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H-IM-QRC

Heatcraft H-IM-QRC Installation And Operation Manual

Quick Response
Controller
H-IM-QRC April 2018 Part No. 29702401
Replaces H-IM-QRC (08/17)
Installation and
Operation Manual
Table of Contents
Heatcraft Quick Response Controller Board Layout ..................................... 2
Installation Tips .......................................................................................... 3
Refrigerant Line Brazing ............................................................................ 4
Power Supply............................................................................................. 4
Wiring ........................................................................................................ 4
Multiple Evaporator Configuration .............................................................. 5
Box Temperature Control Settings .............................................................. 6
Leak Testing .............................................................................................. 6
Start-Up Operation .................................................................................. 7-8
Programming and Reviewing Settings and Changes .............................9-12
Program Review Button Select Button
Enter Button
Monitoring Items .................................................................................11-12
Monitor Button Force Defrost Button Reset Time Button Force Service Button Clear/Test Button
Defrost ...............................................................................................14-15
Checking Operation of Expansion Valve ...............................................17-18
Smart Controller .................................................................................19-20
Diagnostics ......................................................................................... 24-26
Wiring Diagrams ................................................................................. 27-32
Service Record ................................................................................... 34-35
Heatcraft Quick Response Controller Board Layout
Heatcraft Quick Response Controller Board
Evaporator
Fan
Relay
EXV
Test Pins
LED
Display
Spare
Temperature
Defrost
Heater
Relay
Alarm
Contacts
Expansion
Valve
Connection
Selection
Buttons
Room
Temperature
Defrost
Temperature
Suction
Temperature
Suction
Pressure
Terminal
Block
©2018 Heatcraft Worldwide Refrigeration
2
Installation
Installation Tips
• Use a minimum 18 gauge wire for all low voltage connections.
• The Heatcraft Quick Response Controller board gets its 24 VAC power supply from a transformer mounted in the electrical end of each evaporator. On 208-240 volt systems, the multi-tap transformer is shipped from our factory wired for 240 volts. If your supply voltage is 208 volt, you must change to the 208 volt tap on the transformer.
NOTE: On multiple evaporators, since a transformer is in each evaporator, the voltage tap must be set on each evaporator.
• Refer to wiring schematic shipped on units for unit wiring. Schematics in this Installation & Operation Manual are typical wiring schematics only.
• Program ALL slave evaporators as SLAVES.
• Evaporators are shipped from our factory with a preset box setpoint temperature of 35°F for air defrost and -10°F for electric defrost. If your box setpoint temperature requirements are different, this must be set using directions outlined under “Room Temperature Control”.
• Some systems may require the crankcase heater be energized 24 hours prior to start-up. The Heatcraft Quick Response Controller should be
de-energized for this period by placing it in the SERVICE MODE. This is done by pressing the FORCE SERVICE button twice. To start the system cooling, press the CLEAR button.
• Room sensors may be left connected on ALL evaporators. Room sensor must be connected on the Master Coil.
• A pressure transducer is installed on the evaporator. Do not leak test system above 150 PSI or damage to transducer could occur. If leak testing must be greater than 150 psig, disconnect the transducer from the suction header and reconnect after testing is complete.
Condensing Unit
Condensing units do not require a Defrost Timer and should be disconnected if installed. A head pressure control is highly recommended to be installed in condensing unit.
Condensing unit must be installed using proper refrigeration practices and codes. Make sure there is sufficient clearances around unit for adequate air flow and access.
• The suction line temperature sensor MUST be removed from the suction line before brazing the suction tubing. The sensor MUST then be reinstalled on the suction line after brazing is completed and the tubing has cooled. Insulate when finished.
• If electrical power will be connected prior to evacuation and charging of system, unplug electric expansion valve from board until system is ready to be evacuated, leak tested and charged.
• There are built-in ground connections on the Heatcraft Quick Response Controller’s four corner brass spacers. Use four sheet-metal screws to mount the board on the evaporator for common­mode noise filtering. Make sure that the evaporator ground terminal is earth grounded.
Typical condensing unit wiring is shown on page 31. The wiring diagram on page 32 shows how to convert a conventional condensing unit to use Heatcraft Quick Response Controller with the system.
Evaporator Unit
The evaporator contains the Heatcraft Quick Response Controller board, electric expansion valve, pressure transducer, distributor, orifice, transformer and three sensors. These components are all factory mounted and wired. The three sensors are factory mounted and provide input to the controller from the following: defrost temperature, suction temperature, room temperature
Each evaporator unit must be installed using proper refrigeration practices and codes. Make sure the piping is correctly sized and properly routed. It is highly recommended that the liquid and suction lines be insulated. There must also be good clearance around unit. See H-IM-UC Installation and Operation manual for more details. (Available on website).
3
Installation
Refrigerant Line Brazing (Caution)
The electric expansion valve and the suction temperature sensor on the suction line are factory installed.Care must be taken when brazing these lines at the evaporator.
Too high a temperature may destroy these components. Heat absorbing compounds or “wet rags” must be used to protect the electric expansion valve when brazing the refrigerant line connections. THE SUCTION LINE SENSOR SHOULD BE REMOVED
BEFORE BRAZING.
Power Supply
The Heatcraft Quick Response Controller board gets its 24 VAC power supply from a transformer mounted in the electrical end of each evaporator. On 208-240 volt systems, the multi-tap transformer is shipped from our factory wired for 240 volts. If your supply voltage is 208 volt, you must change to the 208 volt tap on the transformer.
VERY IMPORTANT: If the supply voltage to the evaporator is 208 volts, the primary tap of the transformer must be moved to the 208 volt tap.
This must be done for all the evaporators on that system.
If the 24 VAC power supply falls below 18 VAC, the system may power down and shut off. When the power supply is corrected to 24 VAC, the system will restart after the four minute hold-off period and resume normal operation.
Wiring
Wiring at the unit cooler(s) will be as follows (see wiring diagrams):
• High voltage - There may be high voltage on
the defrost heater relay and the fan relay. The evaporator is connected to a separate power supply from the condensing unit. See unit cooler spec. plate for ampacity.
• Low voltage wiring must be 18 gauge minimum. For low voltage wiring, maximum distances are:
Between evaporators 500 ft.
• Multiple units – The multi-in and multi-out are the communication connections. Connection sequence must follow the multi­ out terminal to the multi-in terminal and the multi-out back to the multi-in terminal in a daisy chain loop.
• Alarm circuit - The onboard alarm is a dry set of NC contacts which closes to indicate an alarm or loss of power. The type and wiring for the alarm is customer specified. Note that the alarm circuit does not distinguish or indicate what has caused the alarm.These contacts can handle up to a 2 Amp load.
On Heatcraft Quick Response Controller systems,the main power for the evaporator is supplied separately from the power supply of the condensing unit. All wiring, however, must comply with local electrical codes.
• All wiring must comply with all applicable codes and ordinances.
CAUTION: All 24v wiring must be run separate from the line voltage wiring. Wires/Leads must not touch other component connection points or power wires to avoid damage to the board or its components.
4
Configuration
Multiple Evaporator Configuration (Master/slave)
If there are multiple evaporators on a system, the program for each SLAVE evaporator must be changed to identify it as a SLAVE. To do so, press the “PROGRAM REVIEW” button repeatedly until “SLA” appears then use the “SELECT” knob to select “YES” and press “ENTER”. All Heatcraft Quick Response Controller boards are shipped with the factory default as a MASTER evaporator. Place all
PROGRAM
REVIEW
Up to 4 evaporators can be connected as a master/slave configuration.
DO NOT remove the room sensor from any of the Heatcraft Quick Response Controller boards programmed as Master.
boards in the “SERVICE” mode while you program the setpoints to avoid errors and alarms which may cause troubles at startup.
VERY IMPORTANT: This must be done for each slave board, prior to starting the system.
SELECT
M
S
S
S
M = Master Evaporator S = Slave Evaporator
Each Heatcraft Quick Response Controller board power is supplied by a transformer in the evaporator on which
it is mounted. Do not run any 24 VAC wires between Heatcraft Quick Response Controller boards on the evaporators.
5
Box Temp Control Settings
Box Temperature Control Settings
• There is an on board room thermostat on the Heatcraft
Quick Response Controller board which can be adjusted to the desired room temperature. The temperature differential is 2°F.
Temperature Differential
When a system is in the cooling mode and the box
setpoint is 35°F, the system will continue to cool until the box temperature gets to 34°F. At this point, the compressor will pumpdown and shut off. The system will restart cooling when the box temperature has risen to 36°F.
It is important to note that Heatcraft Quick Response
Controller has a minimum 2 minute “ON” time and a minimum 4 minute “OFF” time. This means that the system will run in the cooling mode a minimum of 2 minutes even if the setpoint temperature is met. In applications where the system is grossly oversized, the box temperature could go below the differential temperature before the system cycles off.
In the “OFF” cycle the system will be off for a minimum of 4 minutes even if the box temperature goes above the differential temperature, before cooling will be restarted.
Leak Testing
After all lines are connected, the entire system must be leak tested. The complete system should be pressurized to not more than 150 psig with refrigerant and dry nitrogen. The use of an electronic type leak detector is highly recommended because of its greater sensitivity to small leaks. As a further check, it is recommended that this pressure be held for a minimum of 12 hours and then rechecked. For a satisfactory installation, the system must be leak tight.
• The on board room thermostat is factory set at 35°F for Air Defrost systems and -10°F for electric defrost system.
Recommended Low Pressure Control Settings for Outdoor Air Cooled Condensing Units
*Minimum Temp.
˚F
50 90 35 70 40
40 70 35 55 25
30 55 35 40 20
10 45 25 30 10
0 25 7 15 0
-10 20 2 15 0
-20 12 1 10 0
-30 8 0 6 0
* Minimum ambient or box temperature anticipated * The standard preset low pressure switch used for pumpdown is set for 15 PSI cut in / 4 PSI cut out and is a good setting for most pumpdown systems
R-404A/R-407A/R-448A R-407C
Cut-In PSI Cut-Out PSI Cut-In PSI Cut-Out PSI
6
Start-Up Operation
Start-Up Operation
Single System With 1 Evaporator
• Check all wiring connections to be sure they are
correct and tight.
• On the condensing unit
- Check the adjustable low pressure switch setting on freezer units. Refer to H-IM-CU (Available on website). On some condensing units, the low pressure switch has a fixed setting and cannot be adjusted.
• Turn power on
• On the evaporator
- Use the “PROGRAM REVIEW” button to scroll
through settings.
- Check “rEF” (Refrigerant Type). Factory defaults are: Air Defrost R-404A, Electric Defrost R-404A. Change to the refrigerant being used.
- Check “bot” (Box Temperature). Factory defaults are: air defrost 35°F and electric defrost –10°F. Change to the desired temperature.
- Review and change other settings if necessary
- See procedures on page 10 for how to change
settings.
Single System With Multiple Evaporators
• Check all wiring connections to be sure they are
correct and tight.
• On the condensing unit
- Check the low pressure switch setting on freezer units. Refer to H-IM-CU (Available on website). On some condensing units, the low pressure switch has a fixed setting and cannot be adjusted.
• Turn power on.
• On the MASTER evaporator
- DO NOT REMOVE the room sensor.
- Use the “PROGRAM REVIEW” button
to scroll through settings.
- Check “rEF” (Refrigerant Type). Factory defaults
are: air defrost R-404A, electric defrost R-404A. Change to the refrigerant being used.
- Check “bot” (Box Temperature). Factory defaults are: air defrost 35°F and electric defrost –10°F. Change to the desired temperature.
- Review and change other setting if necessary.
- See procedures on page 10 on how to change settings.
• On the SLAVE evaporators.
- Each SLAVE Evaporator must be changed to identify it as a SLAVE. Use the “PROGRAM REVIEW” button to scroll until “SLA” appears, then use the “SELECT” knob to select “YES” then press “ENTER.”
- DO NOT NEED TO REMOVE the Room Sensor on any evaporator.
M
S
S
M = Master Evaporator S = Slave Evaporator
S
7
Initial Power On
Start-Up Operation
At the initial application of power to the system, the EEV will be in a 4 minute hold-off cycle and will not start immediately. The evaporator fans will turn on immediately if fan stir cycling is turned off. If fan stir cycling is turned on the fans will stay off for 5 minutes or until there is a call for cooling. When there is a call for COOLING, the expansion valve (EEV) opens. The system will then run for a minimum of 2 minutes in the “hold-on” cycle. (This means that the system will run for a minimum of 2 minutes before shutting off even if the box temperature is met).
The LED alternately displays BOX TEMPERATURE and MODE of operation. On a call for cooling, dLY will show while the expansion valve is opening. After the compressor starts the LED will alternately display BOX TEMPERATURE and Coo.
On multiple evaporator systems, the MASTER evaporator will display
BOX TEMPERATURE and Coo. The SLAVE evaporators will display Coo only.
When the room thermostat setting is satisfied, and if the system ran for at least 2 minutes, the EEV will close and the system will pumpdown and shut off. The evaporator fans will continue to run based on fan stir cycle parameter. The LED will alternately display oFF and BOX TEMPERATURE.
When the room sensor detects a rise in temperature of approximately 2°F, and the system has been off for at least 4 minutes, the EEV will open to its last position and the system will start. The valve is then adjusted as necessary to obtain the setpoint superheat setting. During this time, the system will run for a minimum 2 minutes “hold-on” cycle.
The four minute “HOLD-OFF” can be bypassed and the system started immediately by pressing the “RESET” button on the Heatcraft Quick Response Controller board.
Operating Mode Display
oFF - Off
Coo - Cooling Pdn - Pumpdown dEF - Defrost drn - Draining dLY - Delay tSt - Test SEr - Service
IMPORTANT NOTE:
When a board is installed and power is applied to the system, the following initialization steps should be taken for EACH BOARD in system:
1. Press and Hold the "ENTER" button
2. While continuing to hold the "ENTER" button, press and hold the "CLEAR/TEST" button. "888" will display on the LED display.
3. Continue to hold both "ENTER" and "CLEAR/TEST" until "EE?" displays on the LED.
4. Once "EE?" displays, immediately release and the press the "ENTER" again.
5. The board will now re-initialize and return to the normal display.
If "nch" is displayed, then the board did not properly initialize and the steps 1-5 should be re-taken.
8
Programming & Reviewing
Programming And Reviewing Settings/Changes
The PROGRAM REVIEW button is used to program, review and change all program settings for the system.
Press “PROGRAM REVIEW” button. The setpoint item will appear on the LED. After a few seconds delay, the Setpoint value will display. Each time the button is pressed a different setpoint item is displayed.
Next, use the “SELECT” knob to change value of setpoint item.
“PROGRAM REVIEW” ITEMS
A-E - Set Defrost type
(Air or ELE)
rEF - Set Refrigerant type (R-22, R-404A, R-507, R-407A, R-407C, R-407F, R-448A or R-449A)
bot - Set Box temperature (-30°F to +70°F)
SUP - Set Superheat (4°F to 20°F)
SLA - Set Board as a Slave (Yes or No)
Next, when the desired value is selected, press the “ENTER” button to place it in program memory. If the “ENTER” button is not pressed, the value will not be stored in the memory and thus will not be changed.
ddF - Demand defrost enable (Yes or No)
dFn - Set Number of defrosts per day (1, 2, 3, 4, 5, 6, 8,10 or 12 per day)
dFF - Set Defrost Fail-safe time (10 to 200 minutes)
dFt - Set Defrost End temperature (40°F to 100°F)
dFS - Set Defrost Delay Start Time (0.5 Hours to 23.5 Hours)
ALH - Set Alarm High temperature (-40°F to 90°F)
ALL - Set Alarm Low temperature (-40°F to 90°F)
ALt - Set Alarm time (2 to 120 minutes)
F-C - Set Fahrenheit / Celsius temperature units (°F/°C)
FnS - Off cycle fan stir cycle enable (On or OFF)
9
Programming & Reviewing
Programming And Reviewing Settings/Changes (cont’d.)
Use the “PROGRAM REVIEW” button to select these items:
• Defrost Type – “A-E” - Selection is made for air
defrost or electric defrost coil. This will automatically set the system factory defaults for air defrost and electric defrost. (See default settings.)
• Refrigerant Type - “rEF” - Selection for type of refrigerant
R-22 (22), R-404A (404), R-507 (507), R-407A (47A), R-407C (47C), R-407F (47F), R448A (48A), R449A (49A).
• Box Temperature - “bot” - Select box temperature
setpoint. Selection range is -30°F to +70° F. Defaults: Electric defrost -10°F and air defrost +35°F.
• Superheat - “SUP” - Evaporator superheat is controlled by
the board on each evaporator. Each board measures the evaporator saturation suction temperature and the suction pressure to determine the superheat. The superheat value at the evaporator can be changed to ensure a 20°F to 30°F superheat at the Compressor. Default: 7°F.
• Evaporator Board: Slave? - “SLA” - On multiple evaporator
systems, each evaporator board has to be programmed to be a Master or a Slave. Each board is shipped from our factory set as a Master. You must make this change to each Slave evaporator. A selection of “YES” is made for this setting.
• Defrost fail-safe - “dFF” - This is the maximum time allowed
for a coil to remain in defrost. Defrost will be terminated if the defrost end temperature is not attained when this time has expired. On multiple evaporator systems, this is controlled by the Master unit. Each board should have the same setting. Defaults: electric defrost 30 minutes and air defrost 40 minutes.
• Defrost End Temperature - “dFt” - This is the temperature
at which the defrost will be terminated. Defaults: electric defrost +60°F and air Defrost +45°F.
• Defrost Delay Start Time - “dFS” - This allows the delay of
the start of the first defrost. Default: 0.0 hours.
• Alarm High Temperature - “ALH” - Temperature at which a
high box temperature alarm will be triggered. This does not apply during defrost. Defaults: electric defrost +5°F and air defrost +50°F.
• Alarm Low Temperature - “ALL” - Temperature at which a Low Box Temperature alarm will be triggered. Defaults: Electric Defrost -15°F and Air Defrost +30°F.
• Alarm Time - “ALt” - Time which High Temperature or
Low Temperature condition must exceed before alarm is triggered. Default: 60 minutes.
The default for each board is a Master, so on Single
Evaporator systems no change is required.
• Demand Defrost Enable –“ddF” – Demand defrost is
available for electric defrost systems only. Selection is made to enable demand defrost by a selection of “Yes” or to not enable demand defrost by a selection of “No”. If this parameter is enabled then parameters dFn and dFS will no longer be displayed in the menu as they are no longer used. Default: electric defrost Yes
• Number. of Defrost per Day - “dFn” - A selection must
be made for the number of defrosts cycles per day – 1,2,3,4,5,6,8,10 or 12 per day. If no selection is made, defaults: electric defrost 4 per day and air defrost 2 per day.
10
• °F/°C - “F-C” - Select units to display temperature.
Fahrenheit or Celsius. Default: Fahrenheit. When °C is selected, a red dot will appear in the right bottom corner of the LED display of the Heatcraft Quick Response Controller board.
• Off cycle fan stir cycle enable – “FnS” – This allows
evaporator fan stir cycling in the off cycle utilizing a fixed stir cycle timing of 7 minutes on and 5 minutes off. Selection is made to enable off cycle stir cycling by a selection of “On” or to not enable off cycle stir cycling by a selection of “Off”. Defaults: electric defrost off and air defrost off
Programming & Reviewing
MONITOR
Use the “MONITOR” button to review these items:
SUP - Superheat (°F/°C)
Use this button to “FORCE DEFROST”. To force a defrost, press the “FORCE DEFROST” button. The system will pumpdown. The heaters are then turned on. The display will show “dEF” and room temp.
FORCE
DEFROST
ESP - Expansion valve steps
(0 to 255 steps)
SCt - Suction temperature (°F/°C)
SSt - Saturated Suction temperature (°F/°C)
SCP - Suction pressure at Evaporator (PSIG/HG)
Odt - Outdoor temperature (°F/°C)
dFt - Defrost sensor temperature (°F/°C)
dFS - Time left until next defrost (hours) (on version 1.8 boards)
dFE - Last Defrost Elapsed time (minutes)
AC - Board Voltage
SPt - Spare Temperature reading
Use this button to “RESET TIME”. Pressing this button will reset the time clock in the microprocessor to zero. At initial power up, pressing this button will bypass the “four minute” hold-off and the system will start immediately after the expansion valve opens. This display will show “dLy”.
RESET
TIME
Use this button to “FORCE SERVICE”. Pressing this button TWICE will cause the system to pumpdown. The system will remain off until the “CLEAR” button is pressed. While in the “FORCE SERVICE”, the LED display will only show “SEr”.
FORCE
SERVICE
rEL - Software release program
11
Programming & Reviewing
Programming And Reviewing Settings/
Controller Board
Changes (Cont’d.)
Use this button to “CLEAR/TEST”. Pressing this button ONCE will return the LED display to the default display. With the system in the OFF mode, pressing and holding this button will start the “TEST” mode. In the “TEST” mode, it will cycle through each output for 10 seconds. The display will only show “tst” during “TEST” mode. Test mode will automatically terminate after 3 sequences.
Locking The Heatcraft Quick Response
The Heatcraft Quick Response Controller board is lockable to prevent programmed setting changes by unauthorized personnel. When locked, the program setpoints cannot be changed. To lock the setting:
• Press “PROGRAM REVIEW” button.
• Press and hold “MONITOR” button.
• While holding “MONITOR” button, press “ENTER” button.
• The LED will display Loc.
This will prevent unauthorized personnel program changes. To
unlock, repeat steps above. LED will display “UnL”.
STATUS INDICATOR LED
A RED, three-digit , alphanumeric LED on the Heatcraft Quick Response Controller board indicates status, alarms and error codes.
• OFF Box Temp / oFF Box Temperature/ Mode is displayed All Evaporators
• COOLING
Single Evaporator- Box Temp /Coo Box Temperature/ Mode is displayed Multiple Evaporators Master Evap - Box Temp / Coo Box Temperature/ Mode is displayed Slave Evaps - Coo Operating Mode is displayed
• Pumpdown
All Evaporators Pdn
• DEFROST
All Evaporators dEF
• TEST All Evaporators tSt
• SERVICE
All Evaporators SEr
• ALARMS A 1 High Box Temp A 2 Low Box temp
A 4 Input Fault
Box Temp., Suction Temp., Pressure Transducer open or not installed
12
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