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Carrier HS070-160 Troubleshooting Manual

Flotronic plus reciprocating liquid chillers controls troubleshooting guide
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HEATING
COOLING
Controls Troubleshooting Guide
CONTENTS
S A F E T Y CONSlDERATlONS . . . . . . . . . . . . . . . .
FLOTRONIC PLUS CONTROL SYSTEM . . . . .
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
PROCESSOR MODULE . . . . . . . . . . . . . . . . . . .
LOW-VOLTAGE RELAY MODULE . . . . . . . . . 2
l
. EXV (ELECTRONK EXPANSION
VALVE) DRIVER MODULE . . . . . . . . . . . . . . .
.
KEYBOARD AND DISPLAY MODULE . . . . . 2
.
ELECTRONIC EXPANSION VALVE . . . . . . . . 3
THERMISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
l
. CAPAClTY
CONTROL . . . . . . . . . . . . . . . . . . . .
CONTROL
SEQUENCE . . . . . . . . . . . . . . . . . . . . .
Off Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
l
Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoppage . . . . . . . . . . . . . . . . . . . . .
Complete
Unit
Single-Circuit
Stoppage . . . . . . . . . . . . . . . . . . . . .
Lag Compressor Stoppage . . . . . . . . . . . . . . . . . . .
Restart
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL POWER FAlLURE . . . . . . . . . . . . . .
l
BLOWN FUSE IN POWER FEED
l
DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOW WATER TEMPERATURE
l
CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY INTERLOCK . . . . . . . . . . . . . . . . .
l
OPEN CONTROL CIRCUlT FUSE . . . . . . . . . . 5
l
.
FREEZE PROTECTION . . . . . . . . . . . . . . . . . . . .
LOSS OF CHARGE SWITCH . . . . . . . . . . . . . . .
l
.
COMPRESSOR
DISCHARGE
TEMPERATURE SWITCH . . . . . . . . . . . . . . . . .
.
OIL SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . .
CONTROLS
OPERATION . . . . . . . . . . . . . . . . . . .5-l I
Accessing
Functions
and
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
STATUS
FUNCTION . . . . . . . . . . . . . . . . . . . . . .
. TEST FUNCTION . . . . . . . . . . . . . . . . . . . . . . . .
Functions . . . . . . . . . . . . . . . . . . . .
Programming
.
SET POINT FUNCTION . . . . . . . . . . . . . . . . . .
l
SCHEDULE FUNCTION . . . . . . . . . . . . . . . . . .
l
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . .
Checking Display Codes . . . . . . . . . . . . . . . . . . . .
OPERATING MODE CODES . . . . . . . . . . . . . .
l
. ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Expansion Valves . . . . . . . . . . . . . . . .
CHECKOUT
PROCEDURE . . . . . . . . . . . . . . .
l
EXV OPERATION . . . . . . . . . . . . . . . . . . . . . . . .
l
Thermistors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
l
SENSOR
REPLACEMENT . . . . . . . . . . . . . . . .
l
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flotronic Plus Reciprocating Liquid Chillers
and Electronic Expansion Valves
Page
1
1
2
2
2
3
3
4
4
4
4
5
5
5
5
5
5
5
5
5
5
5
5
5
5
Subfunctions. . . . . . . 5
5
5
5
10
1
11
11
12-26
1 2
12
12
1 4
1 9
19
21
2 2
22
22
2 3
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 and any other
safety precautions that apply.
Follow all safety codes.
l
Use care in handling, rigging and setting bulky
l
equipment.
Use care in handling elcetronic components.
l
Open all remote disconnects before
This unit uses a micreprocessor-based electronic
control system. 190 not use jumpers or other tools
to short out components, bypass or otherwise depart
from recommcndcd
p r o c e d u r e s . A n y short-to-
ground of the control board or accompanying wiring
may destroy the electronic modules or electrical
component.
FLOTRONIC PLUS CONTROL SYSTEM
General
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
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 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.
SHOCK
HAZARD.
Flotronic Plus chillers
the user, controls the unit

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  Summary of Contents for Carrier HS070-160

  • Page 1 (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. 30HR,HS070-160 SAFETY CONSIDERATIONS safety precautions that apply. ELECTRII~ SHOCK HAZARD.
  • Page 2: Features

    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.
  • Page 3: Keyboard And Display Module

    Each function has one or more subfunctions as shown in Table 2. These functions are defined in greater detail in t K Controls Operation section of this book. Fig. 2 - Keyboard and Display Module ELECTROWIC EXPANSION VALVE ~ The micro- processor controls the electronic expansion valve through the EXV driver module.
  • Page 4: Off Cycle

    Table 3 - Thermistors Table 4 - Capacity Control Steps SEQUENCE A ?r Cylinders UNIT :ONTR 3 0 H R EiiqTm- STEPS 3 0 H S C a p . C o m p r 82 - 1 4 . 3 4 2 .
  • Page 5: Unit Shutdown

    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.
  • Page 6 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 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...
  • Page 7 STATUS KEYBOARD ENTI DISPLAY Current alarm displays ALARMS ALARM X Alarm 1 Alarm 2 ALARM X ALARM X Alarm 3 M O D E Current mode displays MODE X Mode 1 STAG ES Capacity stages X STAGE Stage number SET POlNT Current set point Leaving chilled water...
  • Page 8 Table 6 - Keyboard Directory (cant) SERVICE CONFIGURATtONS COMMENT KEYBOARD ENTRY 1 DtSPLAY 3ut a s follows. Shows that confrgura- -0GGED ON \ tlons avaIlable -0G OFF Conflgurations now KXIT again password protected Software version tiERSION number Software version x x x Language optJon Factory configuration FACT CFG...
  • Page 9 Description Display Comp Failure Failure Camp Failure C o m p Bl Comp Failure Loss of charge circuit A Loss of charge circuit B Low cooler flow Low oil pressure circuit A low oil pressure circuit B Freeze protection High suction superheat circuit A High suction superheat circuit B Low suction suoerheat circuit A Low suction superheat circuit B...
  • Page 10: Test Function

    p-JB (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. [3-i (Stages) This subfunction displays the capac- ity stage number, from 1 to 8.
  • Page 11 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.) The operator must use this subfunction to log on before performing any other subfunction, to log off after completing service subfunctions.
  • Page 12: Flotronic Plus Control System

    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 3OHR,HS Installation, Start-Upand Service Instructions along with examples and details on using the control features.
  • Page 13: Quick Test 1

    NOTE: The control does not detect circuit breaker failures. If a circuit breaker trips on the lead compressor in a circuit, a low oil pressure failure will be indicated; on the other compressors, no failure will be indicated. Checkout P~-o~etiur~ (Codes 51-54) - Shut off the main power to the unit.
  • Page 14: Electronic Expansion Valves 1

    COOLER TUBE Bau’ The~~isfor ~ Thermistors mis-located or out of 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 (OOC) or the satu- rated suction is greater than 58 F (14.4 C) and either condition has been true for more than 5 minutes.
  • Page 15 KEYBOARD DISPLAY ENTRY RESPONSE TEST COMP Factory field test of compressors subfunction of test function y $ . q EN T R CAM OFF Circuit A, compressor 1 test CA1 ON Pressing ENTR starts the test; when the compressor should be running the display shows CA1 on CAM OFF If the test is allowed to time out, the...
  • Page 16 Fig. 5 - Compressor 24-V Control Circuit Wiring 2 4 v F E E D DSlO TERM ?$I.- STRIP LC%%R&F CIRCUIT B LOSS OF C H A R G E CiRCUtT Fig. 6 - Pressure Feedback Circuit Wiring (Simplified) T H E P R O C E S S O R O P E R A T E S THESE CONTACTS (Simplified) 24V FEED...
  • Page 17 Table 8a - Thermistsr TEMPERATURE VOLTAGE RESISTANCE DROP (Y) -25.0 4.821 -24.0 4.818 -23.0 4.814 -22.0 4.806 -21.0 4.800 -20.0 4.793 -19.0 4.786 -18.0 4.779 -17.0 4.772 4.764 -16.0 -15.0 4.757 -14.0 4.749 -13.0 4.740 -12.0 4.734 -11.0 4.724 -10.0 4.715 -9.0 4.705...
  • Page 18 Table 8b - Thermistor Temperature vs Resistance and Voltage (Sk) T E M P E R A T U R E RESISTANCE V O L T A G E 4.8961 4.8892 4 4.88177 4.874 4.86577 4.85709 4.84793 4.83a39 4.82808 4.81736 4.80608 4.79421 4.78151...
  • Page 19 Electronic Expansion Valves CHECKOUT PRCKEDCRE ~ 1-<11low diagnose and correct EXV problems, For an explanarjon of EXV operation, see paye 2 1. Step 1 - Check EXV Driver Outputs ~ Chcuk output signals at appropriate terminals on the E.YV driver module (Fig.
  • Page 20 - M U F F L E R S COMPRESSORS 4 - Check Thermistors That Control EXV - Step 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 location.
  • Page 21 The EXV test can be repeated r-rs required by pressing may be due to out-of-calibration thcrmistorfs), or inter- mittent connections between processor board tcrn?inals a n d plug. Recheck all wiring connections ;tnd voltage signals. Other possible causes of improper refrigerant flow control could be restrictions in liquid line.
  • Page 22: L Location

    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, TL, is located in the leav- ing water nozzle.
  • Page 23 Modules Turn controller power off before servicing tha controls. This is to ensure safety and prevent damage to the controller. PROCESSOR MODULE (PSIO), R E L A Y M O D U L E (DSIO) AKD EXV DRIVER MODULE (DSlO) - The PSI0 and DSIO modules all perform continuous diagnostic evaluations of the condi- tion of the hardware.
  • Page 24 On the sensor bus terminal strips, terminal 1 of the PSI0 module is connected to terminal 1 of each of the 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.
  • Page 25 EXV Driver Module (Fig. 16.) Inputs ~ Input on strip 32 am-c discrcre inputs (O?;-OFF). When 24 vat are applied across thy 2 terminals in a channel it is read as an ON signal. Zero voIts is read as an OFF signal. Outputs ~ Two stepper motor driver outputs ;tre used to drive the electronic expansion valves, Terminals I and 7 supply voltage to the valves.
  • Page 26: Troubleshooting

    SYMPTOMS CAUSE Power line open Compressor does not run Control fuse o p e n Safety thermostat tripped (DGT) Tripped power breaker l a t i n g pump not Improperly wired controls Low line voltage Compressor motor defective Seized compressor Compressor Loss of charge control 1 Repair leak;...
  • Page 28 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog 533-030 Printed in U.S.A. Form30HR,HS-1T P g 28 l - 8 9 Replaces: P C 1 1 1 Book 2 T a b --I-...