Carrier HS070-160, Troubleshooting Manual

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