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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.