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Frick Quantum LX Evaporator Operating instructions

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OPERATION – SERVICE
(SESSION LEVEL 2)
FRICK QUANTUM™ LX
EVAPORATOR
CONTROL PANEL
VERSION 3.0x
Form 090-612 O (APRIL 2009)
File: SERVICE MANUAL - SECTION 90
Replaces: S90-612 O (MAR 08)
Dist: 3, 3a, 3b, 3c
OPERATION - SERVICE
090-612 O (APR 09)
Page 2
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
Table of Contents
SETUP DESCRIPTION............................................................................................................................................ 5
Wiring ............................................................................................................................................................... 5
Configuration .................................................................................................................................................... 5
Operation.......................................................................................................................................................... 5
IDENTIFYING AN EVAPORATOR SYSTEM ............................................................................................................. 5
The Operator Interface Panel............................................................................................................................ 5
The Remote I/O Panel....................................................................................................................................... 5
EVAPORATOR SYSTEM CONFIGURATIONS .......................................................................................................... 6
EVAPORATOR SYSTEM COMMUNICATIONS WIRING DIAGRAM............................................................................ 7
SYSTEM INSTALLATION....................................................................................................................................... 8
WIRING FOR AC POWER ...................................................................................................................................... 9
Interface Panel .................................................................................................................................................. 9
Remote Panel(s)................................................................................................................................................ 9
CHECKING THE AC POWER ................................................................................................................................ 10
Interface Panel................................................................................................................................................ 10
Remote Panel(s).............................................................................................................................................. 10
WIRING FOR COMMUNICATIONS ........................................................................................................................11
Interface Panel.................................................................................................................................................11
Wiring for 1 to 5 Remote Panels................................................................................................................11
Wiring for 6 to 10 Remote Panels..............................................................................................................11
Remote Panel(s).............................................................................................................................................. 12
ZONE CONFIGURATION CHART.......................................................................................................................... 13
COMM. 4......................................................................................................................................................... 13
COMM. 3......................................................................................................................................................... 13
INITIAL STARTUP AND LOGIN ............................................................................................................................ 14
VERIFYING COMMUNICATIONS .......................................................................................................................... 15
ZONE CONFIGURATION...................................................................................................................................... 16
Global Zone Configuration............................................................................................................................... 16
Current Zone Configuration............................................................................................................................. 17
CALIBRATING SENSORS ..................................................................................................................................... 17
ESTABLISHING SETPOINTS................................................................................................................................. 17
Cooling Setpoints............................................................................................................................................ 17
Defrost Setpoints ............................................................................................................................................ 18
THE MODE SCREEN............................................................................................................................................ 18
THE HOME SCREEN............................................................................................................................................ 18
ALARMS............................................................................................................................................................. 19
ZONE OVERVIEW SCREEN.................................................................................................................................. 19
TROUBLESHOOTING .......................................................................................................................................... 21
Operator Interface Panel................................................................................................................................. 21
Remote Panels ................................................................................................................................................ 21
TYPICAL SYSTEM CONFIGURATION ................................................................................................................... 22
CONNECTING A COMPUTER DIRECTLY TO A QUANTUM™ LX CONTROL PANEL ................................................ 22
OVERVIEW OF OPERATOR INTERFACES ............................................................................................................ 23
OPERATOR ACCESS........................................................................................................................................... 23
To Change Setpoints....................................................................................................................................... 23
090-612 O (APR 09)
Page 3
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
Keys And Key Functions ..................................................................................................................................24
Menu Structure ............................................................................................................................................... 25
GRAPHIC SCREENS .............................................................................................................................................26
OPERATING STATUS ....................................................................................................................................26
Operational Status Box ............................................................................................................................. 26
Evaporator I/O Status Box......................................................................................................................... 27
ZONE OVERVIEW OPERATING STATUS ........................................................................................................28
USER DEFINED OPERATING STAUS SCREEN .................................................................................................29
MODE SETUP SCREEN ..................................................................................................................................30
SAFETIES
Current Safeties........................................................................................................................................ 31
Safety History ........................................................................................................................................... 32
SYSTEM STATUS
Trending
Trending Setup................................................................................................................................... 33
Real Time Trending ............................................................................................................................34
History Trending................................................................................................................................. 35
Real Time Data Log ............................................................................................................................ 36
History Data Log................................................................................................................................. 37
SETPOINTS
Cooling ..................................................................................................................................................... 38
Heating .....................................................................................................................................................40
Heating Timers ......................................................................................................................................... 41
Mode Schedule .........................................................................................................................................42
Defrost Setpoints......................................................................................................................................43
Defrost Schedule ......................................................................................................................................44
Safety Setpoints........................................................................................................................................45
PID Setup..................................................................................................................................................46
Auxiliaries
Analog Input Safeties – Page 1...........................................................................................................48
Analog Input Safeties – Page 2...........................................................................................................49
Digital Input Configuration..................................................................................................................50
Digital Output Configuration ............................................................................................................... 51
Panel......................................................................................................................................................... 52
CALIBRATION
Analog Inputs............................................................................................................................................ 53
Analog Inputs............................................................................................................................................ 53
Analog Output Calibration......................................................................................................................... 54
Auxiliaries – Page 1 .................................................................................................................................. 55
Auxiliaries – Page 2 .................................................................................................................................. 56
CONFIGURATION
Global Zone Configuration ........................................................................................................................ 57
Current Zone Configuration ...................................................................................................................... 58
Defrost Group Setup ................................................................................................................................. 59
Temperature Configuration.......................................................................................................................60
Communications ....................................................................................................................................... 61
Ethernet.................................................................................................................................................... 63
Security..................................................................................................................................................... 65
SESSION.......................................................................................................................................................66
SERVICE
Communications Log................................................................................................................................. 67
Communications Loop Back Test ..............................................................................................................68
090-612 O (APR 09)
Page 4
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
Diagnostics ............................................................................................................................................... 69
Software Maintenance.............................................................................................................................. 70
ABOUT SCREEN ........................................................................................................................................... 72
MISCELLANEOUS SCREENS.......................................................................................................................... 73
Alpha ........................................................................................................................................................ 73
ALARMS/SHUTDOWNS MESSAGES .................................................................................................................... 74
INDEX.................................................................................................................................................................... 75
Warning
The Quantum™ has the capability of being modified by the user/owner in order to obtain different performance
characteristics. Any modification to the standard default settings may have a severe negative impact on the operation and
performance of the equipment. Any modification to these control settings is the sole responsibility of the user/owner and
Johnson Controls disclaims any liability for the consequences of these modifications. It is possible that the modification of
these settings may cause improper operation and performance that results in property damage, personal injury or death. It is
the responsibility of the user/owner to evaluate and assess the consequences of their actions prior to modifying the controls
for this unit.
090-612 O (APR 09)
Page 5
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
SETUP DESCRIPTION
The following Setup Guide is meant to assist the
installation technician in making all necessary
electrical power, control and communications
connections to a Quantum™ LX Evaporator system.
They will be provided also with the basic information
necessary to login and configure the system. It will
then aid in troubleshooting the system should
problems arise. This Guide will help to ensure:
WIRING
Location of incoming AC source power
to all panels (Interface and Remote)
Basic installation guidelines are
followed.
Location, polarity and grounding of
communications wiring.
Location of all control (I/O) wiring.
Proper powering up of all panels.
CONFIGURATION
Logging into the system.
Verifying communications.
Configuring the Zones.
Calibrating sensors.
Setting up operating Setpoints.
OPERATION
Setting the operating Mode.
Verifying the data being returned to the
Interface panel from all remote panels
(Zones).
Checking and clearing of alarms.
Zone overview
Ammonia Configuration
IDENTIFYING AN EVAPORATOR SYSTEM
A minimum Evaporator system will include one
Operator Interface Panel and one Remote I/O
Panel.
THE OPERATOR INTERFACE PANEL
Each complete Evaporator system will have a
single Operator Interface Panel, as shown
below:
The Operator Interface Panel (we will call it
the Interface Panel throughout the rest of
this guide) is the central point of the system,
whereby all Remote Zone Interface Panels
are attached. It can easily be identified by
the presence of a display screen and a
keypad. The Interface Panel monitors and
controls all of the Remote panels that are
attached to it, through RS-485 serial
communications (to be explained later).
The Interface Panel runs the actual program
that provides the control for the entire
system. Through communications, it
monitors the status of each attached Remote
Zone Interface Panel, and provides the
necessary control instructions for each
Remote Zone Interface Panel to perform.
Additionally, all setpoints are stored in the
Interface Panel.
Status of the entire system may be
monitored form here, and appropriate
changes made to system operation.
THE REMOTE I/O PANEL
Each complete Evaporator system will have
from one to ten Remote I/O Panels, and
each panel is capable of controlling up to 3
Evaporator zones:
Notice that there is a yellow sticker on the
front of the door for each Remote I/O Panel.
This sticker will identify the Remote Panel
number and the Zones it will control. This
will all be explained in greater detail later,
but it is an important fact to note.
The Remote Panels do not have a display or
keypad. Each Remote Panel can control
three independent Zones. Each Quantum™
LX Evaporator system can manage up to 10
Remote I/O Panels, providing the ability to
control as many as 30 Evaporator zones.
Quantum LX Evaporator
Remote Panel Number: ___________
Zone: ___________
Zone: ___________
Zone: ___________
090-612 O (APR 09)
Page 6
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
EVAPORATOR SYSTEM CONFIGURATIONS
As stated before, each complete Evaporator system
will consist of one Interface Panel, and can at least
one Remote I/O Panels Each Remote Panel can
control up to three zones.
See the example below of a minimum system:
A maximum configured system still consists of only
one Operator Interface Panel, however there can be
up to ten Remote Panels in a single system.
Remember that each Remote Panel can control up to
three zones each. See the example below of a
maximum system (a more detailed pictorial can be
found later in this manual):
Zone
Multiple Evaporator systems may be interconnected
via a common Ethernet connection. Each Evaporator
system operates independently of one another yet
they may all be monitored and controlled through a
common computer. Such a system would include the
Quantum™ LX Evaporator Interface Panel, Remote
Zone Controller(s), an Ethernet Hub or Switch, and a
computer running a Web Browser. A simplified
example of such a system (with three Evaporator
systems) is shown here:
Communications from
Comm. 4 (PL14)
on Quantum board
Communications from
Comm. 3 (PL6)
on Quantum board
Remote
I/O
Panel
#6
Remote
I/O
Panel
#7
Remote
I/O
Panel
#8
Remote
I/O
Panel
#9
Remote
I/O
Panel
#10
Zone 16
Zone 17
Zone 18
Zone 19
Zone 20
Zone 21
Zone 22
Zone 23
Zone 24
Zone 25
Zone 26
Zone 27
Zone 28
Zone 29
Zone 30
Interface
Panel
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 7
Zone 8
Zone 9
Zone 10
Zone 11
Zone 12
Zone 13
Zone 14
Zone 15
Remote
I/O
Panel
#1
Remote
I/O
Panel
#2
Remote
I/O
Panel
#3
Remote
I/O
Panel
#4
Remote
I/O
Panel
#5
Remote
I/O
Panel
Interface
Panel
Interface
Panel
Remote
I/O
Panel
#1
Interface
Panel
Remote
I/O
Panel
#2
Computer or
HMI
Ethernet Hub or
Switch
Remote
I/O
Panel
#1
Remote
I/O
Panel
#2
Remote
I/O
Panel
#3
Remote
I/O
Panel
#4
Interface
Panel
Zone 1
Zone 2 (optional)
Zone 3 (optional)
Remote
I/O
Panel
Communications from
Comm. 4 (PL14)
on Quantum board
090-612 O (APR 09)
Page 7
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
EVAPORATOR SYSTEM COMMUNICATIONS WIRING DIAGRAM
Shield
Termination
Twist
Shield
Wires
Together
Twist
Shield
Wires
Together
Operator
Interface
Panel
EVAPORATOR PANEL #1
123456
123456
12345678
DIPSWITCH
Settings
ZONES 1, 2, 3
Analog Board 1
Digital Board 1
Digital Board 6 (opt)
EVAPORATOR PANEL #2
123456
123456
12345678
DIPSWITCH
Settings
ZONES 4, 5, 6
Analog Board 2
Digital Board 2
Digital Board 7 (opt)
EVAPORATOR PANEL #3
123456
123456
12345678
DIPSWITCH
Settings
ZONES 7, 8, 9
Analog Board 3
Digital Board 3
Digital Board 8 (opt)
EVAPORATOR PANEL #4
123456
123456
12345678
DIPSWITCH
Settings
ZONES 10, 11, 12
Analog Board 4
Digital Board 4
Digital Board 9 (opt)
EVAPORATOR PANEL #5
123456
123456
12345678
DIPSWITCH
Settings
ZONES 13, 14, 15
Analog Board 5
Digital Board 5
Digital Board 10 (opt)
EVAPORATOR PANEL #6
123456
123456
12345678
DIPSWITCH
Settings
ZONES 16, 17, 18
Analog Board 1
Digital Board 1
Digital Board 6 (opt)
EVAPORATOR PANEL #7
123456
123456
12345678
DIPSWITCH
Settings
ZONES 19, 20, 21
Analog Board 2
Digital Board 2
Digital Board 7 (opt)
EVAPORATOR PANEL #8
123456
123456
12345678
DIPSWITCH
Settings
ZONES 22, 23, 24
Analog Board 3
Digital Board 3
Digital Board 8 (opt)
EVAPORATOR PANEL #9
123456
123456
12345678
DIPSWITCH
Settings
ZONES 25, 26, 27
Analog Board 4
Digital Board 4
Digital Board 9 (opt)
EVAPORATOR PANEL #10
123456
123456
12345678
DIPSWITCH
Settings
ZONES 28, 29, 30
Analog Board 5
Digital Board 5
Digital Board 10 (opt)
Note: For the
DIPSWITCH settings
shown below, a
shaded box
indicates a closed
or ON position, an
unshaded box
indicates an open
or OFF position.
= OFF
=
ON
Shield
Termination
Twist
Shield
Wires
Together
Twist
Shield
Wires
Together
Shield Wire
Not Connected
COMM. 4 Cable Run COMM. 3 Cable Run
Shield Wire
Not Connected
090-612 O (APR 09)
Page 8
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
SYSTEM INSTALLATION
An in depth installation setup is beyond the scope of
this guide, however some basic rules can be
observed:
▯ Pay particular attention to the yellow sticker
on the front of each Remote I/O Panel. It will
have been filled in at the factory, as to which
panel will control which zone. This is a
close-up of the sticker:
▯ Maintain a total distance of 2000 feet or less
between the Operator Interface Panel, and
the very last Remote I/O Panel on any one
communications cable run. As will be
explained later, it is possible to have two
separate communications cable runs,
depending upon the total number of Remote
I/O Panels. Keep in mind that neither of
these cable runs can exceed 2000 feet in
length.
▯ Remote I/O Panels should be mounted in
close proximity to the zones that they will be
controlling. In some instances, there may be
fan motor starters located in a separate area
from the zone, so it may be more convenient
to locate the Remote I/O Panels near the
starters, than the actual Evaporator unit. The
idea is to minimize the length of the control
wiring, so if there is less wiring to the zone
than to the starters, then install close to the
starters or vice-versa.
▯ The system is capable of Ethernet
communications, this may be something to
consider when placing Interface Panels, as
you would want a nearby Ethernet
connection to be available.
▯ Keep all communications wiring in a separate
conduit from control wiring.
▯ When wiring for communications, it is
important to ground only one end of the
communications cable. This ground will be
located in the very last Remote Panel of
each communications cable run. If the
communications were to be grounded at
both ends, then it would be possible for
ground loops to develop, which could impair
communications between panels.
▯ Interface Panels should be located in easy
access areas, and should be mounted at eye
level for screen viewing.
▯ Remote Panels are rated for both indoor
and outdoor use. Although access to the
Remote Panels will be rare after installation
and setup, it is still advantageous to keep
them accessible for potential maintenance
situations (reasonable lighting, sufficient
door swing, etc.).
▯ Install all panels within a convenient distance
of a power source.
▯ Refer to the Zone Configuration Chart for
additional information
Quantum LX Evaporator
Remote Panel Number: ___________
Zone: ___________
Zone: ___________
Zone: ___________
090-612 O (APR 09)
Page 9
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
WIRING FOR AC POWER
Interface Panel
The incoming AC power will consist of three 14
AWG wires (hot, neutral and ground).
▯ Unlatch the two ¼ turn cover latches to
the Interface panel, and open the door.
▯ Inside the enclosure, you will find a
power supply and a terminal strip, as
shown here:
Connect the three incoming AC wires to
the terminal screws as shown
previously.
Proceed to the section entitled
Checking
the AC Power
.
Remote Panel(s)
As with the Interface panel, the incoming AC
power will consist of three 14 AWG wires (hot,
neutral and ground).
▯ Unlatch the two ¼ turn cover latches to
the Interface panel, and open the door.
▯ Inside the enclosure, you will find a long
DIN rail at the left side of the panel. At
the top of the DIN rail is a terminal strip
(if the unit is equipped with an optional
panel heater, there will also be a circuit
breaker), as shown here:
▯ Connect the three incoming AC wires to
the terminal screws shown above.
▯ Notice that there are multiple number 2
terminals, connection may be made to
any of them.
▯ Proceed to the section entitled
Checking
the AC Power
.
Hot Neutral Ground
Ground
Hot
Neutral
090-612 O (APR 09)
Page 10
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
CHECKING THE AC POWER
Interface Panel
▯ Ensure that the Control Power switch is in
the OFF position.
▯ Energize the 120 Volt circuit at its source.
▯ Using a DVM, measure the voltage at the AC
power terminal strip. Ensure that you read
approximately 120 VAC between Hot and
Neutral, and Hot and Ground. There must not
be voltage between Neutral and Ground.
▯ Once the incoming voltage has been
verified, turn the Control Power switch to
ON.
▯ On the enclosure door, and watch the
Quantum™ LX controller (on the backside of
the door). You should notice various LED’s
blinking or flashing.
▯ Watch the display on the front of the door.
After a short period of time, you should
notice the display showing a boot sequence.
Various text messages will be shown as it
proceeds with the boot-up process. When
finished, a screen similar to the following
image should be visible:
▯ If the panel has reached the point of showing
the above screen, the boot process was
successful. Turn OFF the Control Power
switch, and De-energize the 120 Volt circuit
at its source.
▯ If the panel does not reach to the point of
showing the above screen, then
troubleshooting will be required. Refer to
end of this guide entitled
Troubleshooting
.
Remote Panel(s)
▯ Unlike the Interface Panel, the Remote
panels do not have an external power
switch. Instead, the enclosure will contain
two HOA (Hand-Off Automatic Modules).
These modules allow the technician to
override control signals, by manually
energizing components. An example of one
of these modules is shown here:
▯ Notice in the above pictorial, there is a Red
power OFF tab, and a black power ON
plunger. These items are located on a circuit
breaker for each of the two HOA modules.
Together, they act as the Control Power
switch.
▯ Push each of the Red power OFF tabs down.
The Black power ON plunger should pop up.
If the plunger does not pop up, then the
power was already off. Do this to both HOA
modules.
▯ Energize the 120 Volt circuit at its source.
▯ Using a DVM, measure the voltage at the AC
power terminals (1, 2 and PE). Ensure that
you read approximately 120 VAC between
Hot and Neutral, and Hot and Ground. There
must not be voltage between Neutral and
Ground.
▯ Once the incoming voltage has been
verified, push in the Black power ON
plungers of both HOA modules.
▯ To the right of the HOA modules are several
I/O boards. There will be at least one Digital
board (recognizable by the plug-in I/O
modules), and one Analog board. Inspect all
boards for the presence of flashing, blinking
or steadily lit LED’s. If LED’s are lit on all
boards, then power has been properly
applied.
▯ If LED’s are not lit on all boards, then refer
to the section entitled
Troubleshooting
.
Red, power
OFF tab
Black, power
ON plunger
090-612 O (APR 09)
Page 11
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
WIRING FOR COMMUNICATIONS
NOTE: Refer to the next sections entitled ZONE
CONFIGURATION CHART and EVAPORATOR SYSTEM
COMMUNICATIONS WIRING DIAGRAM, for additional
information about how the system is configured.
Interface Panel
Depending upon the number of Remote Panels
that have been installed, there could be up to
two different communications cables run to the
Interface Panel. One of these cables would feed
Remote I/O Panels 1 through 5, and a second
cable would feed Panels 6 through 10. The
incoming RS-485 communications cable(s) will be
a two-conductor, shielded type. Frick Controls
recommends the use of Belden #9841 or equal.
Wiring for 1 to 5 Remote Panels
For systems that have between 1 and 5
Remote Panels, use the following wiring
procedure:
▯ Open the panel door.
▯ On the inside of the enclosure door,
you will find the Quantum™ LX
controller, and a three position
terminal block, as shown here:
Notice that there are two wires that connect
from the left side of the terminal block, to
the Quantum™ LX at PL14 (Comm. 4). These
are the internal TX / RX communications
wires. You will be connecting the external
field communications wires to the other
(right) side of these terminals.
▯ Take the end of the incoming
communications cable, and strip
about 2 inches of insulation from
the end.
▯ Clip the shield wire back even with
the insulation, and either use heat
shrink tubing to cover the area, or
electrical tape. This will help to
ensure that any strands of the
shield that may be exposed don’t
come into contact with any live
voltage areas of the panel.
▯ Strip the end of each of the two
remaining conductors back about ¼
of an inch. Generally there are only
three color combinations available
depending on the type of cable
used. There will be either a black
and white/clear insulated wire, a
red and white/clear insulated wire,
or a red and black. Either way, one
of the wires should be black. Take
the black wire and insert it into the
top position of the terminal block
(labeled as –TX/RX).
▯ Take the remaining wire
(white/clear or red) and insert it
into the second position down from
the top of the terminal block
(labeled as +TX/RX).
▯ It is very important that the colors
of these wires follow this same
polarity scheme throughout the
daisy-chaining process to all panels.
▯ Refer to the Zone Configuration
Chart later in this guide to verify
dipswitch settings.
Wiring for 6 to 10 Remote Panels
NOTE: There are some earlier designed
systems that will not have the following
converter module. If you are planning to
expand an Evaporator system to 6 or more
Remote Panels, and you find that you DO
NOT have the module listed below, please
contact the Frick factory for instructions.
For systems that have Remote I/O Panels 6
through 10, use the following wiring
procedure:
▯ Open the panel door.
▯ Follow the same guidelines for
insulation and wire stripping as
described earlier.
▯ There is a DIN rail mounted below
the incoming power strip. On the
DIN rail is mounted a RS-232 to RS-
485 communications converter
Comm. 4 Location
+TX/RX
-TX/RX
N/C
090-612 O (APR 09)
Page 12
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
module (Comm. 3), and a power
supply. Both of these components
have been pre-wired at the factory.
All that is left to do is connect the
field connections. Refer to the
following pictorial for connections:
▯ Insert the black wire into the top of
the module in terminal position 4,
and the white/clear or red wire into
position 6, as shown above.
▯ This should complete the Interface
Panel communications wiring.
▯ Refer to the Zone Configuration
Chart later in this guide to verify
dipswitch settings.
Remote Panel(s)
Follow the same description for wire stripping as
with the Interface Panel, with the exception that
the shield wire does NOT get trimmed off.
▯ On Evaporator systems with only one
Remote Panel, the only communications
cable that you will have is that which
comes directly from the Interface Panel.
▯ Insert the stripped end of the black wire
into the terminal marked TX/RX-, and
the white/clear or red stripped wire into
the terminal marked TX/RX+, and the
shield wire into the Ground terminal as
shown (the Ground terminals may be
identified by their Green/Yellow color).
▯ On Evaporator systems with more than
one Remote panel, the first Remote
panel will have two communications
cables; the first will be from the
Interface Panel, and the second will be
going to the next remote panel.
Functionally, it does not matter which
cable is which, as long as the polarity of
both is observed. NOTE: It would be a
good idea at this time however to label
each of the two cables as to where they
are going for future maintenance /
troubleshooting use (refer to the yellow
sticker on the front of each Remote
Panel for the panel numbers).
▯ Insert the black stripped wires from both
cables to the TX/RX-, and the
white/clear or red stripped wires into
the terminal marked TX/RX+. Both
shield wires should be twisted together,
and then taped to prevent them from
touching any live surfaces. The shield
wires DO NOT get connected to any
terminals.
▯ Follow this procedure for all Remote
Panels, except for the very last one.
This panel will have only one
communications cable (label it also),
which will be coming from the previous
panel. The connections for this cable are
the same as that for a single Remote
Panel, that is, the shield wire must be
attached to one of the Ground
terminals.
▯ NOTE: Only the last Remote Panel
should have the shield wire grounded
(terminated).
TX/RX-
TX/RX+
Shield
TX/RX+ TX/RX-
Comm. 3 Location
090-612 O (APR 09)
Page 13
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
ZONE CONFIGURATION CHART
The following table is to be used to set the System
configuration. The following page then shows a
pictorial representation of how this chart applies to a
full system. The columns indicate:
INTERFACE COMMUNICATIONS PORT
COMM. 4 (PL14) – This is an RS-485
serial port physically located on the
Quantum™ LX controller (within the
Operator Interface Panel). This signal
can directly feed all attached Remote
Panels (up to 2000 feet total distance).
This port provides communications to
the digital and analog boards within
Remote Panels 1 through 5 (zones 1
through 15)
COMM. 3 (PL6) – This is an RS-232
serial port physically located on the
Quantum™ LX controller (within the
Operator Interface Panel). This signal
requires conversion to RS-485 to meet
the distance requirements of the
system, so a converter module has been
installed to provide this conversion
(provides up to 2000 feet total
distance). This port provides
communications to the digital and
analog boards within Remote Panels 6
through 10 (zones 16 through 30)
PANEL # - This number identifies each
Remote Panel as a discrete device, similar to
an address. Each Panel can control up to 3
zones.
ZONE # - This number identifies each
individual zone in the system. It is this value
that will appear on many of the Interface
Panel screens to describe the zone that is
being viewed
BOARD # - This lists the available analog
and digital boards within each zone.
DIPSWITCH # - This shows the settings of
how each dipswitch must be configured to
recognize the appropriate I/O board.
DIPSWITCH SETTINGS
INTERFACE
COMMUNICATIONS
PORT
PANEL
# ZONE # BOARD #’s SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
Analog Board 1 Off Off Off Off Off Off Off Off
Digital Board 1 On On On On Off On N/A
N/A
1 1, 2, 3
Digital Board 6 (opt.) Off On Off On Off On N/A
N/A
Analog Board 2 On Off Off Off Off Off Off Off
Digital Board 2 Off On On On Off On N/A
N/A
2 4, 5, 6
Digital Board 7 (opt.) On Off Off On Off On N/A
N/A
Analog Board 3 Off On Off Off Off Off Off Off
Digital Board 3 On Off On On Off On N/A
N/A
3 7, 8, 9
Digital Board 8 (opt.) Off Off Off On Off On N/A
N/A
Analog Board 4 On On Off Off Off Off Off Off
Digital Board 4 Off Off On On Off On N/A
N/A
4 10, 11, 12
Digital Board 9 (opt.) On On On Off Off On N/A
N/A
Analog Board 5 Off Off On Off Off Off Off Off
Digital Board 5 On On Off On Off On N/A
N/A
COMM. 4
(PL14)
5 13, 14, 15
Digital Board 10 (opt.)
Off On On Off Off On N/A
N/A
Analog Board 6 Off Off Off Off Off Off Off Off
Digital Board 11 On On On On Off On N/A
N/A
6 16, 17, 18
Digital Board 16 (opt.)
Off On Off On Off On N/A
N/A
Analog Board 7 On Off Off Off Off Off Off Off
Digital Board 12 Off On On On Off On N/A
N/A
7 19, 20, 21
Digital Board 17 (opt.)
On Off Off On Off On N/A
N/A
Analog Board 8 Off On Off Off Off Off Off Off
Digital Board 13 On Off On On Off On N/A
N/A
8 22, 23, 24
Digital Board 18 (opt.)
Off Off Off On Off On N/A
N/A
Analog Board 9 On On Off Off Off Off Off Off
Digital Board 14 Off Off On On Off On N/A
N/A
9 25, 26, 27
Digital Board 19 (opt.)
On On On Off Off On N/A
N/A
Analog Board 10 Off Off On Off Off Off Off Off
Digital Board 15 On On Off On Off On N/A
N/A
COMM. 3
(PL6)
10 28, 29, 30
Digital Board 20 (opt.)
Off On On Off Off On N/A
N/A
090-612 O (APR 09)
Page 14
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
INITIAL STARTUP AND LOGIN
To initiate the startup and login process, the Interface
Panel and each of the Remote Panels will need to be
powered up. It is assumed that the power has already
been verified in the
Checking The AC Power
section.
Once the Interface Panel has fully booted, the
following screen will appear:
This is the default screen, and will appear each time
power has been cycled.
From the above screen, press the [Menu] key .
The following drop down menu will appear:
Using the keypad up/down arrow keys , scroll
down to highlight Session, and press [Enter] .
The following screen will replace the
Operating
Screen
:
Change the User Level to [3], and enter a password of
[4824]. This sets the Level to 3, which allows access
to all features. Press [Submit] .
Select the [Menu] key again. This time, a more
expanded menu will appear:
From the above menu, select [Home] to return to the
Operating Status
screen.
At this point, the Interface Panel has been set to
allow access for the remainder of all procedures.
090-612 O (APR 09)
Page 15
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
VERIFYING COMMUNICATIONS
The first step in verifying communications is to view
what I/O boards have been detected by the Interface
Panel. This information will appear on the
About
screen, shown here:
Review the information that is shown in the Analog
and Digital Board areas of the screen. Compare what
is shown against what is actually installed.
NOTE: This screen does not update (refresh)
automatically. To see any new or different
information that may occur, you must access a
different screen, then come back to this one to
see any new data.
The analog board area of the screen can list up to the
ten possible analog boards that are allowed, and they
are listed in a single column. In the digital board area,
you will notice that there are two columns. The left
hand column represents Panels 1 through 5 (and
digital boards 1 – 10), and the right hand column
represents Panels 6 – 10 (and Digital boards 1 - 10).
Refer to the
Zone Configuration Chart
and the
Evaporator System Communications Wiring Diagram
for clarification.
Compare what is displayed here with what is actually
installed in your system. If a board is physically
installed in a Remote Panel, yet does not show up on
this screen, then find the Panel that the board is
located in, and visually check the RX and TX LED’s on
the board. These LEDs should be flashing. The RX LED
will be flashing much faster than the TX LED, but
neither should be off completely, as this indicates a
potential wiring problem.
Start by verifying that the boards within Remote
Panel 1 are correctly being detected. Then move on
to the next panel, and so on, for each of the two
potential communications branches (Comm. 3 and
Comm. 4). If Remote Panel 1 shows correctly, but
there is a problem with Remote Panel 2, then do
nothing with the wiring up to and including Panel 1.
Inspect instead Panel 2 for proper communications
polarity and connections. A good indication that you
have wires backwards (reversed) would be that the
RX LED is on solid within the suspect panel. If wiring
WAS found to be incorrect, make the correction, and
then access the
Communications
screen by selecting
Configuration
from the Main Menu, then
Configuration, and finally
Communications
.
On the Communications screen shown above, ust the
[Tab] key to select
Redetect IO Comms
and press
[Enter] . This will cause the Quantum™ LX
controller to reinitiate all communications with the
system. After Redetecting IO Comms, wait about 30
seconds, then access the
About
screen once again. If
the wiring issue has been corrected, the questionable
I/O board should now be listed, and the RX/TX LED’s
for that board should be flashing normally.
If the boards for Remote Panel 2 are now properly
detected, then move on to Panel 3, etc.
When all installed boards have been detected, then
the basic setup is complete. You can now move on to
configuring the system operating parameters.
090-612 O (APR 09)
Page 16
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
ZONE CONFIGURATION
Zone Configuration is the process of setting the operating
parameters of each of the installed zones.
Global Zone Configuration – Use this screen to
enable or disable each independent zone. NOTE:
If a zone is installed, it MUST be enabled before it
can be setup and accessed. The screen also
allows you to custom name each zone.
Current Zone Configuration –Once the Global
Zone Configuration has been setup, use this
screen to setup the parameters for each of the
individual zones (1 -30).
Global Zone Configuration
Access this screen from the Main Menu. Select
Configuration
, then
Global Zone Configuration
. The
following screen will appear:
Each Evaporator zone that is in use should be set to
Enabled
. The Global Zone configuration screen also
provides the ability to supply a unique name for each
zone. After moving the cursor to one of the Name
fields, press the Up Arrow key to access an
alpha/numeric data entry screen, as shown here:
The
Alpha
screen shows a graphic representation of
the numerical keypad. The symbols that appear above
each key on this screen are the possible combinations
of symbols that are associated with the digital portion
of the key.
As an example, suppose that you wanted to modify
the text line in the screen example shown. You want
to change the line from reading
Auxiliary Analog 1
, to
Zone 1
. The first thing you would do, is to use the
[Backspace] key on the keypad to position the
cursor (blinking vertical line), to the far left side of the
text. Notice as the cursor backspaces, it erases the
current line of text.
Press the number [3] key (notice that the capital
Z
is
one of the symbols in the line right above the [3] key).
A capital
Y
will appear in the
Current Character
box.
Continue to press the [3] until the capital
Z
appears
there. Now press the [Up Arrow] key, and notice that
the
Z
has been placed on the text line in the first
position.
Next press the [6] key on the keypad, and continue
pressing it until the small
o
appears in the
Current
Character
box. Press the [Up Arrow] key to place the
o
on to the text line. Continue entering text until you
are satisfied with the changes that you have made,
press the [Enter] key to accept them, and you will be
returned to the previous screen. Once all zones
names have been entered, press the [Submit] key.
NOTE: If many fields need to be renamed, the
user can plug a standard computer keyboard (PS2
style plug) into the socket labeled PL7 of the
Quantum™ LX processor board. Refer to the
following pictorial:
090-612 O (APR 09)
Page 17
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
Current Zone Configuration
Access this screen from the Main Menu. Select
Configuration
, then
Current Zone Configuration
. The
following screen will appear:
Notice in the upper right hand corner of this screen is
a setpoint box that contains a value. You may change
the value in this box to the number of the zone that
you wish to configure. You must then press the
[Submit] button for the screen to display that zone. In
the above example, the number 1 is shown on the
box. Notice that right below the setpoint box, the
words
ZONE #1
is displayed, so Zone 1 is the zone
parameters that are being shown.
Many other screens also show the
Zone
selection box
in the upper right corner. Any screen that displays
this box presents data that pertains exclusively to the
selected zone. The selections on the
Current Zone
Configuration
page must be made for each
Evaporator zone that has been enabled on the
Global
Zone Configuration
page.
The
Current Zone Configuration
page permits the
user to enable any four control functions:
Cooling
Defrost
Dehumidification
Heating
The
Options
section allows the user to configure
various mechanical aspects of the system, which
include the type and operation of valves as well as
the fan type.
CALIBRATING SENSORS
Each temperature or humidity sensor in the Evaporator
should be calibrated before the system is put into
operation.
Access this screen from the Main Menu. Select
Calibration
, then
Analog Inputs
:
The process used for establishing calibration values is
relatively simple. It will however require a container
of ice water or an infrared digital temperature probe.
First, establish the temperature for a specific zone’s
temperature sensor. If a digital infrared measurement
device is used, simply enter the calibrated
temperature into the
Current Value
box and press
[Submit]. The system will automatically calculate the
correct
offset
value to use. If an ice bath is used,
simply allow the temperature of the sensor to
stabilize, and then enter 32 into the
Current Value
box and press [Submit]. This process should be
repeated for each sensor in the system.
ESTABLISHING SETPOINTS
Cooling Setpoints
Access this screen from the Main Menu. Select
Setpoints
, then
Cooling,
and finally
Mode (1-4)
:
090-612 O (APR 09)
Page 18
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
The four Cooling Mode screens allow each zone
to operate with four separate groups of
setpoints. This screen shows the setpoints
available for configuration based upon the
selecting mode on the
Current Zone
Configuration
page. Most importantly, the Liquid
On and Off temperatures should be set, as well
as the Fan On and Off temperatures. It is also
recommended to set the Alarm High and Low
temperatures for each Mode.
Defrost Setpoints
Access this screen from the Main Menu. Select
Setpoints
, then
Defrost,
and finally
Defrost
Setpoints
:
The Defrost Setpoints screen permits the user to
specify the duration of each defrost step.
Additionally, the Defrost Initiation should be set
for each zone. During the configuration process,
it is possible to start a defrost via the
Mode
Setup
screen (see next section). The
Next Stage
button on the Defrost Setpoints screen can then
be used to advance through the defrost in order
to validate valve operation.
THE MODE SCREEN
Access this screen from the Main Menu. Select
Modes
:
This screen is used to set each of the individual zones
as to which Mode (1-4) they will perform. As
described earlier, set the Zone number to the zone
you which to setup.
Zone Active / Off – This drop down menu must
be set to
Active
for the zone to be able to run.
Mode Control – Set this based upon whether you
would prefer
Manual
,
Mode Schedule
or
Digital
Input
operation. Allows the user to manually set
the active mode:
Manual - Allows the zone to follow
whichever Mode (1-4) setpoints have
been setup, based upon the Active
Mode.
Mode Schedule – The zone will follow
the Mode Schedule.
Active Mode – If
Mode Control
is set to
Manual
,
the user can set the active Evaporator mode.
A Defrost can be initiated at anytime be pressing the
[Start Defrost] button.
THE HOME SCREEN
This screen will appear each time the Interface Panel
has been powered up (default). It can also be
accessed from the main menu by selecting Home.
Many of the operating characteristics for each zone
can be viewed from here. The upper left hand corner
of the screen tells you which zone is currently being
viewed, and the zone setpoint box allows you to
enter the number of any other enabled zone that you
may wish to view.
The square grey box in the lower left hand corner will
contain a red blinking dot if any zone being viewed
has an active alarm condition, or a yellow blinking dot
if any zone has an active warning..
This screen will display basic alarm information for
the selected zone, as well as the current temperature
and zone setpoint. At the bottom of this screen, basic
status information is provided about valves and the
090-612 O (APR 09)
Page 19
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
fan. The
Defrost
box provides information when a
defrost is underway.
Refer to 090-612 O (Operation) for specific
information about each of the areas of this screen.
ALARMS
Access this screen from the Main Menu. Select
Safeties
, and then Current:
This screen shows any alarms or shutdowns that are
currently active for the zone selected. To view the
active alarms/shutdowns for another zone, simply
enter the number of the zone into the Zone setpoint
box in the upper right corner of the screen.
If an alarm is allowed to continue, a shutdown could
result. When a shutdown occurs in any zone, that
zone will be prevented from running until the
shutdown is corrected and cleared.
The alarms/shutdowns may be cleared for each zone
by tabbing to the [Clear Safeties] button in the upper
right corner, and press [Enter].
ZONE OVERVIEW SCREEN
Access this screen from the Main Menu. Select
Zone
Overview:
This screen permits the user to view the status of
each Evaporator zone, as well as the current
temperature. In the event that a zone has an active
warning, the temperature will be displayed in yellow,
and if the temperature text is displayed in red, that
zone is currently in shutdown. In either case, the
operator should consult the Safeties screen to
determine the nature of any alarms and resolve the
problem.
AMMONIA CONFIGURATION
The first step in configuring and calibration the
ammonia sensors, is to insure that all sensors are first
plugged in. Channels 4, 5 and 6 of each Remote I/O
Panel are pre-configured to accept three ammonia
sensors on analog inputs.
Access the following screen from the Main Menu;
Select
Calibration
, then
Ammonia Sensors
, and finally
Page 1 (or 2):
Use the above screen to calibrate each ammonia
input channel using an ammonia detector.
After calibrating all ammonia sensors, the alarm
thresholds need to be set. Access the following
screen from the Main Menu. Select
Configuration
,
then
Ammonia
, and finally
Page 1 (or 2):
Use the above page to set the warning and shutdown
ammonia levels for each ammonia sensor, as well as
090-612 O (APR 09)
Page 20
FRICK® QUANTUM™ LX EVAPORATOR CONTROL PANEL
OPERATION – SERVICE
the associated delays. Each sensor may also be given
an individual name from this page.
In order for a zone to properly display and act upon
alarms and shutdowns, the zone must have one or
more ammonia sensors assigned to it. To access this
screen, select
Menu
>
Setpoints
>
Safety
:
Up to four ammonia sensors may be mapped in the
system to any zone. These assignments must be
made to every zone.
Finally, there are four system wide alarm inputs that
can be configured. To access this configuration
screen, select
Menu
>
Configuration
>
Digital I/O:
At the bottom of this screen you can configure the
board and channel for the two system warning and
shutdown alarms. These will alert the user if ANY
zone has an active warning or shutdown. Additionally,
there are two ammonia warning and shutdown alarm
outputs which the board can be configured for. These
will alert the user if any zone has an active ammonia
warning or an active ammonia alarm. These can be
used for plant warnings that pertain to ammonia and
not standard shutdowns or warnings.
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