Carrier 040-420 manual

G Y 040-420 Contrc with h _.- - v----w I CONTENTS Page SAFETY CONSIDERATIONS . . . + . . . . , e +. . , . . , . 1 GENERAL . . . . . . , . . . . , . , . . . , . , . . . . , . , . . . . . . . . 2 MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-4 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . ...2 Low-Voltage Relay Module . , . . .[...]

-%a- GENERAL IMPORTANT: This publication contains controls, op- eration and troubleshooting data for 3OGNO40-420 and 30GT225, 250, and 280 FlotronicTM II chillers, Circuits are identified as circuits A and B, and com- pressors are identified as Al, A2, etc. in circuit A, and BI, B2, etc. in circuit B. Use this guide in conjunction with separate Ins[...]

- -.-...- KEYPAD;DISPLAY GROUND FAULT INTERRUPTER MODULE (HSIO/LID) 208/230-, 460-f%!-3-60-V ONLY LEGEND CCN - c Zarrier Comfort Network TB -1 “erminal Block ELECTRONIC EXPANSION VALVES DRIVER MODULE (DSIO EXV) LOW-VOLTAGE RELAY MODULE (DsroiLv) d TB-7 g-PACK I RELAY BOARD B ;rt’EFUCER SOURCE (PSI) COOLER I RELAY, B ,TB-3 FIELD ZEol CONNECl iE[...]

In the LOCAL/ENABLE position, the chiller is under lo- cal control and responds to the scheduling configuration and set point data input at its own local interface device (key- pad and display module). In the CCN position, the chiller is under remote control and responds only to CCN network commands. The occupied/ unoccupied conditions are defined [...]

OPERATION DATA Capacity Control - The control system cycles compressor to give capacity control steps as shown in Tables 4A-4D. The unit controls leaving chilled water tem- perature. Entering water temperature is used by the micro- processor in determining the optimum time to add or sub- tract steps of capacity, but is not a control set point. The [...]

Table 4A - Capacity Control Steps, 040-070 (cant) I LOADING SEQUENCE A LOADING SEQUENCE B UNIT 30GN I . . . a 1 I 18 ?I 56 73 050 (50 Hz) 060G Hz) Y 1:; 1 28 050 (50 Hz) “g pgy I 050 (50 Hz) 060A~**Hz) 050 (50 Hz) 06g$,y I - - - - 6 - 1 15 060 (50 Hz) 070fc Hz) 060 (50 Hz) 07Odpto**Hz) 060 (50 Hz) oypg~) , *Unloaded compressor. j-Compressor unlo[...]

Table 4A - Capacity Control Steps, 040-070 (cant) T LOADING SEQUENCE A LOADING S % Displacement (Approx) i! ii: 83 WENCE B UNIT 30GN 1 _ . . i ;. 060 (50 Hz) % Displacement tApprod 16 2: :i 100 2 65 i; 100 Compressors Al’,61 100 “‘“G Hz) Al* A-FBI Al ,k Al l ,A2,Bl Al ,A2.B1 - - - - - - Al” Bl* Al& * Al ,‘sl* Al ,Bl Al*,A2,Bl* Al .A[...]

, Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units r UNIT 30GN I LOADING SEQUENCE A LOADING SEQUENCE B % Displacement (4wW z! :: iii 100 Compressors Compressors Al* Al Al*,Bl* Al *,Bi Al ,Bl Al *,A2,Bl Al .A2.B1 Bl* Bi Ai*,Bl* Al,Bl* Al ,Bl Al .A2.81* Ai,A2,Bi Aiti - - Al” Al+yBl* AA’;Jgl Al ,Bl Al *.A2.B1 - - - - - - - -[...]

Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) UNIT CONTROL 30GN STEPS 090 (60 Hz) Aly*,Blt 090 (60 Hz) Alt**,BlY* *Unloaded compressor. tCompressor unloader, standard. **Compressor unloader, accessory TtTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing. l- LOA[...]

Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) r T UNIT 30GN LOADING LOADING SEQUENCE B CONTROL STEPS % Displacement (4wW 7 :;’ ii 43 Pii 60 7”: Ei 100 % Displacement (APPW Compressors Compressors - - - - Al*,BlTT,BZ “d;B~ltt~~2 A1’,Bl*k Al *,A2,Bitt,Bl Al ,A2,BlTt,Bl A.i‘J;,;; i;2 II I BB’.p A;;:;H Al’[...]

Table 40 - Capacity Control Steps, 080-I IO and Associated Modular Units (cant) UNIT 30GN 100, 2406, 270B (60 Hz) Alr*,Blr 100, 240B, 2708 (50 Hz) A1tW-t Wtf2Z$’ Al ,kI2,i31 Altt,A2,Bl *,B2 Al tt,A2,Bl ,B2 Al *,A2,Bl ,B2 Al .A2.Bl.B2 100, 240B, i 2708 (50 Hz) Aft**,Blt ; 9 :: E 14 : - - - - : - - - - 5 - - 100, 2408, 6 - - - - 270B (50 Hz) - - Al[...]

- Table 48 - Capacity Control Steps, 080-110 and Associated Modular Units (cant) UNIT 30GN 110 (60 Hz) Al t**,Bl Y 110 (50 Hz) Alt,Blt LOADING SEQUENCE A % Displacement (ApprW 14 ;A :: s6: 2 - - - - - - - - Compressors Al* &I * Al ‘,Bl Al ,Bi Al l ,A2,Bl* Al *,A2,Bi Al ,A2,Bl Al*,A2,Bl*,B2 Al *.A2.B1 .B2 Al ,A2,Bl ,i32 A/p A;;;# Al ,Bl Al Tt,[...]

Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) UNIT 30GN 110 (50 Hz) Alt**,Blt 110 (50 Hz) Alt,Blv 110 (50 Hz) z Alt**,Blt** i 9 :: 12 CONTROL STEPS : LOADING % Displacement UWrW - - - - - - - - - - - a - - - - - - - - - - - - *;$T Al;; Bl Al *,Bl Al ,Bl *&Wf22il”l’ Al*A2 Bl Al tt,A2,Bi ,B2 Al *,A2,Bl ,B2 Al [...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units UNIT 30GN 130, 240A, 130, 240A, 130, 240A, 130, 240A, 130,24OA, T- LOADING % Displacement Mvrox) :‘: :fz 2; ;i Ei 100 - - - - - - - - - - - - - - EQUENCE A Compressors Al* Al% * Al ‘,Bl Al ,Bl Al *,A2,Bl* Al *,A2,Bl Al ,A2,Bl Al *,A2,Bi *,B2 Al*,A2,Bl ,B2 Al .A2.B1 .B2 ’ [...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT 30GN 130, 24OA, 130,24OA, 130, 240A, CONTROL STEPS r LOADING SEQUENCE A % Displacement hwrox) 6 - - - - - - - Compressors “drt,t AlPtlBl* Al tt,Bl Al l ,Bl Al ,Bl Al tt,A2,Bl* “A’:t;P22~7El Al*A2 Bl Al tt,A2,Bl *,B2 Altt,A2,Bl ,B2 Al *,A2,Bi ,B2 Al ,A2,Bl ,B2 [...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) r EQUENCE A LOADING % Displacement (Apwxl 6 :: :“; zi 49 53 ii i: ii: 95 100 LOADING % Displacement UQwrox) EQUENCE 8 Compressors - - UNIT 30GN Compressors y-p AlPtlBl’ “Att;l”l’ Al ,‘sl AWh$Y; Al ,A2,& Altt,A2,Bi*,B2 Al tt,A2,Bl ,B2 Al *,A2,Bl ,B2 Al ,A2[...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) SEQUENCE B LOADING SEQUENCE A UNIT SIZE % Displacement (4wrox) Compressors Compressors - Bitt - Bl-*. “A;“B’:t;3”2’ Al’,Bl*‘BP Al ,A2,Bl’tt,B2 Al ,A2,Bl *,B2 Al ,A2,Bl ,B2 Al ,A2,A3,Bltt,B2 Al ,A2,A3,Bl*,B2 Al ,A2,A3,Bl ,B2 “B’.p A~i~~~~ - - - - - - -[...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT SIZE 170, 270A,300B, 170,27OA, 300B, 170,27OA, 300B, 33oA/,$cH350 Hz) 9 LOADING SEQUENCE A % Displacement (Aiwrox) - - - - - - - - - - - - - - - - - Compressors - - - - - - - - - - - Al tt Al* Al;Bl* “Alt;tbT’ Al ,Bl Alft,A2,Bl* A&t$$V; Al ,A2,Bl Altt,A2,Bl*[...]

Table 4C - Capacity Control Steps, 130210 and Associated Modular Units (cant) UNIT CONTROL SIZE STEPS 170, 270A, 300B, 33OA/z, t”fB,:“O Hz) I 170, 270A, 3008, 33OA/z, t”609+{,50 Hz) , 170,27OA, 3008, 330~A~~~f; ff Hz) , l- LOAD11 % Displacement (Approx) : 11 19 ;: :i 37 :i z; :: 72 i: ;: 96 100 - - - - - - - - - - - - - - - - - - - - - 81 ii[...]

- Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) l- r SEQUENCE B Compressors LOADIN< % Displacement OVvW 2 41 56 1;: UNIT SIZE CKEL Compressors Ah Al j2,B-i Al ,A2,Bl ,B2 Al ,A2,A3,Bl ,B2 Al ,A2,A3,Bl ,B2,63 Al* yp; Al *,A2,81 Al ,A2,B1 Al *,A2,Bl ,B2 Al ,A2,81 ,B2 Al *,A2,A3,Bl ,B2 Al ,A2,A3,81 ,B2 Al *,A2,A3,Bi [...]

Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) r l- LOADING SEQUENCE A i SEQUENCE B Compressors LOAD11 % Displacement PWprox) 11 :; ii 50 61 7; a3 94 UNIT SIZE CONTROL STEPS % Displacement UVvW Compressors - - - - - - - - - - Al* Al% l Al’,BI Al ,Bl Al*,A2,Bi* Al *,A2,Bl Al ,A2,Bl Al *,A2,Bl *,B2 Al *,A2,Bl ,B2 Al [...]

r- A Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) f LOAD11 LOADING SEQUENCE B i SEQUENCE A Compressors UNIT SIZE % Displacement (Approx) 9 i; Compressors Bl* Al% * Al .Bl* Al* Al% * Al ‘,Bl Al,Bi Al *,A2,Bl* Al *,A2,Bl Al ,A2,Bf Al”,AP,Bi *,B2 Al l ,A2,Bl ,B2 Al ,A2,Bl ,B2 Al *,A2,A3,Bl ‘,B2 Al *,A2,A3,Bi ,B2[...]

Table 4D - Capacity Control Steps, 225, 250,280 UNIT 30GT 225 (60 Hz) 225 (50 Hz) r LOAC % Displacement (Awox) 12 2 46 E 1:; IG SEQUENCE A Compressors *1A’B1 Al ,A2,61 Al ,A2,Bl ,B2 Al ,A2,A3,Bl ,B2 Al ,A2,A3,Bf ,B2,B3 Al ,A2,A3,A4,Bl ,B2,B3 Al.A2.A3.A4.Bl.B2.B3.84 Al* Al?Bl Al ,Bl Al *,A2,Bl Al ,A2,Bl Al *,A2,Bl ,B2 Al ,A2,Bl ,B2 Al l ,A2,A3,Bl[...]

UNIT 30GT 250 (60 Hz) *Unloaded compressor. JCompressor un!oader, standard **Compressor unloader, accessory ttTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing. Table 4D - Capacity Control Steps, 225, 250,280 (cant) r LOAC 22 32 29 32 t: 54 57 s7: :i 96 100 JG SEQUENCE A Compressors Al* Al% *[...]

Table 4D - Capacity Control Steps, 225, 250, 280 (cant) UNIT 30GT 250 (50 Hz) 280 (60 Hz) 250 f& Hz), Al** 250 $;; Hz), Al**,Bl** CONTROL STEPS 1G SEQUENCE A Compressors Al Al ,A2,61 Al ,A2,Bl ,B2 Al ,A2,A3,Bl ,B2 Al ,A2,A3,Bl ,B2,B3 Al ,A2,A3,A4,Bl ,B2,83 Al,A2,A3,A4,Bl,B2,B3,B4 Al” AlA’Bl Al ,Bl Al l ,A2,Bl Al ,A2,Bl Al *,A2,Bl ,I32 Al ,A[...]

Head Pressure Control - The microprocessor con- trols the condenser fans in order to maintain the lowest con- densing temperature possible, thus the highest unit efficiency. Instead of using the conventional head pressure control meth- ods, the fans are controlled by the position of the EXV and suction superheat. As the condensing temperature drops[...]

Table 5 - Condenser Fan Sequence (cant) FAN ARRANGEMENT FAN NUMBER(S) FAN C~;;jACToR CONTROLLED BY 30GT225 30GT250 (60 Hz) 7, 8 FC-1 Compressor Al 9, 10 FC-4 Compressor 61 5, 6 FC-2 First Stage 11, 12 FC-5 Microprocessor 1, 2, 3, 4 FC-3 Second Stage 13, 14, 15, 16 FC-6 Microprocessor 1, 2, 3, 4, 5, 6 FC-2, FC-3 Third Stage 11, 12, f3, 14, 15, 16 FC[...]

Keypad and Display Module (Also Called HSIO or LID) - The only function of this module is to allow the operator to communicate with the processor. It is used to enter configurations and set points and to read data, per- form tests, and set schedules. This device consists of a key- pad with 6 function keys, 5 operative keys, 12 numeric keys (0 to 9,[...]

Table 7 - Functions and Subfunctions FUNCTIONS su6FUNFT’oN Status Test Schedule Service History Set Point 0 STAT cl TEST ICI CHD cl SRVC 0 HIST cl SET 1 Automatic outputs Override Log On and Run Time Set Points Display Log Off (Chiller Fluid) 2 Alarm Compressors Clock Set Version Starts Reset Display and Unloaders (Software) Set Points 3 ;g;faQer[...]

Table 9 - Keypad Directory STATUS 2 ALARMS I 3 MODES 4 STAGE 5 SET POINT 6 TEMPERATURE KEYPAD ENTRY DISPLAY 1 LEGEND CCN - Carrier Comfort Network EXV - Electronic Expansion Valve MOP - Maximum Operating Pressure COMMENT Refer to Automatic Display Operation on page 28 X ALARMS ALARM X ALARM X ALARM X ALARM X ALARM X X MODES MODE X MODE X MODE X MOD[...]

Table 9 - Keypad Directory (cant) STATUS (cant) SUBFUNCTION I KEYPADENTRY 6 TEMPERATURE (cant) cl 4 q t cl 4 cl 4 0 4 7 PRESSURE 8 ANALOG 9 1NPUTS DISPLAY SCTB X SSTB X CTB X SHB X RST X* PRESSURE DPA X SPA X xxxx OPA X DPB X SPB X xxxx OPB X ANALOG REF X LMT X* RST X* INPUT SPW x* DLI X* DL2 X* COMMENT Circuit B Saturated Condenser Temperature Cir[...]

Table 9 - Keypad Directory (cant) SUBFUNCTION 10 OUTPUTS STATUS (cant) DISPLAY OUTPUTS ALMR X FRAI X FRA2 X FRBI X FRB2 X CHWP X* ULAI X ULA2 X* ULBI X ULB2 X* EXVA X EXVB X HGBA X* HGBB X MMA X* MMB X TEST COMMENT Status of Outputs Alarm Relay K3 Fan Relay Kl Fan Relay K2 Fan Relay K4 Fan Relay K5 Cooler Water Pump Relay K6 Unloader Al t Unloader [...]

Table 9 - Keypad Directory (cant) TEST (cant) SUBFUNCTION KEYPAD ENTRY 2 COMPRESSORS AND UNLOADERS During compressor test, compressors start and run for 10 seconds. Compressor service valves and liquid line valves must be open. Energize crankcase heaters 24 hours prior to performing compressor tests. DISPLAY COMP CPA1 X CPA2 X* CPA3 X* CPA4 X* CPBl[...]

Table 9 - Keypad Directory SCHEDULE (cant) DISPLAY PERIOD 1 OCC HH.MM UN0 HH.MM MON X TUE X WED x THU X FRl X SAT X SUN X HOL X To toggle between inputs (Yes/No) Press: Fi Fi COMMENT Period 1 Time Schedule Occupied Time Unoccupied Time Monday Flag Tuesday Flag Wednesday Flag Thursday Flag Friday Flag Saturday Flag Sunday Flag Holiday Flag 4 PERIOD [...]

Table 9 - Keypad Directory (cant) SERVICE (cord) The next 3 subfunctions provide the ability to modify configurations Refer to separate Installation, Start-Up, and Service Instructions supplied with unit for further information on changing configurations. To change a configuration, enter the new configuration and press 4 while on the correct config[...]

Table 9 - Keypad Directory (cant) SUBFUNCTION 1 RUN TIME KEYPAD ENTRY DISPLAY COMMENT r;lm RUN TIME Run Time lnformation 0 + HR X Total Hrs Unit Has a Comp Operating cl 4 HRA X Circuit A Run Time cl b HRB X Circuit B Run Time 2 STARTS 1 2 1 lHlST1 STARTS Starts Information cl + CY x Cycles from Stage 0 to Stage 1 cl + CYA X Circuit A Starts cl + CY[...]

Table 10 - Operationat and Mode Display Codes The operating modes are displayed by name or code num- ber, to indicate the operating status of the unit at a given time. The modes are: STATUS FUNCTION - This function shows the rotating display, current status of alarm (diagnostic) codes, capacity stages, operating modes, chilled water set point, all [...]

Example 2 - Reading Current Operating Modes KEYPAD I DISPLAY ENTRY RESPONSE I COMMENTS TUE 15:45 Keypad has not been used for at LOCAL ON least 10 minutes Rotating summary COOL 1 display appears on screen 0 ALARMS p-lH 2 MODES There are 2 modes currently in effect cl 4 LOCAL ON Unit is on by chiller on/off switch cl + MODE 8 Temperature reset is in[...]

Example 3 - Using Test Function KEYPAD DISPLAY I ENTRY RESPONSE COMMENTS cl + COMP CPA 1 OFF CPA 1 ON CPA 1 OFF CPA 2 OFF Factory/field test of compressors subfunction of test function Circuit A, Compressor 1A test Pressing ENTR starts the test: when the compressor should be running the display shows CPA1 on If the test is allowed to time out (10 s[...]

I. Maximum Reset Amount (CRST2) - allowable range 0” to 20” F (0” to 11” C). This is maximum amount leav- ing chilled water set point is to be increased. 2. Maximum Reset Reference (CREF2) - allowable range 0” to 20” F (0” to 11” C). This is the cooler temperature drop at which reset reaches its maximum value. 3. Minimum Reset Amoun[...]

Temperature Reset Based on External Temperature - If de- sired, temperature reset can be based on an external tem- perature, such as space or outdoor-air temperature. This re- quires a thermistor (TlO, Part No. 30GB660002) located in the space or outdoor air and wired to terminals as follows (also see Field Wiring section on page 71): 4 in/4 out Mo[...]

n POINT NUMBER OF FIRST CHANNEL Q EKE LIMIT (ALARM CODE 312 (MODE 91 4 nw/4 OUJJU PWR I --e-------1- -- __-----a ---mm- _------ __----. __---- --- ---se ___---c--- ---- - - - - - _ - - - - - - - - (MODE 71 ‘-+p-------- f ----__e- ---- -- RFt!EF (ALARM COOE 21) 301 (MODE El __----a- __---- LB--------- A In AOt B d d H = RET I- ’ c 4 z DO+ 5 D ?[...]

16 8 6 0 02 4 68 IO 12 14 16 18 20 RESET REFERENCE SIGNAL (4 -20 MA INPUT) Fig. 7 - 4-20 mA Cooling Temperature Reset Example 7A - Using Demand Limit Example 7B - Using Demand Limit (4-20 mA) (First Log On as Shown in Table 11) (First Log On As Shown in Table 11) KEYPAD ENTRY DISPLAY RESPONSE FLD CFG ERTYP 0 LSTYP 0 LSTYP 1 DEMAND DLSl 100 DLSl 60 [...]

MAX DEMAND KIMAX) = 90 DEMAND LlMlT SIGNAL (4-20 MA INPUT) Fig. 8 - 4-20 mA Demand Limiting Reading and Changing Time Displav - Time is entered Logging On/Longing Off - The service function is pass- and displayed in 24-hour time. The day of the week is en- word protected. Therefore, to gain entry to this function, tered as a number. 1 = Mon, 2 = Tu[...]

Table 12 - Factory Configuration Keystrokes To change a configuration enter the new configuration and press q while on the correct configuration. SUB- FUNCTION 3 FACTORY CFG 5 %FE DISPLAY COMMENTS FACT CFG xxxxxxxx xxxxxxxx xxxxxxxx xxxxxxxx xxxxxxxx xxxxxxxx FACTORY CONFlGURATlON CODES CJz;;g;ration Configuration Code 3 Configuration Code 4 SRV CF[...]

The schedule function can be programmed for inactive, single set point, or dual set point operation. When schedule is configured for inactive, chilled water pump relay remains energized continuously but is not used since chiller is usually controlled by remote chilled water pump interlock contacts. When unit is configured for single set point opera[...]

Example 10 - Holiday Schedule Function Example 9 - Using the Schedule Function (cant) ENTER KEENYTPRAYD I DISPLAY COMMENT DISPLAY HOLIDAY JAN01 02 (Includes Jan Ist and 2nd) APR17 01 (Includes April 17th) MAY21 01 (Includes May 21 st) JUL03 01 (Includes July 3rd) JULO4 01 (Includes July 4th) SEP07 01 (Includes Sep 7th) NOV26 02 (Includes Nov 26th a[...]

TROUBLESHOOTING The FlotronicTY II control has many features to aid the technicians in troubleshooting a Flotronic II Chiller. By us- ing keypad and display module and status function, actual operating conditions of the chiller are displayed while unit is running. Test function allows proper operation of com- pressors, compressor unloaders, fans, E[...]

Alarm Codes - Following is a detailed description of each alarm code error and possible cause. Manual reset of an alarm is accomplished by moving LOCAWENABLE- STOP-CCN Switch to STOP position, then back to LO- CAL or CCN position. See Table 14 for listing of each alarm code. Code 0 No alarms exist Codes 1 - 8 Compressor failure If DSIO-LV or -EXV r[...]

Possible causes of failure: 1. 3 d. 3. 4. 5. 6. High-Pressure Switch Open - High-pressure switch for each compressor is wired in series with 24-v power that energizes compressor control relay. If high-pressure switch opens during operation, compressor stops. This is detected by microprocessor through the feedback terminals. DSIO-LV or DSIO-EXV Modu[...]

Code 30 Reset input failure (4 to 20 mA) Code 31 Demand limit input failure (4 to 20 mA) These codes apply only if unit is configured for these functions. If 4-20 mA signal is less than 4 or more than 20 mA, reset or demand limit function is disabled and unit functions normally. If mA signal returns to the acceptable range, function is automaticall[...]

Possible causes of fault are low refrigerant charge, plugged filter drier, or a faulty EXV or thermistor. Code 48 Low suction superheat, Circuit A Code 49 Low suction superheat, Circuit B If EXV is at minimum position, suction superheat is less than 10” F (5.5” C) or saturated evaporator temperature is greater than MOP (maximum operating pressu[...]

TE7 REO I 24VAC CONTROL 5CtlEliATIC CN5 TNANZ - 32MP w I IlEO2 21V SECONDARY 1 DGT DSIO HPS E! PWR GLN U LEGEND - Contactor - Communications Bus - Compressor Protection Control Module - Discharge Gas Thermostat (Optional) - Relay Module (Low Voltage) - l-tigh-Pressure Switch - Low Voltage - Plug - Power - Terminal Block - Transformer - Unloader Fig[...]

P LEGEND CGF EM” E? kL SNB TB TRAN U Ground Fault Module Communications Bus Compressor Contactor Relay Relay Module (Low Voltage) High-Pressure Switch Low Voltage Plug Snubber Terminal Block Transformer Unloader Fig. IOC - 24-V Safety Circuit Wiring (130-210 and Associated Modular Units) 54[...]

c - CGF - Z” 1 DGT - DSIO - EXV - HPS - /$ :: ;b I: TB - PL12-7 Poll-7 LEGEND Contactor Ground Fault Module Common Control Relay Discharge Gas Thermostat (Optional) Relay Module (Low Voltage) Electronic Expansion Valve High-Pressure Switch Low Volta 8 e Normally losed Plug Reset Button Terminal Board Fig. IOD - 24-V Safety Circuit Wiring (225, 25[...]

1. Electronic Expansion Valve EXV OPERATION - These valves control the flow of liq- uid refrigerant into the cooler. They are operated by pro- cessor to maintain a specified superheat at lead compressor entering gas thermistor (located between compressor motor and cylinders). There is one EXV per circuit. See Fig. 11. High-pressure liquid refrigera[...]

_I.: ,/:. ::. i .‘I Because the EXVs are controlled by the processor mod- ule, it is possible to track valve position. During initial start-up, EXV is fully closed. After start-up, valve po- sition is tracked by processor by constantly observing amount of valve movement. The processor keeps track of EXV position by counting the number of open and[...]

MUFFLERS COMPRESSORS CIRCUIT B r CIRCUIT A J - FILTER I I c DRIER LEGEND DPT - Discharge Pressure Transducer :ppTT - Oil Pressure Transducer - Suction Pressure Transducer T - Thermistor Number Fig. 13 - Thermistor and Pressure Transducer Locations 58[...]

AIR VENT LEAVING : WATER/BRINE THERMISTOR (Tl) COOLER ENTERING FLUID WATER/BRINE BAFFLE CONNECTION SUCTION CONNECTION INLET CONNECTION DRAIN LEAVING WATER/BRINE CONNECTION I COOLER TUBE (TYPICAL) ENTERING WATER/BRINE THERMISTOR Fig. 14 - Thermistor Locations (Circuits A and B, Lead Compressor Only) COUPLING ACCESSORY FERRULES INSIDE JACKETED JACKET[...]

Thermistors - All thermistors are identical in their tem- perature vs. resistance performance. Resistance at various temperatures are listed in Tables 15 and 16. LOCATION - General location of thermistor sensors are shown in Fig. 13. Cooler Leaving Water Thermistor (Tl) - Tl is located in leaving water nozzle. The probe is immersed directly in the [...]

Table 15 - Thermistor Temperature (OF) vs Resistance/Voltage Drop; Flotronic’” II TEMP:;fTURE -2i.b -24.0 -23.0 -22.0 -21.0 -20.0 -18.0 -17.0 -16.0 - 15.0 - 14.0 -13.0 -12.0 -11.0 - 10.0 -9.0 -8.0 -7.0 -6.0 -5.0 -4.0 I;.; -l:o 0.0 ::: too 5:o 7x 8:0 9.0 10.0 11.0 12.0 13.0 14.0 i5.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28[...]

- Table 16 - Thermistor Temperature (“C) vs Resistance/Voltage Drop; Flotronic’” II TEMPERATURE (C) -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 1; -7 1; 1; -2 -1 0 : i z 3 109 VOLTAGE DROP (V) 4.896 Z~ 4.874 4.866 4 857 4 848 4 838 4.828 4.817 4.806 4 794 4.782 4.[...]

THERMISTOR* REFRIGERANT DISCHARGE ENTERING TEMPERATURE PRESSURE CYLINDERS TRANSDUCER* EQUALIZER LINE OIL PRESSURE TRANSDUCER* SUCTION PRESSURE TRANSDUCER* SIGHT GLASS (EACH COMPRESSOR) *Lead compressor only Fig. 17 - Lead Compressor Transducer and Thermistor Locations 63[...]

Control Modules Turn controller power off before servicing controls. This ensures safety and prevents damage to controller. PROCESSOR MODULE (PSIO). 4 IN/4 OUT MODULE (SIO), LOW-VOLTAGE TiELAY’MODULE (DSIO), AND EXV DRIVER MODULE (DSIO) - The PSIO, DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware[...]

PSI0 DSIO DSIO HSIO SIO ( pRocEMssOp (RELAY) (EXV DRIVER) (LID) (4 I;W;UT Fig. 19 - Sensor Bus Wiring (Communications) PROCESSOR MODULE (PSIO) (Fig. 20) Inputs - Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are used. Always refer to individual unit wiring for terminal number[...]

4 IN/4 OUT MODULE (SIO) (Fig. 22) - 4 In/4 Out mod- ule allows the following features to be utilized: 1. Temperature Reset by outdoor air or space temperature. A remote thermistor (Part No, 30GB660002) is also re- quired. NOTE: This accessory is not required for return water temperature reset. 2. Temperature Reset by remote 4-20 mA signal. 3. Deman[...]

SYMPTOMS COMPRESSOR DOES NOT RUN COMPRESSOR CYCLES OFF ON LOW PRESSURE COMPRESSOR SHUTS DOWN ~N&-l;l;PFlESSURE UNIT OPERATES LONG OR CONTINUOUSLY SYSTEM NOISES COMPRESSOR LOSES OIL FROSTED SUCTION LINE HOT LIQUID LINE FROSTED LIQUID LINE COMPRESSOR DOES NOT UNLOAD fgF;RESSOR DOES NOT Table 17 - Troubleshooting CAUSE Power line open Control fuse[...]

ACCESSORY UNLOADER INSTALLATION Some of the 30G FlotronicT” II units come standard with unloader(s), and many permit additional unloader(s) to be added if desired. See Table 18. IMPORTANT: Accessory hot gas bypass cannot be installed with accessory unloaders on units with more than 4 compressors. If accessory unloaders are desired, an accessory u[...]

~13014 115v 0R 230y;f;~RO~ S CHEMATI C i FROM 115V OR 23OV CONTROL SCHEMATIC TRAN -- 13 6 y ‘. 0 0 0 0 r--‘---------‘-‘-“--“‘-“-----------~ 1 IDS00 ! (LWl 1 -9RA 1’ ! - VI0 I I I I I I 1 I L--a--- RED- 080-110 (SO/SO Hz) and 130 (60 Hz) LEGEND ERCS - Contactor - Compressor Protection Control System k z ~~.?ther - Con[...]

130 (50 Hz), 150-210, 225, 250, AND 280 UNITS (and associated modular units) 1. Install control wiring. The minimum wire size for in- stallation is 16 AWC (American Wire Gage). Refer to Fig. 24 and 25 for proper wiring. Open the control box door. Locate unloader relays A and B (URA, URB) in place of the hot gas bypass relays as shown on the com- po[...]

GdYEL & EE Lfh]f ~gl 1 - - - - - - - - - cALARncooE31~ --------- ~~ ------II- (AIJM CODE 21,301 o(oocm I --------- i I ’ I I ’ ! I I r - - - - - - - - I ’ ’ L-B----- I ’ l ’ qg&#g’ CALAM CWE 211 I 1 I ’ w---m-- -- 43 ---- I ’ m I ’ Fam&& r-------- { ---- SWITCH a l ’ ’ ---‘I tRoDEn ‘-%F----- I ’ I ’ Q[...]

r-- --- -- EXTERNAL 3OGN040-210 AND ASSOCIATED MODULAR UNITS + --- u 3 m-7 ---- 4 -cl TB-7 30GT225,250,280 FLOTRONIC II UNITS TB - Terminal Block NOTE: The 30GT225,250,280 Flotronic’” II units require the acces- sory options module package for this feature Fig. 27 - Demand Limit - 4-20 mA Signal (Externally Powered) --j370 4 IN/4 OUT MODULE 30G[...]

&-jQ - 13 a-- 4 IN/4 OUT SWITCH MODULE ,- - m - - - -f-J J7-10 ,~,. $$ & i- - ___ - _-a J7-lf c,: * 30GN040-210 AND ASSOCIATED MODULAR UNITS ---- 1 -El TB-11 --a- -0 2 TBI1 30GT225,250,280 FLOTRONIC’” II UNITS TB - Terminal Block NOTE: The 30GT225,250,280 Flotronic II units require the acces- sory options module for this feature Fig. 33[...]

8. Reinstall all 6 wire connectors and the green ground wire. 9. Carefully check all wiring connections before restoring power. 10. Verify the LOCAL/ENABLE-STOP-CCN switch is in STOP position 11. Restore control power. Verify the red and green lights on top of PSI0 and front of each DSIO module re- spond as described in Control Modules section on p[...]

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Copyright 1994 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 -I- PC 903 Catalog No 563-015 Printed in U S A Form 30GN-2T Pg 76 l-94 Replaces: 30GEl,GT-1 T, Tab 5c 30GN-1T[...]