Carrier HS070-160 User Manual

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HEATING
&
COOLING
30HR,HS070-160
Flotronic Plus Reciprocating Liquid Chillers
Controls Troubleshooting Guide
Alf Model E Units Have Microprocessor Controls
and Electronic Expansion Valves
CONTENTS
SAFETY CONSIDERATIONS
Page
SAFETY
CONSlDERATlONS
................ 1
FLOTRONIC PLUS CONTROL SYSTEM ..... l-4
Generat ..................................... 1
Features .....................................
2
. PROCESSOR MODULE ...................
2
l LOW-VOLTAGE RELAY MODULE .........
2
. EXV
(ELECTRONK
EXPANSION
VALVE) DRIVER MODULE ...............
2
. KEYBOARD AND DISPLAY MODULE .....
2
. ELECTRONIC EXPANSION VALVE ........
3
l THERMISTORS ...........................
3
. CAPAClTY CONTROL ....................
3
CONTROL SEQUENCE .....................
4,5
Off Cycle ....................................
4
Start-Up ....................................
4
Capacity Control ............................
4
l SEQUENCE ...............................
4
Unit Shutdown ..............................
5
Complete Unit Stoppage
.....................
5
Single-Circuit Stoppage .....................
5
Lag Compressor Stoppage ...................
5
Restart Procedure ...........................
5
l GENERAL POWER FAlLURE ..............
5
l BLOWN FUSE
IN
POWER FEED
DISCONNECT ............................
5
l LOW WATER TEMPERATURE
CUTOUT..................................
5
l AUXILIARY INTERLOCK .................
5
l OPEN CONTROL
CIRCUlT
FUSE ..........
5
. FREEZE PROTECTION ....................
5
a HIGH-PRESSURE SWITCH ................
5
l LOSS OF CHARGE SWITCH ...............
5
. COMPRESSOR DISCHARGE
TEMPERATURE SWITCH .................
5
. OIL SAFETY SWITCH .....................
5
CONTROLS OPERATION .................. .5-l I
Accessing Functions and Subfunctions. ......
5
Qisplay Functions ...........................
5
a SUMMARY DISPLAY .....................
5
. STATUS FUNCTION ......................
5
. TEST FUNCTION ........................
10
Programming Functions
....................
1
I
.
SERVlCE
FUNCTION ....................
11
l SET POINT FUNCTION ..................
11
l SCHEDULE FUNCTION ..................
11
TROUBLESHOOTING .....................
12-26
Checking Display Codes ....................
12
l OPERATING MODE CODES ..............
12
. ALARM CODES
.........................
12
Quick Test .................................
14
Electronic Expansion Valves ................
19
l CHECKOUT PROCEDURE ...............
19
l EXV OPERATION ........................
21
Thermistors ................................
22
l LOCATION ..............................
22
l SENSOR REPLACEMENT ................
22
Modules ....................................
23
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.
l Follow all safety codes.
0
Wear safety glasses and work gloves.
l Use care in handling, rigging and setting bulky
equipment.
l Use care in handling elcetronic components.
ELECTRII~ SHOCK HAZARD.
Open all remote disconnects before
servicing this equipment.
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 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 30HR,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 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.
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Summary of Contents

Page 1 - 30HR,HS070-160

HEATING & COOLING30HR,HS070-160Flotronic Plus Reciprocating Liquid ChillersControls Troubleshooting GuideAlf Model E Units Have Microprocessor Co

Page 2

p-JB(Modes) The operating mode codes are dis-played to indicate the operating status of the unit at agiven time. (See Table 7).The modes are explaine

Page 3 - FUNCTIONS

Programming FunctionsSERVICE FUNCTION - The service function allowsthe operator to verify factory configurations and reador change field configuration

Page 4

TROUBLESHOOTINGIf necessary, review the Flotronic Plus Control System,Control Sequence, and Controls Operation sectionsfound in this book. Tables 5 an

Page 5 - after a code has been

NOTE: The control does not detect circuit breakerfailures. If a circuit breaker trips on the lead compressorin a circuit, a low oil pressure failure

Page 6 - Table 5

LEAVING WATERSUCTION,----CONNECTION(T58T6)\INLETCOOLER TUBECONNECTIONTHERMISTOR..ENTERING COOLERWATER SENSOR(T21Fig. 4 - Cooler Sensor LocationsBau’

Page 7 - Keyboard Directory

KEYBOARDIDISPLAYENTRY RESPONSEq u3TESTCOMPy$.CAM OFFqENTRCA1 ONICAM OFFq+CA2 OFFEND TESTCOMMENTSFactory field test of compressorssubfunction of test f

Page 8 - Keyboard Directory (cant)

THE PROCESSOR OPERATESTHESE CONTACTSFig. 5 - Compressor 24-V Control Circuit Wiring(Simplified)24V FEED 24V NEUTRAL24vFEED1/DSlOTERM ?$I.- STRIP24vNEU

Page 9 - Display Codes

Table 8a - Thermistsr Temperature vs Resistance and Voltage (English)TEMPERATUREVI-25.0-24.0-23.0-22.0-21.0-20.0-19.0-18.0-17.0-16.0-15.0-14.0-

Page 10

Table 8b - Thermistor Temperature vs Resistance and Voltage (Sk)TEMPERATURE62-39-38-37-36-35-34-33-32-31-30-29-28-27-26-25-24-23-22-21-20-19-la-17-1

Page 11

Electronic Expansion ValvesCHECKOUT PRCKEDCRE ~ 1-<11low steps below todiagnose and correct EXV problems, For an explanarjonof EXV operation, se

Page 12

-Features - The 30HR,HS control panel is shown inFig. 1.PROCESSOR MODULE - This module contains theoperating software and controls the operation o

Page 13 - Causes for this failure are:

-MUFFLERS MUFFLERS -COMPRESSORS COMPRESSORSFig. 9 - Thermistor LocationsStep 4 - Check Thermistors That Control EXV -Check thermistors that control p

Page 14 - Cooler Sensor Locations

The EXV test can be repeated r-rs required by pressingmay be due to out-of-calibration thcrmistorfs), or inter-mittent connections between processor

Page 15

Thermistors - All thermistors are identical in theirtemperature vs resistance performance. Resistance atvarious temperatures are listed in Table 8.LOC

Page 16

ModulesTurn controller power off before servicing thacontrols. This is to ensure safety and prevent damageto the controller.PROCESSOR MODULE (PSIO),

Page 17 - Thermistsr Temperature

On the sensor bus terminal strips, terminal 1 of thePSI0 module is connected to terminal 1 of each of theother modules; terminals 2 and 3 are connecte

Page 18 - Table 8b

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 achannel it i

Page 19 - and remain

TROUBLESHOOTINGSYMPTOMS CAUSEI REMEDYSYMPTOMSCompressor doesnot runCAUSE REMEDYUnit operateslong orcontinuouslyPowerline openReset circuit breaker.Con

Page 21 - 4 -STEPPER MOTOR

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.--I-

Page 22 - Thermistors

Each function has one or more subfunctions as shown At initial start-up the valve position is initialized to 0.in Table 2. These functions are defined

Page 23 - the modttlc that controls

Table 3 - ThermistorsCONTROL SEQUENCEThe control power (115-l-60 for 60-Hz units; 230-l-50for 50-Hz units) must be supplied directly from a separate

Page 24

When the second or lag refrigeration circuit is started,the circuit will go through a lo-second pumpout unlessthe circuit has been operating in the 15

Page 25

Table 5 - Accessing Functions and SubfunctionsOPERATIONTo access a function, press the subfunction number and thefunction name key. The display will s

Page 26 - TROUBLESHOOTING

Table 6 - Keyboard DirectorySTATUSQUICK TESTKEYBOARD ENTI DISPLAY KEYBOARD ENTRYDISPLAY COMMENTFactory/field test ofinputsLeaving watertemperatureEnt

Page 27

Table 6 - Keyboard Directory (cant)SERVICE CONFIGURATtONSKEYBOARD ENTRYCOMMENTKEYBOARD ENTRY 1 DtSPLAY iCOMMENTDISPLAYOVRD XSCHTYP XPERIOD 1MON XTUE

Page 28

Table 7 - Display CodesOPERATING MODESDisplayDescriptionComp Al AlFailureCamp A2 ii:FailureComp BlFailureCompB2 FailureLoss of charge circuit ALoss o

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