Frick QUANTUM HD UNITY Maintenance Manual
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Frick QUANTUM HD UNITY Maintenance Manual

Frick QUANTUM HD UNITY Maintenance Manual

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FRICK
®
SYSTEM CONTROLLER
Evaporator • Condenser • Vessel • Engine Room
Version 10.0x, 11.0x, and 12.0x
Current Design – April 2020
Check www.FrickCold.com for the latest version of this publication.
Form 090.670-M (APR 2020)
MAINTENANCE
File:
Replaces:
Dist:
MAINTENANCE
QUANTUM
SERVICE MANUAL–Section 070
090.670-M (MAR 2016)
3, 3a, 3b, 3c
HD UNITY
™

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  • Page 1 MAINTENANCE File: SERVICE MANUAL–Section 070 Replaces: 090.670-M (MAR 2016) Dist: 3, 3a, 3b, 3c MAINTENANCE FRICK QUANTUM HD UNITY ® ™ SYSTEM CONTROLLER Evaporator • Condenser • Vessel • Engine Room Version 10.0x, 11.0x, and 12.0x Current Design – April 2020...

  • Page 2: Table Of Contents

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 2 MAINTENANCE Table Of Contents Section 1 - Introduction Active LED ..............28 Digital Inputs .............. 28 General information ............6 Digital Outputs ............29 Introduction To The Quantum HD Unity System ™...
  • Page 3 090.670-M (APR 2020) MAINTENANCE Page 3 Figures Figure 1: Quantum HD Unity system controller ....8 Figure 22: Vessel digital board 5 (optional) ..... 36 Figure 2: Quantum HD Unity ..........9 Figure 23: Vessel digital board 6 (optional) ..... 37 Figure 3: Q5 processor board ..........
  • Page 4 090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 4 MAINTENANCE This page is intentionally left blank...

  • Page 5: Section 1 - Introduction

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 5 SECTION 1 - INTRODUCTION INTRODUCTION TO THE QUANTUM HD UNITY ™ SYSTEM CONTROLLER...

  • Page 6: General Information

    System Controller board to board and from control to control based on the operation. The Quantum HD Unity System Controller consists of two major components. The main system control panel houses • Analog Input / Output Boards - The analog boards...

  • Page 7: What To Do Before Calling The Factory

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 7 To troubleshoot the low-voltage side of the control cir- An example of this is the statement that the Quantum ™ cuits, it is necessary to have the following tools: HD Unity is not booting (the main processor board is not starting).

  • Page 8: Figure 1: Quantum Hd Unity System Controller

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 8 MAINTENANCE Figure 1: Quantum HD Unity system controller A. Display/touchscreen B. Horn/strobe C. Ventilation outlet D. Control power/e-stop E. Ventilation inlet F. Condenser/vessel controller G. Evaporator controller H. Engine room controller I.

  • Page 9: Figure 2: Quantum Hd Unity

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 9 Figure 2: Quantum HD Unity A. Power supplies B. Analog and digital I/O panel C. HOA switches (optional with evaporator control) D. Control power switch...
  • Page 10 090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 10 MAINTENANCE This page is intentionally left blank...

  • Page 11: Section 2 - Q5 Processor And Interface Board

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 11 SECTION 2 Q5 PROCESSOR AND INTERFACE BOARD...

  • Page 12: Q5 Processor Board

    1997. There can be up to three of these con- trollers used with the Quantum HD Unity System Controller. 1. The Analog and Digital I/O boards TX/RX lights will One controller for each major system component: blink.

  • Page 13: Battery Function

    Q5 Interface Board 2. Put on an anti-static wrist band and connect it to the FRICK has developed an interface board which allows the ground wire in the lower left corner of the processor user to interface exterior connections to the Q5 processor board.

  • Page 14: Figure 6: Q5 Processor Board Diagram

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 14 MAINTENANCE Figure 6: Q5 processor board diagram CN_POWER1 Power Ethernet Connector Connector Flash Card located under the board here FUSE Ethernet LED’s JLVDS3 JLVDS2 INVERTER1 Battery Inverter Connector DIMM1 CMOS1 CN1000 Ports COM3...

  • Page 15: Q5 Processor Board Jumpers, Leds, And Connectors

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 15 Q5 Processor Board Jumpers, LEDs, and Connectors Table 1: Jumper table Jumper title Function Jumper setting Jumper title Function Jumper setting 5-Wire Normal 1 - 2 Touch (default) Closed Closed 1 2 3 1 2 3...

  • Page 16: Figure 7: Q5 Interface Board Diagram

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 16 MAINTENANCE Figure 7: Q5 interface board diagram COMM COMM COMM Baud Rate Jumpers J15 Not Installed = 19200 (Default) J15 Pins 1-2 Installed = 38400 J15 Pins 3-4 Installed = 56K J15 Pins 1-2 and 3-4 Installed = 115K COMM Do Not...

  • Page 17: Interconnections

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 17 Interconnections The pictorial below depicts the Q5 processor board, and the necessary interconnects between it and the Interface board. Each of the interconnecting harnesses must be installed as shown for proper operation. Figure 8: Q5 processor board interconnections If the harness for either COMM 1 or COMM 2 is...

  • Page 18: Power Supplies

    When any of the DC voltages begin to stray from Description their optimum range, abnormalities or problems may arise. Three power supplies are used in the Quantum HD Unity To perform measurements and adjustments on the power System Controller: supply voltage, use a reliable, calibrated digital volt meter (DVM).

  • Page 19: Section 3 - Q6 Processor And Interface Board

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 19 SECTION 3 - Q6 PROCESSOR AND INTERFACE BOARD...

  • Page 20: Preface

    Preface This power-up sequence is the first thing that needs checked when troubleshooting the Q6 Processor Board. Frick Controls has released the latest version of the Quan- tum HD Unity Control System. The redesigned micro- Troubleshooting processor, referred to as the Q6 Processor Board, is the brains of the system.

  • Page 21: Battery Replacement

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 21 Battery Replacement The battery is fully accessible but is surrounded by sensi- tive electronic components, so take care when changing. Replace the battery using the following procedure: 1. Power off the panel. 2.

  • Page 22: Figure 11: Q6 Processor Board

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 22 MAINTENANCE Figure 11: Q6 processor board Notes: 1. The triangle symbol ( ) denotes Pin 1 on connectors. See Q6 Processor Board Jumpers, LEDs, and Connectors for jumper settings. 2. Do NOT change jumpers J13, J38, J40, or J43 (changing these jumpers will prevent the processor from powering up).

  • Page 23: Q6 Processor Board Jumpers, Leds, And Connectors

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 23 Q6 Processor Board Jumpers, LEDs, and Connectors Table 7: Q6 Board jumper settings Table 8: Q6 LED definition Jumper title Function Jumper setting Label Color Function LCD backlight Power LEDs Green 12 V Power OK 1 - 2...

  • Page 24: Reset Ip Address To Default

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 24 MAINTENANCE Table 9: Ethernet Connector (J27) LED Definitions Amber Green Link state No link established 1000 Mbps ( 1 Gigabit) No activity Blinking Activity 100 Mbps No activity Blinking Activity 10 Mbps No activity Blinking...

  • Page 25: Figure 12: Q6 Processor Board Mounting

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 25 Figure 12: Q6 processor board mounting Figure X shows the location of the Q6 Processor Board and how it mounts to the back of the display plate...
  • Page 26 090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 26 MAINTENANCE This page is intentionally left blank...
  • Page 27 QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 27 SECTION 4 DIGITAL BOARD...

  • Page 28: Digital Board

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 28 MAINTENANCE Digital Board Preface the board, only that the voltage is enough to energize the voltage sensing circuitry. If a voltage related problem is The information that follows in this section can help locate suspected with regard to a Digital Board, the only way to problems that may occur with Digital Input and Output actually determine this is to read the voltage on a Digi-...

  • Page 29: Digital Outputs

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 29 The following pictorial shows a side view of the 120 VAC Figure 16: Signal connections Input module. The color of an Input module is yellow: Figure 14: Digital input module - side view Position1 Position2 Position3...

  • Page 30: Troubleshooting An Output

    NOTICE 2. If the LED is not on when it should be and there is no operating condition preventing it, contact the FRICK Use an anti-static wrist band for this procedure. Service Department.

  • Page 31: Diagrams

    Diagrams QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 31 Figure 17: Evaporator digital board 1 INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Liquid (Zone A) Suction (Zone A) OUTPUT MODULE NEUTRAL Hot Gas (Zone A) OUTPUT MODULE Bleed (Zone A) OUTPUT MODULE...

  • Page 32: Figure 18: Evaporator Digital Board 2

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 32 MAINTENANCE Figure 18: Evaporator digital board 2 INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Alarm Main Hot Gas OUTPUT MODULE NEUTRAL Main Liquid OUTPUT MODULE OPEN OPEN OPEN NEUTRAL Reheat Coil On (Zone A)

  • Page 33: Figure 19: Condenser Digital Board 1

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 33 Figure 19: Condenser digital board 1 INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Condenser Bleed Output Alarm Output OUTPUT MODULE NEUTRAL Alternate Pressure Control INPUT MODULE OPEN Condenser Step 1 Start/Run OUTPUT MODULE...

  • Page 34: Figure 20: Condenser Digital Board 2 (Optional)

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 34 MAINTENANCE Figure 20: Condenser digital board 2 (optional) INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE INPUT MODULE Digital Aux. Input 3 Digital Aux. Input 4 INPUT MODULE NEUTRAL Digital Aux. Input 5 INPUT MODULE Digital Aux.

  • Page 35: Figure 21: Vessel Digital Board 4

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 35 Figure 21: Vessel digital board 4 INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Alarm Output Vessel 1 Liquid Solenoid A OUTPUT MODULE NEUTRAL Vessel 1 Liquid Solenoid B OUTPUT MODULE Vessel 1 Pump A Run OUTPUT MODULE...

  • Page 36: Figure 22: Vessel Digital Board 5 (Optional)

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 36 MAINTENANCE Figure 22: Vessel digital board 5 (optional) INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE INPUT MODULE Vessel 1 Liquid Makeup A Vessel 1 Liquid Makeup B INPUT MODULE NEUTRAL Vessel 1 High Level Warning (safe closed) INPUT MODULE...

  • Page 37: Figure 23: Vessel Digital Board 6 (Optional)

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 37 Figure 23: Vessel digital board 6 (optional) INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Vessel 1 Pump D Run Vessel 1 Pump D Aux. INPUT MODULE NEUTRAL Pump A Bypass To Vessel 1 OUTPUT MODULE...

  • Page 38: Figure 24: Engine Room Digital Board 1

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 38 MAINTENANCE Figure 24: Engine room digital board 1 INPUT MODULE OUTPUT MODULE POWER AMP794068-1 INSTALLED FUSE OUTPUT MODULE Ventilation Fan A Run Ventilation Fan A Aux. INPUT MODULE NEUTRAL Ventilation Fan B Run OUTPUT MODULE Ventilation Fan B Aux.

  • Page 39: Digital Board Settings

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 39 Digital Board Settings Communications settings Use the following table when configuring the Quantum™ for external communications. Table 11: Communications settings 120 ohm long communications line termination. out* No termination. RS-422/485 transmit pull-up for long communications lines.

  • Page 40: Figure 25: Analog Boards For Evaporator Comms

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 40 MAINTENANCE Figure 25: Analog boards for evaporator Comms Rem. Panel 1 Rem. Panel 2 Rem. Panel 3 Rem. Panel 4 Rem. Panel 5 Group A Group A Group A Group A Group A Evaporator (Zones 1-3)
  • Page 41 QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 41 SECTION 5 ANALOG BOARD...

  • Page 42: Analog Board

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 42 MAINTENANCE Analog Board Preface – The wrong analog output signals being sent from the board. The Quantum™ HD Unity System Controller is capable of reading external analog devices, such as temperature Connections to the Quantum™...

  • Page 43: Figure 30: Signal Connections

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 43 Analog Inputs An open wire, shorted wire, or faulty sensor will usually give a reading at either the minimum or maximum end of An Analog Input is the portion of the hardware that al- the range scale.

  • Page 44: Figure 31: Evaporator Analog Board 1

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 44 MAINTENANCE Figure 31: Evaporator analog board 1 OUTPUTS CH8 – Auxiliary Output - P/I Control CH4 – Modulating Liq. Ctrl. Valve (Zone A) CH7 – Auxiliary Output - P/I Control CH3 –...

  • Page 45: Figure 32: Condenser Analog Board 1

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 45 Figure 32: Condenser analog board 1 OUTPUTS CH8 – VFD Fan Output H CH4 – VFD Fan Output D CH7 – VFD Fan Output G CH3 – VFD Fan Output C CH6 –...

  • Page 46: Figure 33: Vessel Analog Board 2

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 46 MAINTENANCE Figure 33: Vessel analog board 2 OUTPUTS CH8 – Auxiliary Output (P/I Control) CH4 – Vsl 2 Modulating Makeup Valve B CH7 – Auxiliary Output (P/I Control) CH3 – Vsl 2 Modulating Makeup Valve A CH6 –...

  • Page 47: Figure 34: Vessel Analog Board 3

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 47 Figure 34: Vessel analog board 3 OUTPUTS CH8 – OPEN OUTPUT CH4 – Auxiliary Output (P/I Control) CH7 – OPEN OUTPUT CH3 – Auxiliary Output (P/I Control) CH6 – Auxiliary Output (P/I Control) CH2 –...

  • Page 48: Figure 35: Engine Room Analog Board 1

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 48 MAINTENANCE Figure 35: Engine room analog board 1 OUTPUTS CH8 – Auxiliary Output (P/I Control) CH4 – VSD Ventilation Fan D CH7 – Auxiliary Output (P/I Control) CH3 – VSD Ventilation Fan C CH6 –...

  • Page 49: Analog Board Settings

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 49 Analog Board Settings Communications settings Jumper settings The following table is to be used when configuring the Sensors with a 30mA maximum sensor power are re- Quantum™ for external serial communications. served for pins 1-2.

  • Page 50: Figure 36: Digital Boards For Evaporator Comms

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 50 MAINTENANCE Figure 36: Digital boards for evaporator Comms Rem. Panel 1 Rem. Panel 2 Rem. Panel 3 Rem. Panel 4 Rem. Panel 5 Group A Group A Group A Group A Group A Evaporator (Zones 1-3)

  • Page 51: Section 6 - Service Screens

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 51 SECTION 6 SERVICE SCREENS...

  • Page 52: Service - Diagnostics

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 52 MAINTENANCE Service – Diagnostics Diagnostics: The Service page is broken into 4 basic Ping The Below IP Address – Confirm connectivity of a categories: Diagnostics, Communications, Software, and known IP address and the network. Screen Calibration.

  • Page 53: Service - Communications

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 53 Service – Communications Communications: The “Communications” page shown The Comm. Loop-Back Test provides an easy way to verify above provides the following functions: a comm. ports operation. The test requires connecting two comm.

  • Page 54: Service - Software - Saving Setpoints

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 54 MAINTENANCE Service – Software – Saving setpoints Saving Setpoints: The Software Service page provides the A thumb drive must be mounted on the respective con- troller prior to pushing the Submit Changes button. If set- means to save, restore, delete or restore default setpoints.

  • Page 55: Service - Software - Restoring Setpoints

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 55 Service – Software – Restoring setpoints Restoring Setpoints: The Restore Setpoints page has 4 During the Restoring process, the yellow status page options: Restore Setpoints and Calibration Data, Restore below will appear advising the status of the restore.

  • Page 56: Service - Software - Deleting Setpoints

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 56 MAINTENANCE Service – Software – Deleting setpoints Deleting Setpoints: Selecting Delete Setpoints will go to Defaulting Setpoints: Pressing the Restore Default Set- this page listing all the setpoints file saved Locally and to points from the Setpoint Maintenance menu will reset all the mounted USB thumb drive.

  • Page 57: Service - Software - Upgrade Software

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 57 Service – Software – Upgrade software Upgrade Software: Plug a USB Thumb Drive with the soft- Overview page and the user must login again. ware upgrade file into the respective product processor board.

  • Page 58: Service - Software - Touchscreen Calibration

    090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 58 MAINTENANCE Service – Software – Touchscreen calibration Touchscreen Calibration: Select Screen Calibration, then Touching the icon causes it to shift to the right. Continue Calibrate Touch Screen. to touch the icon as it shifts across and down the screen. A total of 16 points are required;...

  • Page 59: Section 7 - Troubleshooting

    QUANTUM™ HD UNITY SYSTEM CONTROLLER 090.670-M (APR 2020) MAINTENANCE Page 59 SECTION 7 TROUBLESHOOTING TROUBLESHOOTING If you encounter a problem that is not easily identifiable or • Is power wiring mixed with sensor wiring? initially appears unexplainable, check the following: •...
  • Page 60 090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 60 MAINTENANCE This page is intentionally left blank...

  • Page 61: Section 8 - Replacement Parts

    Q5 to Q6 Quantum HD Unity condenser/vessel upgrade kit 649C1171G21 Q5 to Q6 Quantum HD Unity evaporator upgrade kit 649C1171G31 Q5 to Q6 Quantum HD Unity engine room upgrade kit Interface boards 639B0116H01 Interface board (used with Q5 processor board only)
  • Page 62 090.670-M (APR 2020) QUANTUM™ HD UNITY SYSTEM CONTROLLER Page 62 MAINTENANCE 643D0072G03 Module #1 (vessel) 643D0072G04 Module #2 (vessel) 643D0072G05 Module #1 (engine room) 643D0072G06 Module #1 (evaporator) 643D0072G07 Module #2 (evaporator) 333Q0001738 Fuse, 2 amp, 250 V Other items 639D0295H01 Ethernet switch, 8 port 639A0185H10...
  • Page 63 April 2020 Form Revisions Throughout - Changed term “controller” to “processor board” - Changed instances of LX to HD Unity - Updated all screenshots in Section 6 - Service Screens Page 6 – Changed Q5 processor to Q6 processor board Page 7 –...
  • Page 64 JOHNSON CONTROLS Supersedes: 090.670-M (2016-03) 100 Cumberland Valley Avenue Subject to change without notice Waynesboro, PA 17268-1206 USA Published in USA • 04/20 • PDF Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/FRICK © 2020 Johnson Controls Int’l PLC - ALL RIGHTS RESERVED...

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