333 1 5495 3 4 73993 i 17 184 55 1 47449 1 4931 0 4 10279 16 325 56 1 43642 7 439 l 4 06471 15 515 57 1 39911 1 3871 2 4 0256 14 749 58 1 36264 1 3374 3 3 98557 14 026 59 1 32693 1 2897 4 3 94454 13 342 60 1
41. ing data Each function has one or more subfunctions as shown in Table 2 These functions are defined in greater detail in t1 Controls Operation section of this book EEO eS E Es 4 5 t LC 3 GT nizisinin Fig 2 Keyboard and Display Module ELECTRONIC EXPANSION VALVE The micro processor controls the electronic expansion valve through the EXV driver module Inside the expansion valve is a linear actuator stepper motor To control the stepper motor s position the thermistor in the cooler and the thermistor in the lead compressor in each circuit are used to maintain a 20 F 1 I C difference Because the com pressor sensor is after the compressor motor which adds approximately 15 F 8 3 C superheat the 20 F t1 C control temperature results in F to 5 F 2 8 C super heat leaving the cooler This improves the performance of the cooler At initial start up the valve position is initialized to 0 After that the microprocessor keeps accurate track of the valve position in order to use this information as input for the other control functions The control monitors the superheat and the rate of change of superheat to control the position of the valve The valve stroke is very large this results in very accurate control of the superheat The electronic expansion valve is also used to limit the maximum saturated suction temperature to 55 F 12 8 C to keep from overloading the compressor during
42. n circuit starts This permits a pump out cycle at start up to minimize refrigerant floodback to the compressor f the compressor in that refrigeration p circuit has run in the 15 minutes before the call for 4 cooling the pumpout cycle is bypassed i After pumpout the liquid line solenoid valve opens and the electronic expansion valve starts to open The electronic expansion valve will open gradually to provide a controlled start up to prevent liquid floodback to the compressor Also during this period the oil pres sure switch will be bypassed for one minute As additional cooling is required the control system will ramp up through the capacity steps available until the load requirement is satisfied As capacity steps are added compressors are brought on line alternating between the lead and lag refrigerant circuits As explained previously the speed at which capacity is increased or decreased is controlled by the temperature deviation from the set NOTE Circuits and compressors designated from ieft to right when viewed point and the rate of change in the chilled water from front of unit temperature 070 PROSO oN mmo Arh AM Oon xoh hosmh ooomrr5jooosmremriooosrr FECE Pigesei i 080 oND OONAN A Anos Purvo CO cimo o0 Danen Oo o noc oan et it M 090 Oo 1 O1 4h29 CO O1cC O1 C C COg ho cG99 P oR Oo I ool D hoa ao 3 Oa t aa E6 O
43. nd to log off after completing service subfunctions Used to verify software version and language option Used to verify factory configurations number of compressors 4 pec e sed to read or change field configuration for number of unloaders and reset type and to enable the machine for load shed pulldown or brine operation NOTE The key is used to enable or turn on certain functions the L key is used to disablethesefunctions When the key is pressed the display will show 00 00 SET POINT FUNCTION Set points are entered through the keyboard Set points can be changed within the upper and lower limits which are fixed The ranges are listed below Chilled Water Set Point Water 40 to 70 F 4 4 to 21 C Brine Special Order Units 15 to 70 F 9 4 to 21 C Reset Set Point 0 to 95 F 17 8 to 35 C Reset Limit 0 to 80 F 17 8 to 26 7 C Reset Ratio 0 to 10096 Demand Limit Set Points Step I Capacity Reduction 0 to 100 Step 2 Capacity Reduction 0 to 100 Set points are grouped in subfunctions as follows E Displays chilled water set points a The first value shown is the occupied chilled water set point b The next value to be displayed depends on how the schedule function has been programmed See below If dual set point has been selected the next set point ter after LY J has been pressed will be the unoccupied chilled water set point this will b
44. nd any other safety precautions that apply e Follow all safety codes Wear safety glasses and work gloves e Use care in handling rigging and setting bulky equipment e Use care in handling electronic components ELECTRIC SHOCK HAZARD Open all remote disconnects before servicing this equipment A WARNING This unit uses a micreprocessor based electronic control system Do not use jumpers or other tools to short out components bypass or otherwise depart from recommended procedures Any short to ground of the control board or accompanying wiring may destroy the electronic modules or electrical component FLOTRONIC PLUS CONTROL SYSTEM General The 3O0HR HS Flotronic Plus chillers feature microprocessor based electronic controls and an electronic expansion valve EXV in each refrigeration circuit The Flotronic Plus control system cycles compressors and compressor unloaders to maintain the selected leav ing water temperature set point It automatically posi tions the EXV to maintain the specified refrigerant superheat entering the cylinders of the compressor Safeties are continuously monitored to prevent the unit from operating under unsafe conditions A scheduling function programmed by the user controls the unit occupied unoccupied schedule The control also operates a Quick Test program that allows the operator to check input and output signals to the microprocessor The control system consists of
45. nd the temperature that cor responds to that resistance this temperature should appear in the Quick Test display 15 Loss of charge and oil pressure switch tests show LOW if the switch is open and NRM or SAFE if the switch is closed The input channel can be tested by disconnecting the switch and using a jumper to simulate a closed or open circuit See Fig 5 Note that the switch is read by the processor period ically not continuously When the switch position is changed it may take a few seconds before the display changes The 2 ubtunction will energize the control outputs except for the compressor control outputs See Fig 6 The liquid line solenoid and unloader solenoid tests will energize the output when ew is pressed It will remain energized until either the key is pressed or 10 minutes have elapsed When the processor energizes the output relay it will display the word ON on the right side of the display The EXV open and close tests drive the EXV fully open or fully closed See The EXV Checkout Procedure for more information The display will read either zero steps open or 760 steps open The subfunction energizes the compressor control relays for 10 seconds and displays the compressor status feedback The liquid line solenoid in the same circuit will ener gize for 10 seconds and the EXV will open 180 steps then close When control power reaches the compressor control relay it also reaches the f
46. nel it is read as an ON signal Zero volts is read as an OFF signal Qutputs Terminal strips J4 and J5 are internal relays whose coils are powered up and powered off by a signal from the microprocessor The relays switch the circuit to which they are connected No power is supplied to these connections by the DSIO module SENSOR BUS CONNECTOR INPUTS 24 VAC CHASSIS v CHANNEL J3 PINS amp 2 GROUND a 2 384 z 3 586 4 788 RED STATUS LIGHT F GREEN COMMUNICATION gt P LIGHT 2 4 6 amp 8 ARE GROUND C 2 COMMON H NC CHANNEL S NC aje COMMON J5 8 NQ i OUTPUT 7 N RELAYS 8 COMMON 5 N 10 4 N 3 COMMON 4 2 NO 9 I NC 12 COMMON n NO 8 io NC sie COMMON g No T J4 T OUTPUT COANN 6 RELAYS 4 NC 3 COMMON 2 NO 5 l NC ADDRESS ADJUSTMENT l NOT SHOWN ON UNDERSIDE Fig 15 Low Voltage Relay Module DSIO EXV Driver Module Fig 16 Inputs Input on strip J3 am c discrete inputs ON OFF When 24 vac are applied across the 2 terminals in a channel it is read as an ON signal Z ro volts is read as an OFF signal Outputs Two stepper motor driver outputs are used to drive the electronic expansion valves Terminals I and 7 supply voltage to the valves Terminals 2 through 5 and 8 through I connect the individual coils 4 per valve to neutral in a repeating sequence to drive the valves in incremental steps SENSOR BUS CONNECTOR 3 1234 87654321
47. or 10 seconds The subfunctions are ex plained below Refer to Table6 for all the elements in the subfunctions oD Tests the outputs from the processor except for compressors TEST Tests the compressors 4 Takes the unit out of Quick Test LJ Displays the status of all inputs NOTE The Quick Test energizes the alarm light and alarm relay They will remain energized as long as the unit is in Quick Test To reach a particular test enter its subfunction number and then scroll to the desired test with the m A test can be terminated by pressing x t r Pressing after a test has started will advance the system to the next test whether the current one is operating or has timed out Once in the next step you may start the test by pressing or advance past it by pressing i C While the unit is in Quick Test you may access another display or function by depressing the appropriate keys however the unit will remain in the Quick Test function until J 9 is entered or if the keyboard is not used for 10 minutes the unit will automatically leave the Quick Test function Programming Functions SERVICE FUNCTION The service function allows the operator to verify factory configurations and read or change field configurations The service subfunctions are listed below See Table 6 for details mn he operator must use this subfunction to log on before performing any other subfunction a
48. period must be programmed to begin at 00 00 hours The time schedule can be overridden to keep the unit in the occupied mode for one 2 3 or 4 hours on a one time basis TROUBLESHOOTING If necessary review the Flotronic Plus Control System Control Sequence and Controls Operation sections found in this book Tables 5 and 6 show how to use the keyboard display module to access functions and sub functions These procedures are also explained in the 30HR HS Installation Start Upand Service Instructions along with examples and details on using the control features A copy of the installation instructions should be kept handy while troubleshooting Checking Display Codes To determine how the machine has been programmed to operate check the diagnostic information di star and operating mode displays 2 star If no display appears follow the procedures in Troubleshooting Modules page 23 If the display is working continue as follows 1 Note all the alarm codes displayed a 2 Note all the operating mode codes displayed 3 Note the leaving chilled water temperature set point in effect and the current leaving water temperature s fee If the machine is running compare the in effect leaving water temperature set point with the current water temperature Remember that if reset is in effect they may be different because the machine is operating to the modified chilled water set point If the current tempera
49. r Module 50 If all mod ules indicate a communication failure check the COMM plug onthe PSIO module for proper seating if a good connection is assured and the condition per sists replace the PSIO module if only a DSIO module indicates a communication failure check the COMM plug on that module for proper seating If a good connection is assured and the condition persists replace the DSIO module All system operating intelligence rests in the PSIO module processor module the module that controls the unit This module monitors conditions through input and output ports and through the DSIO modules low voltage relay module and EXV driver module The machine operator communicates with the micro processor through the HS1O module keyboard display module Communication between the PSIO and ih other modules is accomplished by a 3 wire sensor bus These 3 wires run in parallel from module to module Each module in a panel is numbered 1i 2 3 Each terminal strip on a module is labeled J2 J3 J4 The terminal strip number on the machine schematic com bines the module and strip numbers For example 2J3 is terminal strip J3 on module 2 The module numbers can be found on the component arrangement label z w PSIO ind ADDRESS M SELECTOR Ev Ehe Fig 12 Module Address Selector Switch Locations 23 On the sensor bus terminal strips terminal of the PSIO module is connected to terminal 1 of each of t
50. re If the oil pressure is below 5 1 psig 34 5 6 9 kpa the switch will open Switch Failure If the switch fails open a failure will be indicated Compressor is not running wiring Error If a wiring error exists that causes an open circuit an error will occur Processor Module Failure If the hardware on the processor module fails in a manner that the switch cannot be read properly an error may be indicated Code 65 Cooler Freeze Protection If the leaving water temnerature is below 35 F 1 7 C for a water chiller or is 6 F 3 3 C below the set point for brine applications all compressors will be stopped This safety will auto matically reset when the water temperature is 6 F 3 3 C above the set point The causes for this failure are usually due to low cooler flow or extremely rapid load changes Code 66 and 67 High Suction Superheat The micro processor contains the following logic and if it is satisfied all the compressors in the circuit will be stopped Suction superheat is greater than 75 F 4f 7 C and saturated cooler suction is less than 55 F 12 8 C and these 2 conditions have been true for more than5 minutes To reset this use the manual reset method Causes for this failure are Low Refrigerant Charge A low refrigerant charge will not allow the correct amount of refrigerant to be fed to the evaporator which will result in a high superheat Plugged Filter Drier If the liquid line filter
51. s no Software version Language option TUE X WED X IFACT CFG Factory configuration pn RN m t mnm i Number of unloaders r THU X i COMP X enter number or for zero 2a FRI X 4 FED CFG Field configuration SAT x entry codes harem i SUN X Sunday flag Lt UNLS X Number of unloaders enter number 4 em RSTP X Reset type none 1 return water m 2 space or outside air E In Time periods 2 8 same elements as Load shed enabie period 1 disable 1 enable Ftuid type j SEM ype water i A L Ilole SA Pulldown enable disable 1 enable SET POINT DISPLAY SET POINT KEYBOARD ENTRY COMMENT System set points icwso X Occupied chilled water i set point Unoccupied chilled water set point appears only when unit is in dual set point mode icwsu x Modified chilled water set point read only Set point determined by reset function Reset set points EN Reset set point un Reset limit t Reset ratio 5 Ea DEMAND Demand limit set points 4 DL1 X Demand limit set point Demand limit set point 2 DL2 X TIME DAY 00 00 Current setting Table 7 Display Codes OPERATING MODES Display Description 21 Temperature reset in effect 22 Demand limit in effect 24 Pulldown control in effect 26 Unit st
52. s located in the cooler shell in first baffle space near to tube bundle Actual location is shown in Fig 4 Cooler Saturated Suction Temperature Sensors T5 and 16 are located next to refrigerant inlet in cooler head Thermistors are immersed directly into refrigerant Typical location is shown in Fig 4 Compressor Suction Gas Temperature Sensors T7 and T8 are located in lead compressor in each circuit in a suction passage between motor and cylinders above oil pump es 23 REF 70mm PACKING NUT CABLE ASSEMBLY FERRULES 22 70mm BODY SENSOR REPLACEMENT Ti T2 T5 T6 T7 T Compressor and Cooler CAUTION Sensors are installed directly in refrigerant or water circuit Relieve all refrigerant pressure or drain water before removing Proceed as follows refer to Fig I D I Remove and discard original sensor and coupling IMPORTANT Do not disassemble new coupling install as received 2 Apply pipe sealant to I 4 in NPT threads on replace ment coupling and install in place of original Do not use packing nut to tighten coupling this would damage ferrules see Fig II 3 Insert new sensor in coupling body to its ful depth Hand tighten packing nut to position ferrules then finish tightening 1 1 4 turns with a suitable tool Ferrules are now attached to sensor which can be withdrawn from coupling for unit servicing FERRULES COUPLING INSIDE ASSEMBLY S
53. t The following is a summary of possible causes Thermistor Failure A shorted or open circuit ther mistor will cause the failure Wiving Failure A shorted or open circuit will cause the failure Processor Module Failure If the circuitry in the pro cessor module fails the error could occur NOTE The reset thermistor is an optional thermistor and is only used with outside or space temperature reset It will only be read by the processor if the unit is con figured for outside or space temperature reset The absence of a thermistor failure does not necessarily mean that a thermistor is accurate To determine accuracy the reading must be compared with a measure ment of the actual temperature to which the thermistor probe is exposed 14 158 ERUIT INLET CONNECTION THERMISTOR ENTERING COOLER WATER SENSOR T2 Cooler Sensor Locations Quick Test The Quick Test feature allows the service technician to individually test all the inputs and outputs of the control system The test function operates the Quick Test diagnostic program When the unit is in STANDBY mode the test subfunctions will energize the solenoid valves unloaders electronic expansion valves and compressors The solenoids and unloaders will energize for 3 minutes The electronic expansion valve will travel to fully open in one test and to fully closed in the next The compressors will energize for 10 seconds The subfunctions are
54. the affected refrigeration circuit If a shutdown occurs due to loss of charge or low oil pressure the EXV driver module communicates this to the processor module and the processor module locks the compressors off in the affected refrigeration circuit The proper fault code s will appear on the display whenever a safety switch opens KEYBOARD AND DISPLAY MODULE Fig 2 This device consists of a keyboard with 6 function keys 5 operative keys 12 numeric keys 0 to 9 and an alphanumeric g character LCD Key usage is explained in Table Table 1 Keyboard and Display Module Key Usage FUNCTION KEYS STAT i Status Displaying diagnostic codes and Current operating information about the machine a m m A Quick Test Checking inputs and outputs for proper operation Li E 4 History This key appears on the keyboard but is not used on the 30HR HS Mode E machines Service Entering specific unit configuration information v X ded Set Point Entering operating Set points and day time information SCHI H Schedule nb occupied unoccupied schedules for unit operation OPERATIVE KEYS XPN E Expand Display Displaying a non abbreviated expansion of the display Clear Clearing the screen of all displays Up Arrow Returning to previous display position Flee Down Arrow Advancing to next display position Enter
55. ther restart Restart Procedure after cause for stoppage is corrected GENERAL POWER FAILURE Unit will restart automatically when power is restored BLOWN FUSE IN POWER FEED DISCONNECT Replace fuse Restart is automatic LOW WATER TEMPERATURE CUTOUT Move RUN STANDBY switch to STANDBY then back to RUN Restart is automatic AUXILIARY INTERLOCK condition is corrected OPEN CONTROL CIRCUIT FUSE Replace fuse Unit will restart automatically FREEZE PROTECTION Unit will automatically restart when leaving water temperature is 6 degrees F above the leaving water set point HIGH PRESSURE SWITCH LOSS OF CHARGE SWITCH COMPRESSOR DISCHARGE TEM PERATURE SWITCH AND OIL SAFETY SWITCH Move the RUN STANDBY switch to STANDBY then back to RUN Unit will restart automatically Automatic restart after CONTROLS OPERATION Accessing Functions and Subfunctions Table 5 Refer also to Table 2 which shows the 5 func tions identified by name and the subfunctions identified by number Table 6 shows the sequence of all the ele ments in a subfunction Display Functions SUMMARY DISPLAY Whenever the keyboard has not been used for 10 minutes the display will auto matically switch to an alternating summary display This display has 4 parts shown below which alternate in continuous rotating sequence Display Expansion TUE 12 45 TODAY IS TUE TIME IS 12 45 MODE 26 UNIT STANDBY 1 STAGES NUMBER OF STAGES IS 1 2 ALARMS 2 ALAR
56. to function properly the micro processor will indicate an error Processor PSIO Failure If the hardware that monitors the feedback switch fails or the processor fails to energize the relay module relay to ON an error may be indicated A NOTE The control does not detect circuit breaker failures If a circuit breaker trips on the lead compressor in a circuit a low oii pressure failure wil be indicated on the other compressors no failure will be indicated Checkout Procedure Codes 51 54 Shut off the main power to the unit Turn on control power then step through the Quick Test to the proper compressor number i e failure code 3 is step CBI Next energize the step If the step works correctly then the failure code is due to HPS open e DGT open e Misplaced feed back wire from 2H5 strip to 2J3 strip e Ground wire and 24 voit feeds reversed on one or more points on 2 3 The 24 voit ground wire brown jumps terminals 2 4 6 and 8 Feeds from compressors Al A2 Bl and B2 connect to pins I 3 5 and 7 The processor closes the contacts between 255 ter minals 12 and 1I to start the compressor See Fig 3 The safeties shown to the right of 2 15 must be closed for power to reach the compressor controi relay CR 1 and the feedback input terminal on 213 Failure of power to terminal on 213 when contacts 2J5 I and I2 should be closed wilt cause a code 5 1 alarm Terminal 2 on 293 is the other le
57. ture is equal to the set point but the set point is not the one desired recall that if dual set point has been selected in the schedule function there are 2 set points to which the machine can be operating Check the programming of the schedule function to see if the occupied or unoccupied set point should be in effect OPERATING MODE CODES Following is an explanation of the operating mode codes Temperature Reset 21 In this mode the unit is using temperature reset to adjust the set point and the unit is controlling to the modified set point This means that the leaving water temperature may not equal the chilled water set point The set point can be modified based on return water outside air temperature or space temperature Demand Limit 22 This indicates that the capacity of the unit is being limited by the demand limit control option The unit may not be able to produce the desired leaving water temperature because the unit may not load to full capacity Pulldown Control 24 If this option is in effect and ihe cooler water temperature is warm extra stages will not be added if the water temperature leaving the cooler is decreasing faster than F 0 6 C per minute Standby 26 The unit is being held in the standby mode either because the RUN STANDBY switch is open or a set of relay contacts in series with the RUN STANDBY switch is open contacts wired between terminals TBl 13 and TBI 14 Unoccupied Mode 27
58. ty Control Steps on control operation SEQUENCE A SEQUENCE B Off Cycle During unit off cycle when the RUN T Opar cylinders Oper Cylinders STANDBY switch is in the STANDBY position the UNIT CONTR CHA ELLA CktB crankcase heaters and the control system are energized 30HS Cap Compr Tot Compr The electronic expansion valves are also energized i Le NOTE The control circuit power must be on at all times AP BITB2 B2 Meret DOWEL T14 Eu 4 a even when the main unit power is off Start Up When the RUN STANDBY switch is moved from the STANDBY to the RUN position and there is a call for cooling after l 1 2 to 3 minutes have passed the first compressor will start unloaded The first NC circuit to start may be circuit A or B due to the automatic lead lag feature Capacity Control See Table 4 The rate at which the compressors are turned on will depend on the leaving water temperature difference from the set point the rate of change of leaving water temperature the return water temperature and the number of compressor stages on The control is primarily from leaving water temperature and the other factors are used as compensation SEQUENCE On a call for cooling the control system i starts the initial compressor The control will randomly 4 select either circuit A or B The liquid line solenoid valve 4 remains closed for 10 seconds after the initial compressor on that refrigeratio
59. vaporator is normally 10 F 5 6 C and motor then adds approximately 5 to 20 degrees F 8to 11 degrees C resulting in approximately 30 F 16 7 C super heat entering cvlinders The EXV controls superheat entering cylinders to approximately 20 F 1E CY Thus superheat leaving cooler is approximately 3 Fto5 F 2C to 3 C or less Because the EXVs are controlled by the processor module it is possible to track valve position During initial start up EXV is fully closed After start up valve position is tracked by processor by constantly observing amount of valve movement The processor keeps track of the EXV position by counting the number of open and closed steps it has sent to each valve 1t has no direct physical feedback of valve position Whenever the unit is switched from STANDBY to RUN both valves willbe initialized This means the processor will send enough closing pulses to the valve to move it from fully open to fully closed and then reset the position counter to zero The EXV open Quick Tests will send enough pulses to the valve to drive it from fully closed to fully open The position of the valve at the start of the test has no effect on the number of pulses sent In the same manner the EXV close Quick Tests will send enough pulses to the valve to drive it from fully open to fully closed When the EXV opens the metering slots are not uncovered until step 160 This is fully closed position when the circuit is operating The
60. ve to pin 8 9 10 1 in succes sion during the EXVB Quick Test Step 2 Check EXV Wiring Check wiring to elec tronic expansion valves from terminal strip on EXV driver Fig 8 I Check color coding and wire connections Make sure they are connected to correct terminals at driver and EXV plug connections i2 H T 9e ge ve 6 jem BRN MERE oe ae i N E EXV A 2 GRN C RED D Fig 8 EXV Cable Connections to EXV Driver Module 2 Check for continuity and tight connection at all pin terminals 3 Check plug connections at driver and at EX Vs He sure EXV connections are not crossed Step 3 Check Resistance of EXV Motor Windings Remove niue at 1j7 terminal strip and check resistance between common lead red wire terminal D and remain ing leads A B C and E see Fig 8 Resistance should be 25 ohms 2 ohms CONDENSER CIRCUIT A MUFFLERS a Wa oN Ou COMPRESSORS l i NZ LN CIRCUIT B CONDENSER CIRCUIT B MUFFLERS COMPRESSORS a Bi B2 T8 FILTER DRIER SOLENOID Te ExvB VALVE B CIRCUIT A COOLER TI it T2 K EXVA SOLENOID 75 VALVE A Q Fig 9 Thermistor Locations Step 4 Check Thermistors That Contro EXV Check thermistors that control processor output voltage pulses to EXVs Circuit A thermistors are T5 and T7 Circuit B thermistors are T6 and T8 Refer to Fig 9 for

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