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CVHE-SB-32A 41

lnput/Output Module

Provided only when chiller is equipped with Hot Gas Bypass (HGBP) option.

The I/O module (1U10) operates the Hot Gas Bypass valve on CVHE and CVHF units in

response to signals from stepper module 1U3.

The module also receives input on HGBP valve position from the HGBP valve end switch.

Low Voltage (<30VAC) Inputs:

115 V HGBP valve drive signal

High Voltage (>30VAC) Inputs

10 V HGPB valve proof-of-closure signal from valve end switch

High Voltage (>30VAC) Outputs:

HGBP Open Triac

HGBP Close Triac

Figure 4

Input/Output Module

IP Communications

Hot Gas Bypass

Valve End Switch

Proof of Closure

Hot Gas Bypass Valve

24 VAC

Main Page

Table of Contents2
General Troubleshooting Index6
UCP2 Control Panel and Module Description9
Unit Control Panel9
UCP2 Control Panel and Module Description11
Chiller Module11
Circuit Module11
Stepper Module11
Starter Module11
Purge Module12
Local Clear Language Display12
Remote Clear Language Display Panel and Remote Clear Language Display Interface Module12
Options Module12
Module Setpoints Relating to the Options Module12
Tracer Communications Interface12
Printer Interface Module13
Secondary Printer Options13
Duplex Control Module (DCM)13
General Troubleshooting Information14
Problem 1: AFD (Adaptive Frequency Drive) Diagnostics14
Problem 2: Failure to Accelerate or DID Not Accelerate14
Problem 3: Approach Temperature Reads -40°F14
Problem 4: Auto X-Former Starter: Runs (3) Seconds and Trips. Unit will Not Transition14
Problem 5: IGV BPI Not Found or Low14
Problem 6: Bearing Temperatures 1 and 2 Locations15
Problem 7: Capacity Limited by High Current When the15
Problem 8: Current Overload15
Problem 9: Chiller Loss of Communication with Circuit Module and IGV Overdriving Close15
Problem 10: Check Clock (Lfw) Informational15
Clock Does Not Keep Time if There Is an Extended15
Power Loss (Greater than 15 Seconds)15
Problem 11: Chiller Loss of Communication with Starter and the IGV Calibrates16
Problem 12: Chiller Loss of Communication with Starter or Circuit Loss of Communication with Chiller Diagnostics16
Problem 13: Clear Language Display Won't Go into Demo Mode16
Problem 14: Communication Diagnostic; None or Degraded Communications16
Problem 15: Loss of Communication with Starter Diagnostics at Startup with no Inlet Guide Vane Action. Mode Is "Resetting" and Can Move through the Menus16
Problem 16: Loss of Communication or Intermittent17
Problem 17: no Communication, on a Power Up, Get18
Action in the IGV18
Problem 18: no Communication, on a Power Up, Get Message "No Communication, Data Not Valid" but the Inlet Guide Vane Calibrates18
Problem 19: Starter Loss of Communication with Chiller. no Other Diagnostic18
Problem 20: TCI Loss of Communication with Chiller18
Problem 21: High Compressor Discharge Temperature18
The Compressor Discharge Temperature Exceeded 200×F18
Problem 22: Cond. Pressure 2-10 VDC Output will Not Work19
Problem 23: Condenser Pressure Delta-Pressure Output Does Not Show up19
Problem 24: Cond. Refrig. Temp. Sensor Diagnostic19
Problem 25: Condenser and Evaporator Entering and Leaving Water Temps. Changing Rapidly and Reading In- Correctly, I.e. -25°F to 900×F19
Problem 26: Condenser Water Flow Lost Diagnostic. Unit will Not Restart until Manually Reset19
Problem 27: Capacity Limited by Current Limit19
Problem 28: Custom Menu - Unwanted Items that You DID Not Install and You Cannot Remove19
Problem 29: Display Is Locked Up. no Communication, Data Not Valid Diagnostic20
Problem 30: Display on the CLD Is Flashing20
Problem 31: External Chilled Water Setpoint Problems20
Problem 32: External Current Limit Setpoint Does Not Work21
Problem 33: Fault Relay Open on an AFD (Air Cooled Adaptive Frequency Drive)21
Problem: 34 Fault Relay Open on Solid State Starter (SSS)21
Problem 35: Free Cooling (FC) Operation Problems21
Problem 36: Evaporator Water Temperatures Are Reversed (2 Pass Units Only)22
Problem 37: Low Evaporator Refrigerant Temperature22
Problem 38: 2F1, 2F2 and 2F3 Fuses Blow - on 200-575 Volt Units When Switching the Starter Disconnect from OPEN to CLOSED22
Problem 39: Gpm/Tonnage Option Problems22
Problem 40: High Vacuum Lockout22
Problem 41: Hot Gas Bypass (HGBP) Does Not Work23
Problem 42: Ice Making23
Problem 43: IGV will Not Move in the Service Test Manual Mode24
Problem 44: IPC Buffer Diagnostics24
Problem 45: KW Reads High by a Factor of 3, with Optional PT Installed24
Problem 46: Loading Problems24
Problem 47: Memory Error25
Problem 48: Momentary Power Loss (MPL)25
Problem 49: Motor Winding Temperatures Changing Rapidly and Randomly26
Problem 50: Differential Oil Pressure Calibration Diag- Nostic Following Post Lube. Secondary Problem May be the Oil Pump will Not Shut off after Post Lube26
Problem 51: Differential Oil Pressure26
Problem 52: Oil Temperature High27
Problem 53: Oil Temperature Low (Startup)27
Problem 54: Low Oil Temperature (Running)27
Problem 55: Enhanced Oil Temperature Function Not Working27
Problem 57: Over/Under Voltage Diagnostic on Startup28
Problem 58: Phase Loss28
Problem 59: Severe Phase Unbalance30
Problem 60: Phase Reversal30
Problem 61: Printer will Not Work30
Problem 62: Purge Compressor will Not Run in the Manual "ON" Mode31
Problem 63: Sensor Errors31
Problem 64: Transition Resistors Stay in too Long31
Problem 65: Setpoints Are Not Being Stored, Service Tests will Not Work and We Are Calling Many Diagnostics on the CLD31
Problem 66: Starter Contactor Interrupt Failure Diagnostic When Powering up the UCP32
Problem 67: Starter Dry Run Test Diagnostic Upon Entering a Starter Dry Run Test32
Problem 68: Starter Dry Run will Not Work32
Problem 69: Starter Fault Type 1, 2 or 332
Problem 70: Stepper Motor Is Humming32
Problem 71: Extended Surge33
Problem 72: Pressure Transducer Shift in Calibration. Diagnostics will be Sensor Calibration Related such as Sensor Failure or Oil Pressure Sensor Calibration33
Problem 73: Rapid Time of Day Scrolling or Date Jumps Back One Day33
Problem 74: Unit DID Not Transition Diagnostics33
Problem 75: Tracer Diagnostics E.g.,Tracer Loss of Comm with Options, Starter, Etc. as Well as Other Tracer Related Diagnostics34
Problem 76: Unit Tons Read-Out on CLD Does Not Work34
Problem 77: Unknown Diagnostics 1217 Informational Warning34
CVHE/F/G Trim Balance Procedure35
Run Procedure35
Start Sequence35
Stop/Reset Sequence35
Sensor and Transducer Operating Ranges36
Temporary Forced Unload Setup37
Communications Test38
Troubleshooting IPC Communication Diagnostics39
For a "No Communication, Data Not Valid" Message on the Clear Language Display39
For a "Loss of Comm with Stepper" Diagnostic39
Heat Sink Temperature40
Module Compatibility41
UCP2 Module Compatibility41
Description of UCP2 Options42
Tracer Communications Interface Module (Com 3 Module)42
Tracer Communications Interface Module (Com 4 Module)42
Remote Clear Language Display Module42
Options Module42
Printer Interface Module42
Chilled Water Reset Outdoor Air Temperatures43
Water Pressure Sensors for Evap and Cond System Pressure Less than 150 Psig43
Bearing Oil Temperature Sensors43
Phase Voltage Sensors43
10. Enhanced Condenser Limit43
11. Discharge Temp Sensor43
12. Starter by Others43
UCP2 Modules44
Chiller Module44
Circuit Module45
Lnput/Output Module46
Options Module47
Purge Module48
Starter Module Values49
Stepper Module50
Duplex Module51
Module Dip Switch Settings52
UCP2 Board Dip Switch Settings52
Chiller Module52
Options Module52
Tracer COM 352
Tracer COM 452
IPC Buffer52
Duplex Control Module (DCM)53
Printer53
Diagnosing a Non-Working Stepper Module55
Method to Troubleshoot a UCP2 Stepper Module and Actuator55
Overview55
II. Quick Test of Stepper Board55
II. Check Stepper Motor and Wiring for Shorts and Opens57
IV. Motor Voltages for CTV Stepper Motor59
Procedures for Module Set-Up60
External Current Limit Setpoint60
Refrigerant Monitor Input60
RLA Output60
External Chilled Water Setpoint61
External Auto-Stop62
Analog Input Table Abbreviations64
Pressure Vs Voltage for Oil Pressures64
Pressure Vs Voltage for Water Pressures66
Purge Compressor Suction Temp69
Bearing Temp., Oil Temp. and Compressor Discharge Temp77
Information on the Oil Pressure Sensor Calibration Diagnostic87
Transducer Checkout Procedure88
Quick Test Procedure for Mediamate Water Pressure Transducer88
Starter Contactor Sequence90
Current Input Transfer Function91
Starter Module CT Voltage and Currents92
From UCP2 Initial Release (July 93) to 10/21/96 Software Release93
Troubleshooting the Percent Condenser Output94
As of the 10/21/96 Software Release Including Fastpak and UCP2 Enhancements94
Refrigerant Differential Pressure Indication94
External Current Limit Setpoint96
Percent RLA Output97
Current Overload Protection98
Evaporator Refrigerant Temperature Limit100
Condenser Refrigerant Pressure Limit101
Head Relief Request101
Free Cooling Relay Checkout103
Hot Gas Bypass105
Install and Enable105
Guide Vane Closed Travel Stop106
Maximum HGBP Time106
Hot Gas Bypass Control Algorithm106
HGBP Mode, IGV Target107
Ice Machine Control108
Recommended Wire Lengths for Pts111
Checking for an Open, Burnt, or Shorted Centravac Motor Winding112
Information on Tracer112
Leds113
Dip Switches113
Ucp2/Tracer Compatibility List113
UCP2 Clock114
The Year 2000114
Chilled Water Reset116
Using the Equation for Calculating CWR for Outdoor Air Temp119
Information on the Printer Option123

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