GENE$YS UI'"

FHP MANUFACTURINGFlorido Heot Pump Environmenlql Equipmenl

ENGINEERING APPTIGATION MANUII

TABLE OF CONTENTS

I n t r o d u c t i o n . . . . . . . . . 1

T h e r m o s t a t l n p u t s . . . . 1

L o w V o l t a g e O u t p u t s . . . . . . . . 2

H i g h V o l t a g e O u t p u t s . . . . . . . . 2

O u t p u t l . E . D t . . . . . . . 2

S " f t t y D e v i c e l n p u t s . . . . . . . . . 2

S e q u e n c e o f O p e r a t i o n . . . . . . . 3

F a u l t l n d i c a t i o n . . . . . . 4

L o c k o u t . . . . . . 4

De ta i lComponen tLayou t . , . . 5

Connection Diagram SXSingle Speed . . . . . . . 6

Connection Diagram SXTwo Speed. . . . . . . . .7

Connection Diagram Dual Compressor . . . . . . 8

INTRODUCTION:

The Gene.qrs VIrM micro processor based integrated heatpump controller was dweloped to accomplish all thenecessary control functions associated with FHPManuhcturing heat pump units that conventiondelectro-mechanical controls provided in the past. Inaddition to the normal control functions, many specialfeatures have been added to insure a safe, quiet, andreliable operating control system.

Trouble shooting of the Genesys VIrM controller has been

made very simple by incorporating a RS-485communications port on the control board to which ahand held diagnostic tool can be connected. All boardinputs, outputs, malfunctions, etc... can be determined by

the use ofthe hand held device. (See installation andoperating manual for hand held diagnostic tool) On SX

Series units, an additional RS485 port is located in theunits electrical corner post for easy access.

On-board diagnostic L.E.D.'s also enable the servicetechnician to trouble shoot the heat pump with relative

ease. The Genesys VIrM controller also allows thespecifring engineer to determine his unique controlrequirements that correspond to the Genesys VIrM uniquecontrol features.

The Genesys VIrM controller may be applied to dl FHPManufacturing Heat Pumps currently beingmanufactured. The Genesys VITM controller is standardin all SX-Series Heat Pumps, both single and two speedmodels. The controller is option in all other heat pumps.FHP recommends the use of the Geneqys VIr" controllerin dual compressor heat pumps when micro Processorbased controls are specified. On single compressor heat

pumps containing PSC fan motors FHP recommends the

use of the Genesys IVtt controller. (See installation and

operating manual for Genesys IVrM)

THERMOSTAT INPUTS:

The inputs from the thermostat are connected to the

controller at the top center of the mother board.Thermostats are always connected to this point. The

FHP Manufacturing a HARR0W Company 601 N.W. 65th Court, Fort Lauderdale, FL 33309Phone: 954177 6-547 1 Fax: 9541776-5529

Page 2

connector is removable ro make field wiring easier. TheSX-interface board is arrached to rhe mother board whenthe controller is being used in an SX-Series. \Vhen rhisboard is installed, the micro processor is ser to the SX-control algorithm. When this board is nor installed, themicro processor is set to the dual compressor controlalgorithm. The SX-interface module provides moror conrrolfunctions for the variable speed programmable motorsutilized in the SX Series. It also contains the rwo speedcompressor thermal sensor logic rhat monitors compressorthermal and current draw characteristics.There are nine (9) thermostar inpur connections and onethermostat output connection along with a commonthermostat connection at the thermostat field connecror.The nomenclature on the connector is as follows: (from lefrto right)

R Hot Side of Transformer

ML Malfunction Ught (see note.;

E Emergcncy Heat

H Humidistat

\f3 Auiliary Heat

EM Energy Management/Night SecBack Relay

G Fan

O Rwersing Valve (energized in cooling mode)

YZ High speed compressor in two speed units or

compressor number two in dud compressor unics

Yl low speed compressor in wo speed units or

compressor number one on dual compressor units

C Transformer Common

NOTE: The thermostat malfunction light may either be

powered from the hot "R",

terminal or common, "C"

terminal. The jumper pin located on the lower left portion

of the board marked "R"

or "C"

dictates rhe mdfrrnction

light output voltage supply. On most mercury bulb

thermostats the pin placement will be "C"

and for most

programmable or digital thermostats the pin placement will

be "R".

Review of the thermostat sub-base wiring is

necessary to insure proper pin placement. Factor;' pin

placement is "R". Improper pin placement may cause

damage to the controller and/or the thermostat.

Following is a list of FHP oflbred thermostats with thecorresponding MALFUNCTION LITE pin placements.

FHP T'STAT PiN PIN PLACEMENT

64r-060 R641-06r R641-068 C641-072 R

Input L.E.D.'s are present when the SX-interface board is

utilized on SX models only. L.E.D.'s present on the SX-

GENESYS VI

board are illuminated based on what inpur signals arepresent from the thermostat.

LOW VOLTAGE OUTPUTS:

All oFthe low voltage control ourpurs are located on thelower right portion of the conrroller. These outpur relaysare double pole normally open relays. They are rated at 3Amps @ 24VAC. All low voltage ourpur relays wirh theexception of the "Y2"

output relay have monitoring poinr(dry contact) capabilities associated with them. Themonitoring points are located on the lower center porrionofthe board. There are seven low voltage output relayslocated in the lower left portion ofthe board siruated asfollows: (left to right)

FAULT REIAY Dry ConractsEHR

R.EV. VALVEFAN

HGRCOMP I

COMP 2

Emergency Heat/Auxiliary Heat Output

Reversing Valve output

Fan output (used to control motor

contactor on large tonnage machines

Hot Gas Reheat Solenoid output

Compressor One or

Low Speed Compressor

Compressor Two or

High Speed Compressor

HIGH VOLTAGE OUTPUTS:

There are three high voltage output relays provided on theGenesys VIrM controller. These relays are located on the leftedge of the board. The relays are single pole-single throwrelays rated at 30 amps @ 277 Yoks or 2HP @ 277 Yoks.The relays are designated for the following firnctions:

FAN High voltage fan relay to directly power aPSC single phase hn motor

HEAT High voltage heat recovery relay toRECOVERY power the heat recovery pump

LOOP/REM. High voltage relay to power the loopPUMP pump or a high voltage water solenoid

NOTE: Do not use the high voltage output relays to powera compressor motor. The inrush (LRA) ratings of the relaywill not withstand compressor motor starts.

OUTPUTL.E.D.'S:

There are seven (7) green output L.E.D.'s located above the

output relays on the board. These L.E.D.'s are illuminated

when the associated output relays have been energized.

GENESYS VI

SAFETYDEVICE INPUTS:

The safery device inputs are connected to the board at theupper right edge of the controller. The safery device inputsare as follow: from bottom ro top)

HI TEMP Hi Temperarure LimitLO TEMP Lo Temperature LimitHI PRESS Hi Pressure SwirchLO PRESS Low Pressure Switch

COND Condensate Overflow Swirch

These devices are all normally closed inputs that will signala fault upon opening. The condensate switch input can beprogrammed as either normally open or normally closed.The condensate input, hi remp inpur, and lo temp inpurscan be enabled or disabled through the hand held device.Factory default serrings are as follows:

HI TEMP DisabledLO TEMP Disabled

Cond.Overflow Enabled-normallyclosedBrown-Out Setting 18 VAC

Random Start 30 SecondsRemote Reset On (For reset at thermostar.

For power reset onlycapabiliry remore reset is off)

A board mounted reser buron is located on top left centerof the main board. This reser burron is provided for useduring trouble shooting to avoid numerous trips to thethermostat when in default (remote reset-on) mode, or tothe unit disconnect when in the remore reset-off mode,indicating power reser feature is enabled. The reset buttoninitiates the beginning of the microprocessor's algorithmand all timing sequences reverr back ro the initiationsequence. The board mounted diagnosric fault L.E.D. (red)is located directly above the reser burron. This fault L.E.D.provides on board diagnostics by blinking a prescribednumber of times indicating the associared safery inputdevice causing the fault. (see blink codes in sequence ofoperation) A board mounted automorive rype fuse rated at5 Amps is located in the lower left center of the board. Thisfuse protects the logic circuit within the controller itself. Ifthis fuse blows it is an indication of a severe short in thecontrol circuit components or the controller itself. A highvoltage transient may also cause the fuse to blow. Replacethe fuse only once when troubleshooting the control. If thesecond fuse blows, consult the factory before proceeding introubleshooting.

The compressor sensor input circuit is located on the SX-interface board. The sensor leads from the compressorthermistors located in the compressor moror windings areattached directly ro rhe sensor input on the interface board.This circuit is enabled through the hand held ar the factorywith two speed SX models. When the sensor inpur isdisabled through the hand held, however, the fault L.E.D.on the upper level of rhe hand held device will remainilluminated. This is normal and does nor indicare an actual

Page 3

motor sensor failure since no motor sensor input exists.(Also see sequence ofoperarion flow chart and hand helddevice operaring instruct ions).

Power is applied to the controller by rhe unit's Class 2transformer. The24 Volt secondary power is connected tothe

"R" and "C"

terminal smip located on rhe lower leftbottom edge of rhe board. The output relay buss is alsopowered by the unit's transformer. A board mounted

"green"

power L.E.D. is illuminated when power is present. ThisL.E.D. is located directly above the MALF LITE selecr pin.

SEQUENCE OF OPERATTON:

Upon power-up rhe brown-out condition is continuouslymonitored. If the secondary voltage drops below 17. I VAC(5% below rhe default serring of l8 VAC) or 5%o below thebrown-out setting programmed through the hand helddevice, all control functions are inhibired and one blink ofthe malfuncrion L.E.D. indicates a brown-out fauk. \(henthe secondary voltage rerurns to 18.9 VAC or 5olo above thebrown-out setpoint, the fault clears and the controller isenabled.

In the cooling mode the reversing valve output is energizedthrough the

"O" input from the thermostat.

'When ir is on

it is on, and when it is off it is off, There are no delays orshifts of the reversing valve in rhe cooling mode. Shiftingthe reversing valve can cause extensive wear and excessivenoise to occur within the reversing valve. Vhen the

"O"

line is energized rhe "\73"

and "E"

ourpurs are inhibited.This disables the resisrance heat in the cooling mode.

The fan comes on when the "G" line input is made from

the thermostat. In the consranr on position the fan will runconstantly. In SX-Series units, the fan operates based onthe internal programs contained in the ICM motor. In allother applications, when the

"G" line is operated in the

auto mode from the thermosrat, i t operates in conjunctionwith the

"Yl" or

"H" inpurs from the thermostat. In this

mode the fan is delayed for 10 seconds after "Yl"

or "H"

inputs are initiated. When "Yl"

or "H"

is de-energized, thefan continues to run for a period of30 seconds afterwards.This delay on make and break of the fan moror providestwo functions: On start up the air coil of the heat pumpcan cool down or hear up thus eliminating unwanted coldor warm drafts depending on the mode of operation. Also,on shutdown the residual heating or cooling thermal energystored in the coil can be transferred to rhe space. On a callfor electric auxiliary heat or emergency heat the fan delay onmake is eliminated so thar whenever resistance hearers areenergized the fan comes on insranraneously. The fancontinues to run for 30 seconds after srrip heater de-energization.

When the "Yl"

input line is energized from rhe rhermostatcalling for lst stage heating or cooling, the Remote Solenoidor Loop Pump Output Relay is energized after the random

Page 4 GENESYS VI

srarr rime has been satisfied (30-600 seconds selectable). FAULT INDICATION:

Also, the anti-short rycle period of 60 seconds must have

elapsed since rhe previous start. After the above timing All safery device inputs are normally closed switches with

periods, the I st stage compressor output relay is energized the exception of the condensate overflow switch which can

in conjunction with the hear recovery output relay. On be set to either N.O. or N.C. through the hand held dwice.

shutdown the fan and loop pump/remote solenoid outputs The safery device fault codes generated through the on

remain energized for 30 seconds. board red fault L.E.D. are as Follow:

\fhen the "Y2"

input line is energized from the thermostat Brown-Out I

calling for 2nd stage heating or cooling, and the SX- Hi Pressure 2

interface board is present, the heat pump operates in the Lo Pressure 3

rwo speed mode. On a call for "Y2"

the "Yl "

output is de- Hi Temperature 4

energized. This eliminates the possibiliry of energizing both Lo Temperature 5

compressor windings simultaneously. After a 60 second Condensate Overflow 6

delay, the "Y2"

output relay is engaged and high speed Compressor Overload (SX-2 spd.) 7

cooling or heating is initiated. tWhen the SX-interface board

is not present the heat pump operates in the dual

compressor mode. In this mode the "Y2"

output is LOCKOUT:

energized 60 seconds after the "Yl"

output. If60 seconds

has already elapsed between "Yl"

and "Y2"

inputs the The low pressure input is bypassed for a period of 180

second srage compressor will start instantaneously. On dual seconds upon the initiation of the "Yl"

output to allow for

compressor or two speed heat pumps the "Y2"

output cold start applications. After 180 seconds it is enabled.

remains active unril the "Yl" input is satisfied. This unique

high stage lock-in logic reduces compressor run time and The condensate overflow input is monitored for 270

eliminates cycling back and forth from low to high speed, or seconds before a lockout is initiated.

from single to dual compressors. On single speed SX units,

use rhe "Y2"

input on the board connected to the "Yl "

All other safery input openings dictate an immediate

ourput of the thermostat. lockout situation. A l0 minute intelligent reset feature is +

rn rhe hearing mode the sequence of operation is exactly ff:"tJi:[l:]ilTixT;:'iJr;'}...,T::il:,'fi*'that as cooling mode operation with the absence of the

"O" lockout. If the safery device resets itself within this time

input/output, reversing valve energized. period normal sequencing is re-initiated. Ifany

malfunction occuts or re-occurs within a 30 minute time

On a call for "W3"

from the thermostat, the auxiliary heat frame a hard lockout is initiated. A lockout mode can be

ourpur is energized and the electric heat is enabled. This is reset by either pushing the board mounted reset button or

third stage heat which supplements the compressor in the turning the unit's thermostat offfor a 60 second period and

heating mode. then back on.

On a call for "E"

from the thermostat, the emergency heat The controller can be run in a test mode by the use of the

ourpur is energized. The electric heat is enabled and all hand held device. In the test mode all sequence timings are

orher ourpurs are disabled. In both auxiliary heat and reduced to l0 seconds to allow for quick diagnostics and

emergency heat modes the fan motor is energized troubleshooting. See the operating manual on the hand

instantaneously. held device for troubleshooting with the hand held.

Thermostat connections do not have to be removed from

In the reheat mode (dual compressor units only, reheat not the controller when troubleshooting with the hand held

available on SX models) the H input from rhe humidistat device. The fan switch must be in the constant on position

drives "Yl "

and "Y2"

ourpurs off for a 60 second period. when troubleshooting with the hand held device on all SX

The reversing valve output is energized and the hot gas Series units

reheat solenoid output is energized. After the 60 second off

delay the compressor output is enabled. Shutdown

sequence is identical to cooling mode operation.

!7hen the EM input is made from an energy

management/night setback relayltime clock, all outPuts are

inhibited. The random start feature is initiated upon

termination of power supply, night setback period, or EMS

mode.

Page 5GENESYS VI

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