TemperZone 6 Instruction Manual

Temperzone Unit Controller 6 - Operation and installation- Hydronic Issue 1
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UNIT CONTROLLER 6 (UC6)
Operation and Installation
Hydronic
Date: 12 October 2015
Issue: 1

Temperzone Unit Controller 6 - Operation and installation- Hydronic Issue 1
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Contents
1. Introduction ....................................................................................................................................... 4
2. Features ............................................................................................................................................. 4
3. Lower board connections .................................................................................................................. 5
3.1. Power supply terminals .............................................................................................................. 6
3.2. Output terminals ......................................................................................................................... 6
3.3. Input terminals ............................................................................................................................ 7
4. Upper board connections................................................................................................................... 9
4.1. Digital input signals .................................................................................................................... 9
4.2. Digital output signals ................................................................................................................ 10
4.3. Analogue output signals ........................................................................................................... 10
4.4. Communication ports ............................................................................................................... 11
4.4.1. Temperzone TZT-100 thermostat connection ...................................................................... 11
4.4.2. Power+ inverter driver connection ....................................................................................... 12
4.5. Electronic expansion valves ..................................................................................................... 13
5. Operation ......................................................................................................................................... 13
5.1. Remote on/off ........................................................................................................................... 13
5.2. Variable duty units ................................................................................................................... 13
5.3. Water flow valve Y2 ................................................................................................................ 13
5.4. Indoor fan control ..................................................................................................................... 14
5.5. Heating mode ........................................................................................................................... 14
5.6. Crankcase heater ....................................................................................................................... 14
5.7. Electronic expansion valve control .......................................................................................... 14
5.8. Demand response management ................................................................................................ 15
6. Protection functions ..................................................................................................................... 15
6.1. Minimum compressor run time ................................................................................................ 15
6.2. Minimum compressor off time ................................................................................................. 15
6.3. Minimum compressor cycle time ............................................................................................. 15
6.4. High pressure protection (HP) .................................................................................................. 15
6.5. Loss of refrigerant protection (LOR) ....................................................................................... 16
6.6. High suction line temperature (HiST) ...................................................................................... 16
6.7. Indoor coil frost protection (FROST) ....................................................................................... 16
6.8. High discharge line temperature protection (HDT).................................................................. 17
6.9. No Water Flow Protection ........................................................................................................ 17
6.10. Water Float Protection .......................................................................................................... 17
6.11. Low output water temperature protection ............................................................................. 18
6.12. Compressor lock-out ............................................................................................................. 18
6.13. Sensor alarm ......................................................................................................................... 18
6.14. Loss of RS485 communications alarm ................................................................................. 18

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7. Test mode ........................................................................................................................................ 18
8. Commissioning mode ..................................................................................................................... 19
9. Display summary ............................................................................................................................ 20

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1. Introduction
The temperzone Unit Controller 6 (UC6) is the successor to the OUC4 controller.
The UC6 provides increased capability and flexibility in indoor-, outdoor- and
packaged units. The complete controller combines the µPC controller board from
Carel plus an interface board to connect temperzone standard sensors and plugs.
The UC6 receives requests such as “Unit On/Off”, “Start compressors”, “Activate
HEAT (Reverse Cycle)” and transfers these requests to the outputs after enforcing
safety timers. The UC6 ensures unit safety by continuously monitoring input
signals such as pressures and temperatures. Beside the normal controls and unit
safety the UC6 has many other functions, for example head pressure control,
capacity control, superheat control, serial communications and more.
2. Features
The UC6 has the following features:
Normal controls:
- One controller can manage two complete refrigeration circuits
- Two drivers for uni-polar electronic expansion valves (EEV)
- Outdoor fan control
- Reversing valve change over management
- Variable speed compressor management
- Crankcase heater control
- BMS interface with optional board(BACnet/IP, Ethernet, MS/TP)
- DRED input and control
Safety functions:
- Compressor minimum cycle time, minimum run time, minimum off time.
- High pressure protection via high pressure transducer
- Low pressure protection via low pressure transducer
- Loss of refrigerant protection
- Indoor coil frost protection
- No water flow protection
- Water float protection
- Low water output temperature protection
- Repeat fault lock out
- Error code display
- Alarm logging
Commissioning functions:
- Commissioning mode
- Automatic test sequence

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3. Lower board connections
The paragraphs on the following pages give details how the UC6 should be
connected both for packaged units and for the outdoor unit of a split system.
Care must be taken that the correct connections are made as the UC6 can be
configured in various modes.
Important:
 The UC6 controller must be mounted inside an electrical panel.
 To minimise electrical interference low power signal wires from temperature
sensors, pressure transducers and low voltage control signals must be kept
physically separate from wiring and cables that carry mains power.
Never run power cables and signal cables in the same conduits.
 Contact temperzone if the controller has malfunctioned. Do not attempt to
repair the controller.

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3.1. Power supply terminals
The UC6 is powered by 24V ±10% AC. A class 2 safety transformer with a
minimum rating of 24VA must be used in the installation. The power supply to the
UC6 controller must not be used to power other electrical devices. If the 24V
secondary winding of the transformer is earthed then make sure that the earthed
wire connects to terminal “µPC supply 0V”.
A yellow LED indicates when the UC6 is powered.
Terminal Signal Notes
HOT
(µPC supply)
24V AC HOT Do not inadvertently connect
230V AC to these pins!
0V
(µPC supply)
24V AC COMMON
Output supply Relay common power supply for
switched output signals:
CMC1 CMC2
RV1 RV2
CCH CCS
This terminal normally
connects to 230V AC phase.
Fan supply Power supply for fan control
terminals.
Depending on the
connections to the fan or fan
controller this terminal
normally connects to
24V AC HOT
or 230V AC phase
3.2. Output terminals
When the UC6 is configured as three speed indoor fan:
Terminal Signal Notes
Low1 Indoor fan(s) Low speed terminal
When active these outputs
electrically connect to the
Fan supply terminal.
Low2
Med1 Indoor fan(s) Medium speed terminal
Med2
Hi1 Indoor fan(s) High speed terminal
Hi2

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When the UC6 is configured indoor fan as EC motor:
Terminal Signal Notes
Low1 No function.
Low2
Med1 No function.
Med2
Hi1/Hi2 Active to turn on the EC fan contact
Terminal Signal Notes
CMC1 Compressor On/Off
When active these outputs
electrically connect to the
Output supply terminal.
CMC2 Circulation pump control
RV1 Reversing valve/Electric heater
circuit1(if fitted)
RV2 Condensate pump
CCH Crankcase Heater/Electric heater
circuit2(if fitted)
CCS Water Pump
3.3. Input terminals
Terminal Signal Notes
CS This input can have one of two
functions:
(1) 0 to 1V Analogue input
(2) Return or supply air
temperature
For variable capacity systems
For fixed capacity systems
ST1 Compressor suction line
temperature
NTC blue wires
ST2 NA
DT1 Compressor discharge line
temperature
NTC red wires
DT2 Electric heater temperature
sensor (if used)

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Terminal Signal Notes
SP1 Compressor suction line pressure 0-5V transducer
OR
SP2 NA
HP1 Compressor discharge line
pressure
HP2 NA
TS1 Water In temperature NTC Blue wires
TS2 Water Out temperature
OAT Outdoor air temperature NTC black wires

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4. Upper board connections
The digital input port common pins DIC1 and DIC2 are internally directly
connected to the local board 0V.
4.1. Digital input signals
When the UC6 is configured as three indoor fan speed:
DI Signal
1 Indoor fan LOW speed input
2 Indoor fan MEDIUM speed input
3 Indoor fan HIGH speed input
When the UC6 is configured as EC fan motor:
DI Signal
1 Active the indoor fan contact
2
3
DI Signal Notes
4 Reverse cycle request Heat
5 Compressor request
Or overload input
Without TZT-100: Compressor
With TZT-100: Overload input
6 Water Float Switch Input Normally close. If the float switch is
activated, there may be a water leak from
the pipe. It will stop the compressor
immediately.
7 Remote on/off This input must be closed circuit to allow
the UC6 to switch compressors and fans on.
9 Water verification Water Flow Verification Switch when there
are water flow through the pipe switch is
closed

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When the UC6 is configured for DRED function:
DI Signal Notes
8 DRED1 When activated the compressors will be OFF.
The indoor fan is allowed to continue.
9
DRED2 or DRED3
(configurable via UC6
service interface)
DRED2 active: Total unit energy
consumption will be reduced to less than
75% of rating.
DRED3 active: Total unit energy
consumption will be reduced to less than
50% of rating.
DI Signal Notes
10 Push button
Press and hold the push button on the lower
board 1 to 5 seconds to start test mode.
Test mode can only be activated when both
compressors are OFF.
Press and hold the push button on the lower
board 10 to 15 seconds to start
commissioning mode.
4.2. Digital output signals
DO Signal Notes
NO7 Normally open
Alarm output relay C3 Common
NC7 Normally closed
4.3. Analogue output signals
AOUT Signal Notes
Y1 Indoor fan speed 0-10V (if used)
Y2 Water flow Valve 0-10V control water flow
Y4 LED display control Controls the 1-digit LED display used to
show alarm codes.

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4.4. Communication ports
Several types of communication ports are available on the UC6.
COMM
PORT Signal Notes
RS485
1
MODBUS RS485 Thermostat, Inverter
pLAN UC6 service tool Programmable graphic display
PLD
1
Fieldbus (RS485 or TLan) Supervisory System
BMS
RS485 MODBUS
(BACnet/IP,MS/TP or
Ethernet optional)
Available only with additional plug-in
module connected to the “BMS” connector
(adjacent to the Digital Input connector).
Note 1: Connectors to the UC6 show R+/T+ for signal A, R-/T- for signal B.
4.4.1. Temperzone TZT-100 thermostat connection
The UC6 can connect directly to the temperzone TZT-100 thermostat using a
shielded cable with two twisted pair wires suitable for RS485 serial
communications. The drawing below shows connection details.

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4.4.2. Power+ inverter driver connection
BLDC compressor driver Power+ is connected to UC6 at same port with TZT-100
using a shielded cable. See the details at below drawing.

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4.5. Electronic expansion valves
The UC6 has two drivers to control electronic expansion valves (EEV).
The EEV outputs are EEV1 and EEV2
Note: Only one valve must be connected to each connector.
EEV type 6-wire uni-polar stepper motor
Motor supply voltage 12V DC±10%
Motor winding current 0.3A maximum (each winding)
Motor winding resistance 40Ω minimum
Maximum power each EEV 7W
EEV step frequency Set by temperzone software
5. Operation
5.1. Remote on/off
The remote on/off function can be enabled or disabled by using a UC6 service
tool.
When the function is enabled the remote on/off signal must connect to input
DI7, signal return is DIC1. The remote on/off signal must be an external voltage
free switched relay contact.
The unit is active when DI7 is connected to DIC1.
5.2. Variable duty units
The UC6 can control a variable speed compressor or a digital scroll compressor.
Temperzone pre-configures the unit to the correct compressor type; a UC6
service tool is required if the compressor type configuration must be changed.
The capacity input signal must connect to input CS (0-1V, duty 10% per 0.1V).
The minimum compressor duty is:
20 to 30% for a variable speed compressor (depends on compressor model)
16% for a digital scroll compressor
When a capacity signal is present on input CS that is lower than the minimum
duty (for example 0.0V) then the compressor will continue to operate on
minimum duty. Safety functions may place further restrictions on the minimum
duty and may act at any operating condition.
5.3. Water flow valve Y2
When a unit is in cooling, the Water Flow Valve is used to regulate the condensing
temperature via the 0-10V signals Y2.
When a unit is in heating mode the Water Flow Valve remains fully open.
The condensing temperature is converting from the high pressure reading from
HP1.

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5.4. Indoor fan control
The UC6 can be used to control the indoor fan speed. The configuration of the
UC6 can be set using a UC6 service tool. If the UC6 is configured to control the
indoor fan then the following applies.
Indoor fan control input signals are:
 If the UC6 is configured to use digital input signals then the indoor fan
control signals are:
o DI1: Low
o DI2: Medium
o DI3: High
 If the system uses a temperzone TZT-100 thermostat then the indoor fan
input signals are received from the TZT-100 through the RS485
communications cable.
Two types of outputs are available for indoor fan speed control:
 Relays to control a three speed indoor fan motor
o Low1 and Low2
o Med1 and Med2
o Hi1 and Hi2
 A 0-10V signal on analogue output Y1 for electronically controlled fans.
5.5. Heating mode
When input DI4 is made active the unit is placed in heating mode. The reversing
valves are connected to outputs RV1. If the unit was cooling when the input
signal changed the compressors will be stopped first and the change-over of the
reversing valves will be delayed to prevent “gas rush”. The length of the delay is
adjustable by using a UC6 service tool.
If heating mode is requested but the compressors are not started within 5
minutes then the reversing valves are switched off again to save power. They will
re-activate as soon as a compressor run request is received. The duration of the 5
minute timeout is adjustable by using a UC6 service tool.
If the compressor is configured as cooling only and electric heater is fitted then
RV1 is used to switch the electric heater on.
5.6. Crankcase heater
Crankcase heaters are controlled by output CCH.
The crankcase heaters are activated when the following conditions are met:
Mains power has just been turned on
OR:
One or both compressor(s) is (are) OFF
The compressor(s) has (have) not run for at least one hour
The outdoor ambient temperature is below +7°C.
5.7. Electronic expansion valve control
On units equipped with electronic expansion valves (EEV) the EEV are used to
regulate suction side superheat. The EEV connect to outputs EEV1 and EEV2

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Suction side superheat is defined by the difference between the evaporating
temperature and the compressor suction line temperature. The evaporating
temperature normally is calculated from the suction line pressure.
HWP291 is a single compressor with two coils system unit. EEV1 and EEV2
operate synchronized by same a pair of control signal (suction temperature and
pressure). Temperzone has selected optimum EEV control parameters to
guarantee best unit performance when cooling and when heating.
5.8. Demand response management
The UC6 provides 2 or 3 inputs (depends on unit configuration) for the D.R.E.D.
function. D.R.E.D. stands for “Demand Response Enabling Device”. The aim of the
function is to have a measure of control over the total energy that is consumed
by the unit as measured over a half hour period. Refer to Australian draft
standard AS4755.3.1 for detailed information.
The UC6 achieves compliance to the standard by “duty cycling” or stopping one or
two compressors.
Inputs for the DRED function are:
DI8 DRM1
DI9 DRM2 or DRM3 (configurable)
If the unit is configured with Quiet mode enabled then input DI9 is not available
for the DRED function.
Display indication with DRM1 active letter b
6. Protection functions
6.1. Minimum compressor run time
Minimum time that a compressor must run when started. This ensures that an
adequate amount of compressor lubricating oil is returned to the compressor after
start up.
Display indication when timer is active number 2
6.2. Minimum compressor off time
Minimum time that a compressor must remain off after it has stopped. This time
ensures that a compressor is not re-started while there still is a high pressure
differential across the compressor.
Display indication when timer is active number 1
6.3. Minimum compressor cycle time
A compressor is allowed a maximum of 10 starts per hour (one start per 6
minutes). This limits the amount of stress on the compressor motor.
Display indication when timer is active number 1
6.4. High pressure protection (HP)
If high pressure transducers are connected to inputs HP1 then a compressor is
switched off when the discharge line pressure reading exceeds 42.0bar.

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The UC6 will automatically reduce capacity of a variable compressor before the
maximum value of 42bar / 66°C is reached.
When a compressor is stopped due to high pressure it is held off for a period of 3
minutes, after which it is allowed to restart (provided pressure has fallen well
below the maximum).
If three consecutive trips occur then the unit will be “locked out”. The trip counter
is reset to 0 when there has been no compressor run request for longer than 60
minutes.
Display indication when protection is active number 4 (flashing)
6.5. Loss of refrigerant protection (LOR)
When a compressor is running the UC6 continuously monitors the various
temperatures and pressures. The controller software applies logic that enables it
to determine whether the system has an adequate amount of refrigerant. Signals
used for this check are suction temperatures ST1 and suction line pressures SP1.
The check is not made during the first 5 minutes after a compressor is started to
allow pressures and temperatures to settle.
If the compressor is a variable speed type or a digital scroll type then the check is
made only when the capacity is at 100%.
When a compressor is stopped due to loss of refrigerant it is held off for a period
of 3 minutes, after which it is allowed to restart.
If three consecutive trips occur then the unit will be “locked out”. The trip counter
is reset to 0 when there has been no compressor run request for longer than 60
minutes.
Display indication when protection is active number 3 (flashing)
6.6. High suction line temperature (HiST)
When the suction line temperature is above 30°C and continuously for 15
minutes, stop the compressor.
If the compressor is a digital scroll type then the check is made only when the
capacity is at 100%.
When a compressor is stopped due to high suction temperature, it is held off for a
period of 3 minutes, after which it is allowed to restart.
If three consecutive trips occur then the unit will be “locked out”
Display indication when protection is active number 4 (flashing)
6.7. Indoor coil frost protection (FROST)
When the unit is cooling the evaporating temperature in the indoor coil must
remain above -4°C (adjustable from -10°C to -2°C by using a UC6 service tool).

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If this temperature falls below the threshold then some amount of ice (frost) is
likely to have formed on the indoor coil.
When indoor coil frost protection is activated the compressor is stopped for 15
minutes, after which it is allowed to restart.
If three consecutive trips occur then the unit will be “locked out”. The trip counter
is reset to 0 when there has been no compressor run request for longer than 60
minutes.
Display indication when protection is active number 7 (flashing)
6.8. High discharge line temperature protection (HDT)
The controller monitors the discharge line temperature (inputs DT1) and should it
rise above 110°C the compressor will be stopped.
When high temperature protection is activated the compressor is stopped for at
least 3 minutes. The compressor is allowed to restart after 3 minutes provided
that the discharge line temperature has fallen to below 100°C.
If three consecutive trips occur then the unit will be “locked out”. The trip counter
is reset to 0 when there has been no compressor run request for longer than 60
minutes.
Units with a variable compressor or digital scroll compressor will automatically
reduce capacity before the discharge temperature rises close to the threshold.
Display indication when protection is active number 9 (flashing)
6.9. No Water Flow Protection
If the Water Flow Verification Switch input (Din_9) is opened during the
compressor running cycle, stop the compressor immediately and report a fault.
This fault will be recovered automatically after the Water Flow Verification Switch
contact is closed for certain time.
If the Water Flow Verification Switch input is opened 3 times within 2 hours, the
compressor will be lockout.
Display indication when no water flow number 8
6.10. Water Float Protection
Normally the Float Switch (Din_6) should not ever be activated because the
condensate pump is running at all the time. If the float switch is activated, there
may be a water leak from the pipe then the compressor will stop immediately and
the condensate pump will keep running until the float switch resets.
Display indication when Water Float number 8

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6.11. Low output water temperature protection
If the output water temperature is blow 2°C for a contain time, stop the
compressor. Minimum output water temperature and the delay time are
configurable variables on UC6 service tools Service Configuration page.
Display indication when Water Float number 8
6.12. Compressor lock-out
Certain faults (as outlined in the preceding paragraphs) can cause the unit to be
“locked out” if they occur three consecutive times while the compressor-run
request has remained active. When a unit is locked out the compressor is not
allowed to start until the lock-out is manually reset. Lock-out protects the unit
from repeatedly starting the compressor when a serious fault exists that requires
the attention of a service technician.
When a unit is locked out the alarm relay output (NO7, NC7) will be active.
A unit that is locked out can be reset by either of the following two methods:
1. Remove mains power from the unit for at least 3 seconds, and then restore
power.
2. Use a UC6 service tool to manually reset the lock-out condition.
Display indication when protection is active letter F (flashing)
6.13. Sensor alarm
If the signal of a temperature sensor or pressure transducer is out of normal
operating range the UC6 will generate an alarm. The sensor may be faulty,
disconnected or short circuit.
Display indication temperature sensor alarm number 5 (flashing)
Display indication pressure transducer alarm number 6 (flashing)
6.14. Loss of RS485 communications alarm
If the UC6 does not receive correct responses from a device that connects via the
RS485 Modbus serial communications port then an alarm is generated. Examples
of such devices are: a TZT-100 thermostat, a Carel Power+ inverter.
Display indication for communications fault letter C (flashing)
7. Test mode
Test mode can only be activated when both compressors are OFF.
To start test mode press and hold down the push button on the lower board
between 1 and 5 seconds.
In test mode each output is activated for 5 to 10 seconds, one output at a time.
When test mode completes the unit automatically returns to normal operation.
Display indication during test mode letter A

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8. Commissioning mode
To start commissioning mode press and hold down the push button on the lower
board between 10 and 15 seconds.
In commissioning mode all time delays are reduced to 1/10th their standard value
to enable rapid diagnostic testing.
Commissioning mode automatically completes after 30 minutes and the unit will
return to normal operation. Cycling mains power off and on again also ends
commissioning mode.
Display indication during commissioning mode letter
S.e.r

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9. Display summary
Description Notes Section
Normal operation
1
Compressor timer active Compressor is held OFF until timer
expires
6.2 6.3
6.4
2
Compressor timer active Compressor is held ON until timer
expires
6.1
3 Loss of refrigerant alarm 6.5
4 High pressure alarm
Or
High Suction temp. alarm
Stop the compressors if HP
exceeds the 42 bar threshold. Or
Suction temperature is above 30°C
continuously for 15 minutes.
6.4
6.6
5 Temperature sensor
signal out of range
A temperature sensor may be
faulty, disconnected or short
circuit.
6.13
6 Pressure transducer
signal out of range
A transducer may be faulty,
disconnected, short circuit,
inadvertently swapped with
another, or the wrong type is
fitted.
6.13
7 Indoor coil frost alarm In the cooling cycle, if the
evaporator temperature is less
than -4°C (adjustable between -2
and 10°) for a period of time, the
compressor will stop for 15 mins.
6.8
8 Water Flow Verification
Water Float
Low water output
temperature
If the Water Pump is active for a
certain time, Water Flow
Verification Switch is open, stop
compressor.
If Water Float switch is open, stop
compressor
If the water output temperature is
below 2°C stop compressor
6.9 6.10
6.11
9 High discharge line
temperature alarm
If the discharge line temperature
rises above 110°C the compressor
will be stopped.
6.9
A Test mode Unit is in test mode 7
b D.R.E.D. active (reduced
capacity operation)
One of the 3 possible DRM modes
is activated.
5.8
C RS485 Modbus
communications alarm
Check connections with TZT-100
thermostat and/or any inverter
compressor driver in the unit.
6.14
d Unit turned OFF by an
external On/Off signal,
Phase Rotation error, or
an Open Circuit Overload.
When a TZT-100 thermostat is
used then inputs DI5 and id used
as overload input signals. Usually
these monitor condenser fan
overloads.
5.1