Frick QUANTUM Guide

MAINTENANCE
FRICK QUANTUM
COMPRESSOR
CONTROL PANEL
VERSION 4.1x
S90-010 M/JUL 2001
File: SERVICE MANUAL - SECTION 90
Replaces: S90-010 M/DEC 00
Dist: 3, 3a, 3b, 3c

S90-010 M FRICK QUANTUM COMPRESSOR CONTROL PANEL
Page 2 MAINTENANCE
Table of Contents
Quantum Identification _____________________________________________________________5
Quantum 3 ______________________________________________________________________________ 5
Quantum 4 ______________________________________________________________________________ 5
TROUBLESHOOTING ______________________________________________________________5
THE QUANTUM CONTROL PANEL __________________________________________________________ 5
General Information: _____________________________________________________________________ 5
What To Do Before Calling The Factory______________________________________________________ 6
What Should Occur When Powering Up The Panel _____________________________________________ 6
What If The “Operating Status” Screen Is Not Shown ___________________________________________ 6
DISPLAY ASSEMBLY COMPONENT REPLACEMENT GUIDE_____________________________________ 8
Quantum 3 ____________________________________________________________________________ 8
Quantum 4 ____________________________________________________________________________ 8
TROUBLESHOOTING ANALOG AND DIGITAL PROBLEMS ______________________________________ 9
"About" Screen _________________________________________________________________________ 9
Diagnosing an Analog or Digital Board Problem _______________________________________________ 9
"Service Screen" - Digital Board Inputs and Outputs ___________________________________________ 10
Troubleshooting Digital Inputs and Outputs __________________________________________________ 10
Troubleshooting Analog Inputs and Outputs _________________________________________________ 11
ADDING AND REPLACING BOARDS________________________________________________________ 12
Quantum _____________________________________________________________________________ 12
Analog And Digital Boards _______________________________________________________________ 12
Display Replacement ___________________________________________________________________ 13
TROUBLESHOOTING A PROBLEM THAT APPEARS UNEXPLAINABLE ___________________________ 14
COMPRESSOR MODEL DIFFERENCES ______________________________________________18
JUMPER AND DIPSWITCH SETTINGS________________________________________________19
DIGITAL BOARD________________________________________________________________________ 19
Digital I/O Board CommunicationsSettings__________________________________________________ 19
Digital I/O Board Dipswitch Settings________________________________________________________ 19
ANALOGBOARD________________________________________________________________________ 19
Analog Board CommunicationsSettings____________________________________________________ 19
Analog Board Dipswitch Settings__________________________________________________________ 19
Analog Board #1_______________________________________________________________________ 20
Analog Board #2 _______________________________________________________________________ 21
QUANTUM 3____________________________________________________________________________ 22
CommunicationsSettings Com-1__________________________________________________________ 22
CommunicationsSettings Com-2__________________________________________________________ 22
CommunicationsSettings Com-3__________________________________________________________ 22
QUANTUM 4____________________________________________________________________________ 23
CommunicationsSettings Com-1__________________________________________________________ 23
CommunicationsSettings Com-2__________________________________________________________ 23
SETPOINT DATA SHEETS _________________________________________________________25
FACTORY SETUP _______________________________________________________________________ 25
PANEL SETUP__________________________________________________________________________ 26
CALIBRATION__________________________________________________________________________ 28
CAPACITYCONTROLSETPOINTS_________________________________________________________ 29
Suction Pressure Control Mode #1_________________________________________________________ 29
Suction Pressure Control Mode #2_________________________________________________________ 30
Process Temp Control Mode #1 ___________________________________________________________ 30
Process Temp Control Mode #2 ___________________________________________________________ 31
Discharge Pressure Control Mode #1_______________________________________________________ 31
Discharge Pressure Control Mode #2_______________________________________________________ 32
Discharge Temp Control Mode #1_________________________________________________________ 32
Discharge Temp Control Mode #2_________________________________________________________ 33
COMPRESSORSAFETIES ________________________________________________________________ 33

FRICK QUANTUM COMPRESSOR CONTROL PANEL S90-010 M
MAINTENANCE Page 3
Discharge Safeties______________________________________________________________________33
Suction Safeties________________________________________________________________________34
Entering ProcessTemperature____________________________________________________________34
High Level Shutdown Delay_______________________________________________________________34
MOTOR CONTROL_______________________________________________________________________34
Power Failure Restart___________________________________________________________________34
Ram Dbs Motor Starter __________________________________________________________________35
OIL SETPOINTS_________________________________________________________________________35
Main Oil Injection _______________________________________________________________________35
Liquid Injection_________________________________________________________________________35
Filter Pressure Setpoints _________________________________________________________________35
SLIDE VALVESETPOINTS________________________________________________________________36
OPTIONS_______________________________________________________________________________36
Setback Schedule______________________________________________________________________36
Condenser Control Setpoints______________________________________________________________36
Analog Control _________________________________________________________________________36
Compressor Sequence Setpoints__________________________________________________________37
AuxiliaryInputs Setup___________________________________________________________________37
Suction Pull-Down______________________________________________________________________37
AuxiliaryAnalogs_______________________________________________________________________38
Pumpdown/Dx Circuits___________________________________________________________________38
WIRINGDIAGRAMS
FLOWDIAGRAM D.C. VOLTAGEHARNESS __________________________________________________39
POINT-TO-POINT FIELD WIRING DIAGRAM__________________________________________________39
QUANTUM PANEL DC POWER SUPPLY DIAGRAM (CONDOR) __________________________________40
QUANTUM PANEL D.C. POWER SUPPLY DIAGRAM (POWER-ONE)______________________________40
QUANTUM 3 MAIN PROCESSORBOARD ____________________________________________________41
QUANTUM 4 MAIN PROCESSORBOARD ____________________________________________________42
DIGITAL I/O BOARD #1___________________________________________________________________43
DIGITAL I/O BOARD #2___________________________________________________________________44
ANALOGBOARD #1______________________________________________________________________45
ANALOGBOARD #2______________________________________________________________________46
QUANTUM 3 CONTROL CENTER ASSEMBLY________________________________________________47
QUANTUM 3 CONTROL CENTER ASSEMBLYRXF 12-50 ONLY__________________________________49
QUANTUM 4 CONTROL CENTER ASSEMBLY________________________________________________51
QUANTUM 4 CONTROL CENTER ASSEMBLYRXF 12-50 ONLY__________________________________53
WIRING DIAGRAM - RWF_________________________________________________________________55
WIRING DIAGRAM – RWB II _______________________________________________________________59
WIRING DIAGRAM – RXF(12-50) ___________________________________________________________63
WIRING DIAGRAM – RXF(58-101) -RXB_____________________________________________________67
WIRING DIAGRAM – RDB_________________________________________________________________71
WIRING DIAGRAM QUANTUM DIGITAL I/O BOARD 2 __________________________________________75
WIRING DIAGRAM QUANTUM ANALOGI/O BOARD 2 __________________________________________77
Quantum 3 Communications Wiring Diagrams________________________________________________79
Quantum 4 Communications Wiring Diagrams________________________________________________80
PRESSURE TRANSDUCER CONVERSIONDATA_______________________________________81
RECOMMENDED SPARE PARTS ____________________________________________________82

S90-010 M FRICK QUANTUM COMPRESSOR CONTROL PANEL
Page 4 MAINTENANCE
QUANTUM PUBLICATIONS
S90-010 O Frick Quantum Control Panel OPERATION
S90-010 CS Frick Quantum Control Panel
COMMUNICATIONS SETUP (setup and
wiring for data communication
using available protocols)
E90-010 SPC Frick Quantum Control Panel
SPECIFICATIONS (& jumper and dip switch
settings)
S90-010 M Frick Quantum Control Panel
MAINTENANCE
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation or practice which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation or practice which, if not
avoided, will result in damage to
equipment and/or minor injury.
NOTE: Indicates an operating procedure, practice, etc., or
portion thereof which is essential to highlight.
CAUTION
!
WARNING
!
DANGER
!

Quantum Identification
Frick Controls has over the years, strived to remain on the
cutting edge of microprocessor technology and
development. And because of the ever-increasing speed,
memory, features and power of microprocessors, Frick
Controls will, from time to time, introduce the latest
advancement in microprocessor control technology.
Our microprocessor family has shared the name
Quantum, over the past five years. There are currently
four controllers within this family. The first two of these
controllers (known as Quantum 1 and Quantum 2) are no
longer in production, and as such, will not be further
mentioned in this manual. The two current members in
production of the Quantum family are the Quantum 3, and
the Quantum 4. It is critical to the end user to be able to
identify the differences between these controllers. Refer to
the section in this manual entitled "Quantum 3 Main Board
History and Identification" and "Quantum 4 Main Board
History and Identification" for additional information as to
how to identify the particular Quantum controller that you
have.
Throughout this manual, the two different controllers will
be talked about for the most part as one (as they do
function the same). Where there is a difference between
these boards, as in jumpers or wiring, the different models
will be identified by name. This is why it is important for
you to be aware of which Quantum board you have.
Quantum 3
Quantum 4
TROUBLESHOOTING
THE QUANTUM CONTROL PANEL
This section contains information on troubleshooting and
making corrections to the boards and control circuits of the
Quantum. Reference the drawings at the end of this
manual.
GENERAL INFORMATION:
The components within the control panel can be
inadvertently damaged by static electricity or
mishandling. Only qualified technicians should
directly handle these components.
1. DO NOT attempt to make corrections to the power
supply without shutting off the power to the control
panel. Accidental shorts can irreparably damage
the processor boards or the display screen.
2. DO NOT HANDLE the panel boards when their
cables are disconnected without first attaching a
properly grounded wrist ground strap to prevent
static electrical discharge from your body.
Most problems encountered with the microprocessor and
control circuits will be the result of a wiring fault, a blown
fuse, faulty I/O module or failure of a peripheral control
such as a solenoid coil or a pressure transducer. Faults in
the computer, while possible, are unlikely. If a fault
develops in the computer, the probability is that all
functions will cease and the display screen will go blank.
The control system of the compressor consists of an AC
(high voltage) side, which can be either 120 volts, or 230
volts, and a DC (low voltage) side. The AC side actuates
solenoids, relays, alarms, and other electromechanical
functions. The DC side operates the computer and it's
various sensors.
When working within the panel, the AC high voltage
side, which can be either nominal 120 VAC or nominal
230 VAC, CAN CAUSE INJURY OR DEATH.
To troubleshoot the low-voltage side of the control circuits,
it is necessary to have the following tools:
1. Accurate digital multimeter*
2. Small wire stripper
3.Small screwdriver
4.Small snip nose pliers
5.Wrist Grounding strap*
6.Static free grounded work surface
Note: Proper panel voltage refers to the AC (high volt-
age) that has been supplied to the panel which could
be either nominal 120 VAC or nominal 230 VAC
(Reference the Control Panel Power Specifications).
Some problems that are encountered involve
troubleshooting the panels digital inputs and outputs. The
Digital I/O (Input/Output) boards have six Digital I/O (DIO)
board connectors labeled P1 through P6. The input and
output modules are wired into a DIO connector plug.
Position 3 pro-vides power and position 4 is a neutral on
the DIO connectors.
FRICK QUANTUM COMPRESSOR CONTROL PANEL S90-010 M
MAINTENANCE Page 5

S90-010 M FRICK QUANTUM COMPRESSOR CONTROL PANEL
Page 6 MAINTENANCE
WHAT TO DO BEFORE CALLING THE FACTORY
·The “Operating Status” screen is shown.
When someone calls in to the factory with a Quantum
problem, they usually don’t provide enough information.
An example of this is the statement that the Quantum is
not “booting” (the main processor board is not starting).
Unfortunately, this description is usually vague and only
means that there is nothing on the display. A blank screen
could be the result of many different problems. Following
is a list of possible reasons for no display:
·No power
·Loose or Faulty Display Cable or Inverter Cable
·Bad Display
·Bad Backlight Inverter
·Bad Backlight Fluorescent Tube
·Faulty CPU Board
·Wrong Combination of Display, Cable, Inverter,
or Software
Before calling the factory for assistance, review the
following information and try to discover and resolve your
Quantum problem.
WHAT SHOULD OCCUR WHEN POWERING UP
THE PANEL
The first thing that should be checked when
troubleshooting the Quantum is it’s powering up
sequence.
When powering up the Quantum the following sequence of
events are indicative of a properly working main processor
board:
Quantum 3
·The LED’s for +5V, +12V, and –12V will turn
on solid. (Lower left corner of Main PCB)
·LED KB will begin to blink. (Left side of Main
PCB)
·Several initialization screens will appear
(these will look very similar to the way the
screen of a desktop computer appears when
it is booting.
·The last of the initialization screens is the
“System Configuration” screen.
·The screen will go blank for several seconds.
·The “Operating Status” screen is shown.
After the Quantum has properly powered up, the
following sequence of events is indicative of
proper communication to the analog and digital
boards:
·The TX/RX LED’s near the white connector
will begin to blink.
·The Analog and Digital I/O boards TX/RX
lights should be blinking.
·Each I/O board should have the power LED
(next to the white connector) lighted and the
“Active” LED (next to the blue DIP switch)
should be blinking.
Quantum 4
·Green PWR (Power) LED will turn on solid
(upper right corner of main PCB).
·Red FLASH LED will begin to intermittently
during the Boot process. It will then go out
once the "Operating Status" screen appears.
·LED D8 (on the smaller board) will start to
blink at the rate of about once per second. It
will continue to blink after the Quantum has
booted.
·Once the screen displays "Loading…", LED's
D4 , D5, D7 and D8 will be on solid.
·The "Operating Status" screen will appear.
·Once actual data has been displayed on this
screen, LED D13 will come on solid and
D10, D11, and D12 will start to flash at a
quick rate.
After the Quantum has properly powered up, the
following sequence of events is indicative of
proper communication to the analog and digital
boards:
·The TX/RX LED’s near the white connector
will begin to blink.
·The Analog and Digital I/O boards TX/RX
lights should be blinking.
·Each I/O board should have the power LED
(next to the white connector) lighted and the
“Active” LED (next to the blue DIP switch)
should be blinking.
WHAT IF THE “OPERATING STATUS” SCREEN
IS NOT SHOWN
If the “Operating Status” screen is not shown, check the
following items:
Quantum 3
1. If no LED’s are lighted, then check power AC
and DC.
2. Check if the lighting of the LED’s is occurring
as de-scribed in the “What Should Occur
When Powering Up The Panel” section.
·If the powering up sequence continues
to repeat without displaying the
“Operating Status” screen, then there is
a booting problem.
3. Check if an error message is displayed when
booting.
·Be sure to write down any error
messages that appear.
4. Check that the software is OK:
·Is the correct software installed?
·Did you just install new software?
·If you need to clear the numerical
setpoint and calibration areas of
memory for any reason, clear the
memory as described in the S90-010
FSI publication. NOTE: This
information will be replaced by
factory default values, so any

FRICK QUANTUM COMPRESSOR CONTROL PANEL S90-010 M
MAINTENANCE Page 7
setpoint and calibration data values
that need to be customized must be
reentered.
5. Check for bad connections.
6. Check the display. If the CPU board is
booting but you have no display, check the
following:
·Check the LCD backlight tube. Look
very closely at the display to see if
anything is visible in the dark screen.
You will need good lighting and look for
any “ghost” type image. If it appears that
there is something on the screen but
very dark, the problem maybe the LCD
backlight tube. On the LG Philips, NEC
and Sharp displays this tube is field
replaceable. On the Samsung LCD
display it is not available and the display
will have to be replaced. You must take
the display apart to identify the display
manufacturer.
·Verify that both the display cable and
the inverter cable are firmly seated. It
may be necessary to remove the video
cable from the back of the LCD display
and reseat it to be sure it is connected
properly. Note: This is a small
connector and caution should be
observed so that it is not damaged
due to excessive force.
·Check the backlight inverter connector
(P4). When the Quantum board is
mounted in the panel, this connector is
located at the middle left of the board.
The pins on the right side are odd
numbered, with pin P(1) at the bottom -
pin P(9) at the top. The pins on the left
side are even numbered, with pin P(2)
at the bottom - pin P(10) at the top. After
the Quantum has booted, pin P(3)
should measure +2.4Vdc, pins P(4) and
P(5) are DC grounds, and pins P(6) and
P(7) should measure +12Vdc. A bad
inverter will also cause a dark display.
·Reference the "Display Assembly
Component Replacement Guide" at the
end of this section and check that the
LCD, LCD cable, and software versions
are matched correctly.
Quantum 4
1. If no LED’s are lighted, then check power AC
and DC.
2. Check if the lighting of the LED’s is occurring
as de-scribed in the “What Should Occur
When Powering Up The Panel” section.
·If the powering up sequence continues
to repeat without displaying the
“Operating Status” screen, then there is
a booting problem.
3. Check if an error message is displayed when
booting.
·Be sure to write down any error
messages that appear.
4. Check that the software is OK:
·Is the correct software installed?
·Did you just install new software?
·If you need to clear the numerical
setpoint and calibration areas of
memory for any reason, clear the
memory as described in the S90-010
FSI publication. NOTE: This
information will be replaced by
factory default values, so any
setpoint and calibration data values
that need to be customized must be
reentered.
5. Check for bad connections.
6. Check the display. If the CPU board is
booting but you have no display, check the
following:
·Check the LCD backlight tube. Look
very closely at the display to see if
anything is visible in the dark screen.
You will need good lighting and look for
any “ghost” type image. If it appears that
there is something on the screen but
very dark, the problem maybe the LCD
backlight tube. On the LG Philips, NEC
and Sharp displays this tube is field
replaceable. On the Samsung LCD
display it is not available and the display
will have to be replaced. You must take
the display apart to identify the display
manufacturer.
·Verify that both the display cable and
the inverter cable are firmly seated. It
may be necessary to remove the video
cable from the back of the LCD display
and reseat it to be sure it is connected
properly. Note: This is a small
connector and caution should be
observed so that it is not damaged
due to excessive force.
·Reference the "Display Assembly
Component Replacement Guide" that
follows, and check that the LCD, LCD
cable, and software versions are
matched correctly.

S90-010 M FRICK QUANTUM COMPRESSOR CONTROL PANEL
Page 8 MAINTENANCE
DISPLAY ASSEMBLY COMPONENT REPLACEMENT GUIDE
Quantum 3
MANUFACTURER
DESCRIPTION SAMSUNG NEC
(OBSOLETE) SHARP LG PHILIPS
(CURRENT)
10.4” TFT Display 333Q0001180 333Q0001494 333Q0001581 649C1078H01
Backlight Inverter 333Q0001582 (OR 333Q0001181) 333Q0001495 333Q0001582 333Q0001582
Cable - CPU to Display 640B0036H01 640B0043H01 640B0045H01 640B0065H01
Cable - CPU to Inverter 640B0032H01 640B0044H01 640B0032H01 640B0032H01
Replacement - Backlight Not Available 333Q0001587 333Q0001588 333Q0001785
Display Replacement Assy. 640C0021G01 640C0021G01
Rev (A) 640C0021G01 Rev (B) 640C0052G01
DISPLAY ASSEMBLY COMPONENT REPLACEMENT GUIDE
Quantum 4
MANUFACTURER
DESCRIPTION SAMSUNG NEC
(OBSOLETE) SHARP LG PHILIPS (CURRENT)
10.4” TFT Display 333Q0001180 333Q0001581 649C1078H01
Backlight Inverter 333Q0001582 (OR 333Q0001181) 333Q0001582 333Q0001582
Cable - CPU to
Display/Inverter 649D4824H01 649D4824H01 649D4824H01
Replacement - Backlight Not Available 333Q0001588 333Q0001785
Display Replacement Assy. 640C0021G01
SEE NOTE
"A"
640C0021G01
Rev (B) 640C0052G01
NOTE A: When upgrading from a Quantum 3 with an NEC Display, to the Quantum 4, the display will need
to be upgraded also. Order 640C0021G01 to replace the display.

FRICK QUANTUM COMPRESSOR CONTROL PANEL S90-010 M
MAINTENANCE Page 9
TROUBLESHOOTING ANALOG AND DIGITAL PROBLEMS
The information that follows in this section can help locate
problems that can occur with Analog and Digital input and
output circuit boards.
"About" Screen
The “About” screen shows the Analog and Digital boards
that have been detected. If a board has lost
communications, a shutdown will be issued. All outputs
are turned off on a Digital Board that has lost
communications. All outputs will get set to their minimum
value range on an Analog Board that has lost
communications. A loss of communications to an analog
board will probably result in sensor fault shutdown
messages that are associated with the sensors on that
board.
Diagnosing an Analog or Digital Board Problem
The Analog and Digital Boards have built-in features that
help to troubleshoot faulty boards. Following is a
description of the built-in features:
1. The Analog and Digital Boards have an “Active “
LED indicator on the board that blinks when the
board’s software is running.
·If the “Active” LED is not blinking, check to
ensure that the EPROM is installed properly.
2. There is also a “Power” LED that lights when DC
power is applied to the board.
·If the power LED is not lighted, check the
cable for proper connectivity. Note: Each
board provides the necessary
connections to feed all signals to the
following connectors. If the auxiliary
Analog or Digital Board is not present
then a jumper plug (Part # 640B0039H01)
must be installed to daisy chain the
signals.
3. The main indication of communications is the
RX/TX LED’s on the I/O board. These LED’s
should blink in response to the blinking of the
main processor board’s I/O communication
activity RX/TX LED’s. If the RX LED on the I/O
board is blinking but the board was not detected
on the “About” screen, or an I/O Comm failure
occurs, check the address of the board.
·Reference the "JUMPER AND DIPSWITCH
SETTINGS" section later in this manual. This
section contains the dipswitch settings for
addressing the Analog and Digital I/O
Boards numbers (1) through (6). When these
switches are properly set, the main
processor board is able to serially
communicate with each board and provide
control signals and data exchange.

S90-010 M FRICK QUANTUM COMPRESSOR CONTROL PANEL
Page 10 MAINTENANCE
"Service Screen" - Digital Board Inputs and Outputs
Troubleshooting Digital Inputs and Outputs
The “Service Screen” has been provided to view the raw
data from a Digital Board. There is a separate screen for
each of the Digital Boards that are present. Digital values
are shown as ON or OFF.
Checking the Digital Inputs and Outputs
Some problems that are encountered involve
troubleshooting the digital inputs and outputs. The Digital
I/O (Input / Output) boards have six Digital I/O (DIO) board
connectors labeled P1 through P6. The input and output
modules are wired to a DIO connector plug. Position 3
provides power and position 4 is a neutral on the DIO
connectors. Position 1, 2, 5, and 6 are signal connections.
The Digital I/O board’s I/O modules are configured by
proper module selection, AC or DC, operating voltage,
input or output, and moving the fuse to the “in” or “out”
position. An LED is associated with each module and
displays the state of each module. A lighted LED
represents an Input that is “High” or an Output that is “On”.
Each of the sixteen modules has a corresponding software
configuration screen.
If a properly configured Digital I/O is not responding
correctly, first look at the digital board on the “Service
Screen” and check if the module is on. If it is not on, check
if the LED on the digital board is also not lit. If the LED is
not lit, then check the fuse. If the fuse is OK, then check
the module.
FUSE TESTING AND REPLACEMENT
1. Power off the panel.
2. Open the panel door.
3. Remove the questionable fuse.
4. Place the questionable fuse into the fuse tester at
the bottom of each digital I/O board.
5. Power on the panel.
6. Check the LED on the tester. If the LED is lit, the
fuse is OK.
7. Power off the panel.
8. If the fuse is faulty, replace the fuse with a new
plug-type fuse (Part # 333Q0001326).
Input and Output Module Testing and
Replacement
1. Power off the panel.
2. Open the panel door.
3. Replace the questionable module.
4. Power on the panel.
5. If it is an output module, check for proper panel
voltage on the DIO connector plug. Check the
voltage between position 4 (neutral) and the
associated position to the output module.
6. If it is an input module, check if the associated
LED is on when power is applied to the module.
Troubleshooting an Output
1. Make sure the LED associated with the output is
on when power is applied to the module.
2. If the LED is not on when it should be and there
is no operating condition preventing it, contact
the Frick Service Department.
3. If the LED is on when it should be, check for
proper panel voltage on the DIO connector plug.
Check the voltage between the position 4
(neutral) and the associated position to the output
module.
4. If the voltage is OK, check for proper panel
voltage between the associated position to the
output module on the DIO connector and the
associated position on the terminal strip.