30GN040-420 Flotronic™ II Reciprocating Liquid Chillers 50/60 Hz Controls, Operation, and Troubleshooting with Microprocessor Controls and Electronic Expansion Valves CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-5 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Low-Voltage Relay Module . . . . . . . . . . . . . . . . . . .
Table 1 — Unit Sizes and Modular Combinations SAFETY CONSIDERATIONS UNIT MODEL 30GN 040 045 050 060 070 080 090 100 110 130 150 170 190 210 230 245 255 270 290 315 330 360 390 420 Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.
COMM 3 PWR POINT NUMBER OF FIRST CHANNEL X X EXV LV STATUS STATUS COMM COMM 5VDC 1 Potter & Brumfield CZ770 HK35AA002 2 COMM 1 COMM 3 4- 3+ J5 PWR S1 J4 J4 X X S2 EQUIP GND 99NA505322 D FUSE 1 LO C A L / ENABLE SW1 STOP CCN FUSE 3 F U SE 9 5 6 1 2 3 TEST ENTR – 0 • HIST CLR F 8 4 SET EXPN E U SE FU S 7 SCHD SRVC STAT FUSE 2 GFI - CO ( 5 AMP MAX ) CB5 CB6 30GT510568 – LEGEND CCN — Carrier Comfort Network TB — Terminal Block Fig.
Table 2 — LOCAL/ENABLE-STOP-CCN Switch Positions and Operation also controls the EXV driver module (as appropriate), commanding it to open or close each EXV in order to maintain the proper superheat entering the cylinders of each lead compressor. Information is transmitted between the processor module and relay module, the EXV driver module, and the keypad and display module through a 3-wire communications bus. The options module is also connected to the communications bus.
The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler by monitoring the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless absolutely necessary. When TXV is used, thermistors T7 and T8 are not required. The TXV is designed to limit the cooler saturated suction temperature to 55 F (12.8 C).
Table 4A — Capacity Control Steps, 040-070 UNIT 30GN 040 (60 Hz) A1†,B1 040 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1 040 (50 Hz) 045 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1** 045 (50 Hz) 050 (60 Hz) A1†,B1 045 (50 Hz) 050 (60 Hz) A1†,B1** 045 (50 Hz) 050 (60 Hz) A1†**,B1 045 (50 Hz) 050 (60 Hz) A1†**,B1** 045 (50 Hz) 050 (60 Hz) A1†,B1** CONTROL STEPS 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 6 7 LOADING SEQUENCE A % Displacement C
Table 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN 045 (50 Hz) 050 (60 Hz) A1†**,B1** 050 (50 Hz) 060 (60 Hz) A1†,B1 050 (50 Hz) 060 (60 Hz) A1†,B1** 050 (50 Hz) 060 (60 Hz) A1†**,B1 050 (50 Hz) 060 (60 Hz) A1†**,B1** 050 (50 Hz) 060 (60 Hz) A1†,B1** 050 (50 Hz) 060 (60 Hz) A1†**,B1** 060 (50 Hz) 070 (60 Hz) A1†,B1 060 (50 Hz) 070 (60 Hz) A1†,B1** 060 (50 Hz) 070 (60 Hz) A1†**,B1 060 (50 Hz) 070 (60 Hz) A1†**,B1** 060 (50 Hz) 070 (60 Hz) A1†,B1** CONTROL STEPS 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4
Table 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN 060 (50 Hz) 070 (60 Hz) A1†**,B1| 070 (50 Hz) A1†,B1 070 (50 Hz) A1†,B1** 070 (50 Hz) A1†**,B1 070 (50 Hz) A1†**,B1** 070 (50 Hz) A1†,B1| 070 (50 Hz) A1†**,B1| CONTROL STEPS 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 LOADING SEQUENCE A % Displacement Compressors (Approx) 16 A1†† 33 A1* 50 A1 66 A1††,B1 83 A1*,B1 100 A1,B1 19 A1* 27 A1 65 A1*,B1 73 A1,B1 92 A1*,A2,B1 100 A
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units UNIT 30GN CONTROL STEPS 080, 230B (60 Hz) A1†,B1† 080, 230B (60 Hz) A1†**, B1† 080, 230B (60 Hz) A1†,B1†** 080, 230B (60 Hz) A1†**,B1†** 080, 230B (50 Hz) A1†,B1† 080, 230B (50 Hz) A1†**,B1† 080, 230B (50 Hz) A1†,B1†** 080, 230B (50 Hz) A1†**,B1†** 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 LOADING SEQUENCE A % Displacemen
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS 090, 245B (60 Hz) A1†,B1† 090, 245B (60 Hz) A1†**,B1† 090, 245B (60 Hz) A1†,B1†** 090, 245B (60 Hz) A1†**,B1†** 090, 245B (50 Hz) A1†,B1† 090, 245B (50 Hz) A1†**,B1† 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING SEQUENCE A % Displacement Compressors (Approx) 18 A1* 27 A1 35 A
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 090, 245B (50 Hz) A1†,B1†** 090, 245B (50 Hz) A1†**,B1†** 100, 255B, 270B (60 Hz) A1†,B1† 100, 255B, 270B (60 Hz) A1†**,B1† 100, 255B, 270B (60 Hz) A1†,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING SEQUENCE A % Displacement Compressors (Approx) — — — — — — — — — — — — — — —
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 100, 255B, 270B (60 Hz) A1†**,B1†** 100, 255B, 270B (50 Hz) A1†,B1† 100, 255B, 270B (50 Hz) A1†**,B1† 100, 255B, 270B (50 Hz) A1†,B1†** 100, 255B, 270B (50 Hz) A1†**,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LOADING SEQUENCE A % Displacement Compressors (Approx) 8 A1†† 16 A1*
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 110, 290B, 315B (60 Hz) A1†,B1† 110, 290B, 315B (60 Hz) A1†**,B1† 110, 290B, 315B (60 Hz) A1†,B1†** 110, 290B, 315B (60 Hz) A1†**,B1†** 110, 290B, 315B (50 Hz) A1†,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 LOADING SEQUENCE A % Displacement Compressors (Approx) 14 A1* 21 A1 29 A1*,B1* 36 A1
Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 110, 290B, 315B (50 Hz) A1†**,B1† 110, 290B, 315B (50 Hz) A1†,B1†** 110, 290B, 315B (50 Hz) A1†**,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 LOADING SEQUENCE A % Displacement Compressors (Approx) 8 A1†† 17 A1* 25 A1 33 A1††,B1 42 A1*,B1 50 A1,B1 58 A1††,A2,B1 67 A1*,A2,B1 75 A1,A2,B1 83 A1††,A2,B1,B2 92 A1*,A2,B1,B2 100 A1,A2,B1,B2 — — — — — — — — — — — — —
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units UNIT 30GN 130 (60 Hz) A1†,B1† 130 (60 Hz) A1†**,B1† 130 (60 Hz) A1†,B1†** 130 (60 Hz) A1†**,B1†** 130 (50 Hz) A1†,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING SEQUENCE A % Displacement Compressors (Approx) 14 A1* 21 A1 28 A1*,B1* 35 A1*,B1 42 A1,B1 58 A1*,A2,B1* 64 A1*,A2,B1 71 A1
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN 130 (50 Hz) A1†**,B1† 130 (50 Hz) A1†,B1†** 130 (50 Hz) A1†**,B1†** 150, 230A, 245A, 255A (60 Hz) A1†,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING SEQUENCE A % Displacement Compressors (Approx) 6 A1†† 10 A1* 14 A1 22 A1††,B1* 31 A1††,B1 35 A1*,B1 39 A1,B1 40 A1††,A2,B1*
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN 150, 230A, 245A, 255A (60 Hz) A1†**,B1† 150, 230A, 245A, 255A (60 Hz) A1†,B1†** 150, 230A, 245A, 255A (60 Hz) A1†**,B1†** 150, 230A, 245A, 255A (50 Hz) A1†,B1† 150, 230A, 245A, 255A (50 Hz) A1†**,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LOADING SEQUENCE A
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 150, 230A, 245A, 255A (50 Hz) A1†,B1†** 150, 230A, 245A, 255A (50 Hz) A1†**,B1†** 170, 270A, 330A/B (60 Hz) A1†,B1† 170, 270A, 330A/B (60 Hz) A1†**,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 LOADING SEQUENCE A % Displacement Compressors (Approx) — — — — — — — — — — —
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 170, 270A, 330A/B (60 Hz) A1†,B1†** 170, 270A, 330A/B (60 Hz) A1†**,B1†** 170, 270A, 330A/B,360B (50 Hz) A1†,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 LOADING SEQUENCE A % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1† 170, 270A, 330A/B, 360B (50 Hz) A1†,B1†** 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 LOADING SEQUENCE A % Displacement Compressors (Approx) 5 A1†† 9 A1* 14 A1 14 A1††,B1* 1
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 190, 290A, 360A/B, 390B (60 Hz) A1,B1 190, 290A, 360A/B, 390B (60 Hz) A1**,B1 190, 290A, 360A/B, 390B (60 Hz) A1,B1** 190, 290A, 360A/B, 390B (60 Hz) A1**,B1** 190, 290A, 360A, 390B (50 Hz) A1,B1 190, 290A, 360A, 390B (50 Hz) A1**,B1 CONTROL STEPS 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 LOADING SEQUENCE A %
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 190, 290A, 360A, 390B (50 Hz) A1,B1** 190, 290A, 360A, 390B (50 Hz) A1**,B1** 210, 315A, 390A, 420A/B (60 Hz) A1,B1 210, 315A, 390A, 420A/B (60 Hz) A1**,B1 210, 315A, 390A, 420A/B (60 Hz) A1,B1** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING % Displacement (Approx) — — — — — — — — — — — — 1
Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 210, 315A, 390A, 420A/B (60 Hz) A1**,B1** 210, 315A, 390A, 420A/B (50 Hz) A1,B1 210, 315A, 390A, 420A/B (50 Hz) A1**,B1 210, 315A, 390A, 420A/B (50 Hz) A1,B1** 210, 315A, 390A, 420A/B (50 Hz) A1**,B1** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOADING % Displace
Head Pressure Control Keypad and Display Module (Also Called HSIO or LID) — The only function of this module is to allow EXV UNITS (All 30GN units except 040 and 045 with optional brine) — The microprocessor controls the condenser fans in order to maintain the lowest condensing temperature possible, thus the highest unit efficiency. Instead of using the conventional head pressure control methods, the fans are controlled by the position of the EXV and suction superheat.
Table 5 — Condenser Fan Sequence FAN ARRANGEMENT 30GN FAN NUMBER(S) FAN CONTACTOR (FC) CONTROLLED BY 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 First Stage Microprocessor 4 FC-B2 Second Stage Microprocessor 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3, 4 FC-A2 First Stage Microprocessor 5, 6 FC-B2 Second Stage Microprocessor 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 4 FC-B2 First Stage Microprocessor 3, 4, 5, 6 FC-A2, FC-B2, FC-A3, FC-B3 Second St
Table 6 — Keypad and Display Module Usage FUNCTION KEYS 3. All functions are made up of a group of subfunctions. To enter a subfunction, first press subfunction number desired. Then press the function key in which the subfunction resides. To move within that subfunction, press USE STATUS — For displaying diagnostic codes and current operating information about the machine. HISTORY — For displaying run time, cycles and previous alarms. SERVICE — For entering specific unit configuration information.
Table 8 — Accessing Functions and Subfunctions KEYPAD ENTRY OPERATION DISPLAY RESPONSE To access a function, press subfunction no. and function name key. Display shows subfunction group. To move to other elements, scroll up or down using arrow keys. NOTE: These displays do not show if control is not configured for reset. When the last element in a subfunction has been displayed, the first element is repeated. To move to next subfunction it is not necessary to use subfunction number.
Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 4 STAGE 5 SET POINT 6 TEMPERATURE DISPLAY COMMENT STAGE Capacity Staging Information COOL X Number of Requested Stages CAPT X Percent of Total Capacity CAPA X Percent Circuit A Total Capacity CAPB X Percent Circuit B Total Capacity AVAIL X Percent Available Capacity AV A X Percent Circuit A Available Capacity AV B X Percent Circuit B Available Capacity LMT X† Demand Limit Set Point (percent) CIRA X Circuit A C
Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 7 PRESSURE 8 ANALOG 9 INPUTS 10 OUTPUTS DISPLAY COMMENT PRESSURE Refrigerant System Pressure (psig) MM DD YY Date of Last Calibration DPA X Circuit A Discharge Pressure (psig) SPA X Circuit A Suction Pressure (psig) XXXX XXX Circuit A Discharge/Suction (psig) OPA X Circuit A Oil Pressure Differential (psig) DPB X Circuit B Discharge Pressure (psig) SPB X Circuit B Suction Pressure (psig) XXXX XXX Circuit B Disc
Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 10 OUTPUTS (cont) DISPLAY COMMENT EXVB X EXVB Percent Open** HGBA X† Hot Gas Bypass Relay Circuit A (on/off)** HGBB X† Hot Gas Bypass Relay Circuit B (on/off)** MMA X† MotormasterT A Output Percent** MMB X† Motormaster B Output Percent** TEST To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position. To operate a test, scroll to desired test. Then, press to start test. Press to stop test.
Table 9 — Keypad Directory (cont) TEST (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY 2 COMPRESSORS AND UNLOADERS (cont) 3 CALIBRATE TRANSDUCERS COMMENT CPA3 X† Test Compressor A3 (on/off)** CPA4 X† Test Compressor A4 (on/off)** CPB1 X Test Compressor B1 (on/off) CPB2 X† Test Compressor B2 (on/off)** CPB3 X† Test Compressor B3 (on/off)** CPB4 X† Test Compressor B4 (on/off)** UNA1 X Energize Unloader A1 (on/off)** UNA2 X† Energize Unloader A2 (on/off)** UNB1 X Energize Unloader B1 (on/off)**
Table 9 — Keypad Directory (cont) SCHEDULE (cont) SUBFUNCTION KEYPAD ENTRY 3 PERIOD 1 (cont) To toggle between inputs (Yes/No) Press: (no) or DISPLAY COMMENT FRI X Friday Flag (yes/no) SAT X Saturday Flag (yes/no) SUN X Sunday Flag (yes/no) HOL X Holiday Flag (yes/no) (yes) 4 PERIOD 2 PERIOD 2 Period 2 Time Schedule PERIOD 3 ... PERIOD 7 Period 3 ... Period 7 Time Schedule 10 PERIOD 8 PERIOD 8 Period 8 Time Schedule 11 HOLIDAYS HOLIDAYS Define Calendar Holidays DAT MM.
Table 9 — Keypad Directory (cont) SERVICE (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY 3 FACTORY CONFIGURATION (cont) 4 FIELD CONFIGURATION COMMENT XXXXXXXX Configuration Code 5 XXXXXXXX Configuration Code 6 XXXXXXXX Configuration Code 7 FLD CFG Adjustable Field Configuration ENO X CCN Element Address BUS X CCN Bus Number BAUD X CCN Baud Rate FLUID X Cooler Fluid Select (water/medium brine) UNITS X Display Unit Select (English/Metric) DELAY X Delay at Power Up (minutes) NULA X No.
Table 9 — Keypad Directory (cont) HISTORY SUBFUNCTION KEYPAD ENTRY 1 RUN TIME 2 STARTS 3 ALARM/ALERT HISTORY†† DISPLAY COMMENT RUN TIME Run Time Information HR X Total Hrs Unit Has a Comp Operating HRA X Circuit A Run Time HRB X Circuit B Run Time HA1 X Circuit A, Comp A1 Operating Hours HA2 X Circuit A, Comp A2 Operating Hours** HA3 X Circuit A, Comp A3 Operating Hours** HA4 X Circuit A, Comp A4 Operating Hours** HB1 X Circuit B, Comp B1 Operating Hours HB2 X Circuit B, Comp B2 Op
Table 9 — Keypad Directory (cont) SET POINT To read a set point, go to proper subfunction and read desired set point. To change a set point, enter new set point value, then press LOCAL/ENABLE-STOP-CCN switch must be in LOCAL/ENABLE or STOP position. SUBFUNCTION KEYPAD ENTRY 1 SET POINTS 2 RESET SET POINTS 3 DEMAND SET POINTS 4 DATE AND TIME DISPLAY .
To reset alarms/alerts using keypad and display module: STATUS FUNCTION — This function shows the rotating display, current status of alarm and alert (diagnostic) codes, capacity stages, operating modes, chilled water set point, all measured system temperatures and pressures, superheat values, pressure switch positions, analog inputs, and switch inputs. These subfunctions are defined on pages 36 and 37.
Table 10 — Operational and Mode Display Codes The operating modes are displayed by name or code number, to indicate the operating status of the unit at a given time. The modes are: (Set Point) — This subfunction displays leaving fluid temperature and leaving chilled fluid set point. If unit is programmed for dual set point, the chilled fluid set point currently in effect (either occupied or unoccupied) is displayed. If reset is in effect, the unit operates to the modified chilled fluid set point.
Keypad entry SET POINT FUNCTION — Set points are entered through the keypad. Set points can be changed within the upper and lower limits, which are fixed. The ranges are listed below. allows the operator to make the following checks by using : • LID display check. Proper display is 8.8.8.8.8.8.8.8. • Operation of alarm relay. • Operation of condenser fans. • Operation of chilled fluid pump. • Operation of liquid line solenoids. • Operation of the hot gas bypass relays. • Operation of EXVs.
Example 4 — Reading and Changing Chilled Fluid Set Point KEYPAD ENTRY DISPLAY RESPONSE COMMENTS SET POINT System set points CSP1 44.0 Present occupied chilled fluid set point is 44.0 F CSP1 42.0 Press the . Display shows new occupied chilled fluid set point is 42.0 F Present unoccupied chilled fluid set point is 44.0 F CSP2 44.0 CSP2 50.0 RESET configuration.
Example 5B — 4 to 20 mA and Internally or Externally Powered Reset In this example, the unit set point is reset from full load at 4 mA to a maximum reset value of 10 F (5.5 C) at 20 mA. Internally powered 4 to 20 mA option is used in this example. NOTE: To use externally powered reset, when CRTYP Temperature Reset Based on External Temperature — If desired, temperature reset can be based on an external temperature, such as space or outdoor-air temperature. This requires a thermistor (T10, Part No.
Fig. 6 — Cooling External Temperature Reset LEGEND COMM — Communications Bus PWR — Power SW — Switch NOTE: For specific connection points, see Fig. 25 - 29. Fig.
Fig. 8 — 4-20 mA Cooling Temperature Reset Table 12 — Service Functions To view and modify configurations, the password must be entered under the log on subfunction. Example 6 — Changing Reset Type To change type of reset, first log on as shown in Table 12. Also refer to Set Point Function section, page 38, for information on entering reset set points using reset feature.
the loadshed demand delta, which defines the percent of the load to be removed when a loadshed command is in effect. The third set point is maximum loadshed time, which defines the maximum length of time that a loadshed condition is allowed to exist. The allowable range for this entry is zero to 120 minutes. Subfunction displays date, time, and day of the week. At field configuration step, select 4 to 20 mA loadshed by entering (internally powered) or (externally powered) when the LSTYP 0 display appears.
Fig. 9 — 4-20 mA Demand Limiting replaced in the field, the 2 groups of configuration codes must be entered through the keypad and display module. The 2 groups of configuration codes (groups 8 and 9) that apply to the unit being serviced can be found on a label diagram inside the control box cover. See Table 13 for keystroke information to enter configuration codes 8 and 9. The remaining items in this subfunction are read-only data provided to assist in service evaluations.
Table 13 — Factory Configuration Keystrokes To change a configuration enter the new configuration and press SUBFUNCTION 3 FACTORY CFG 5 SERVICE CFG Table 14 — Adjustable Field Configurations FIELD CONFIGURATION ITEM AND CODES while on the correct configuration.
Example 9 — Using the Schedule Function (cont) NOTE: This is true only if the occupied period starts at 00:00 (midnight). If the occupied period starts at a time other than midnight, then the occupied period must end at 00:00 hours (midnight) and new occupied period must be programmed to start at 00:00 in order for the chiller to stay in the occupied mode past midnight. The time schedule can be overridden to keep unit in occupied mode for one, 2, 3, or 4 hours on a one-time basis. See Example 9.
Periods 4 and 5 can be programmed in the same manner, flagging Thursday and Friday yes for period 4 and Saturday yes for period 5. For this example, periods 6, 7, and 8 are not used: they should be programmed OCC 00.00, UNO 00.00. NOTE: When a day is flagged yes for 2 overlapping periods, occupied time will take precedence over unoccupied time. Occupied times can overlap in the schedule with no consequence.
Unit Shutoff — To shut unit off, move LOCAL/ENABLESTOP-CCN switch to STOP position. Any refrigeration circuit operating at this time continues to complete the pumpout cycle. Lag compressors stop immediately, and lead compressors run to complete pumpout. If stoppage occurs more than once as a result of any of the above safety devices, determine and correct the cause before attempting another restart. Complete Unit Stoppage — Complete unit stoppage can 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Table 16 — Alarm and Alert Codes 0 ALARM OR DESCRIPTION ALERT — No Alarms or Alerts Exist — — 1 Compressor A1 failure Circuit A shut down No Manual Compressor A2, A3, A4 failure Compressor B1 failure Compressor B2, B3, B4 failure Compressor shut down Circuit B shut down Compressor shut down Yes No Yes Manual Manual Manual Leaving fluid thermistor failure Entering fluid thermistor failure Compressor A1 sensor failure Compressor B1 sensor failure Reset thermistor failure Unit shut down Unit shu
Table 16 — Alarm and Alert Codes (cont) DISPLAY ALARM OR ALERT 63 DESCRIPTION ACTION TAKEN BY CONTROL CIRCUIT PUMPDOWN RESET METHOD PROBABLE CAUSE Alarm Complete unit shutdown Alarm only — Auto. Check individual alarms 64 65 Alert Loss of charge, circuit A Loss of charge, circuit B Circuit cannot start Circuit cannot start — — Auto. Auto. Refrigerant leak or transducer failure 66 Alarm FSM communication loss FSM forces removed — Auto.
C CB COM, COMM CPCS — — — — CR DGT DSIO HPS LV NC NO PL PWR SNB TB TRAN U — — — — — — — — — — — — — LEGEND Contactor Circuit Breaker Communications Bus Compressor Protection Control Module Compressor Contactor Relay Discharge Gas Thermostat (Optional) Relay Module (Low Voltage) High-Pressure Switch Low Voltage Normally Closed Normally Open Plug Power Snubber Terminal Block Transformer Unloader Fig.
C CB COMM CPCS DGT DSIO HPS LV PL PWR TB TRAN U — — — — — — — — — — — — — LEGEND Contactor Circuit Breaker Communications Bus Compressor Protection Control Module Discharge Gas Thermostat (Optional) Relay Module (Low Voltage) High-Pressure Switch Low Voltage Plug Power Terminal Block Transformer Unloader *And associated modular units. Fig. 11B — 24-V Safety Circuit Wiring (080-110 and Associated Modular Units) The voltage supplied to the processor is polarized.
CB CGF COMM CR DSIO HPS LV PL SNB TB TRAN U LEGEND — Circuit Breaker — Ground Fault Module — Communications Bus — Compressor Contactor Relay — Relay Module (Low Voltage) — High-Pressure Switch — Low Voltage — Plug — Snubber — Terminal Block — Transformer — Unloader *And associated modular units. Fig.
Code 50 Illegal configuration (alarm) This fault indicates a configuration error. Unit is not allowed to start. Check all configuration data and set points and correct any errors. Code 51 Initial configuration required (alarm) This fault indicates factory configuration has not been done, and unit is not allowed to start. Refer to unit wiring label diagrams for factory configuration codes. There are 9 groups of 8-digit numbers that must be entered. The first 7 groups must be entered under subfunction.
15 psig. This alarm does not function in units using different part number transducers for suction and discharge pressure, since the discharge transducer in that application does not function below 20 psig. Code 66 Flotronic™ System Manager loss of communications (alarm) If the FSM has established communication with the control, and the communication is subsequently lost for more than 20 seconds, the control will remove all forces on the chiller variables.
vapor). To control refrigerant flow for different operating conditions, sleeve moves up and down over orifice, thereby changing orifice size. Sleeve is moved by a linear stepper motor. Stepper motor moves in increments and is controlled directly by the processor module. As stepper motor rotates, motion is transferred into linear movement by lead screw. Through stepper motor and lead screws, 1500 discrete steps of motion are obtained.
Other possible causes of improper refrigerant flow control could be restrictions in liquid line. Check for plugged filter drier(s) or restricted metering slots in the EXV. Formation of ice or frost on lower body of electronic expansion valve is one symptom of restricted metering slots. However, frost or ice formation is normally expected when leaving fluid temperature from the cooler is below 40 F. Clean or replace valve if necessary.
Table 17 — Thermistor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ II TEMPERATURE (F) −25.0 −24.0 −23.0 −22.0 −21.0 −20.0 −19.0 −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 −3.0 −2.0 −1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0 51.0 52.0 53.0 54.0 55.0 56.
Table 18 — 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 −9 −8 −7 −6 −5 −4 −3 −2 −1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 VOLTAGE DROP (V) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.
DPT EXV OPT SPT T — — — — — LEGEND Discharge Pressure Transducer Electronic Expansion Valve Oil Pressure Transducer Suction Pressure Transducer Thermistor Number Fig. 14 — Thermistor and Pressure Transducer Locations Pressure Transducers — A single style of pressure transducer is used for both high- and low-pressure sensing on Flotronic™ II chillers. However, this transducer must be calibrated before the unit will operate.
Fig. 15 — Thermistor Locations (Circuits A and B, Lead Compressor Only) COMPRESSOR SUCTION GAS TEMPERATURE THERMISTORS T7 AND T8 (ALL UNITS) AND FLUID-SIDE TEMPERATURE THERMISTOR T1 (ALL UNITS) FLUID-SIDE TEMPERATURE THERMISTOR T2 (ALL UNITS) Fig.
Fig. 17 — Lead Compressor Transducer and Thermistor Locations 3. Unscrew transducer from 1⁄4-in. male flare fitting. When installing new pressure transducer, do not use thread sealer. Thread sealer can plug transducer and render it inoperative. 4. Insert weathertight wiring plug into end of transducer until locking tab snaps in place. 5. Check for refrigerant leaks. TRANSDUCER REPLACEMENT Transducers are installed directly in the refrigerant circuit.
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 RELAY MODULE (DSIO-LV), AND EXV DRIVER MODULE (DSIO-EXV) — The PSIO, DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware.
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 numbers. Outputs — Output is 24 vdc. There are 3 terminals, only 2 of which are used, depending on application. Refer to unit wiring diagram. NOTE: Address switches (see Fig. 20) must be set at 01 (different when CCN connected).
3. Install the additional unloader cylinder head on the lead compressor, A1 or B1, according to instructions provided by the compressor manufacturer in the accessory package. 4. Continue installation per either 040-110, 130 (60 Hz) units or 130 (50 Hz), 150-210 units section as appropriate. 040-110, 130 (60 Hz) UNITS (And Associated Modular Units) 1. Wire the solenoid before any field wiring begins. Wiring between components and control box must be enclosed in conduit.
Table 19 — Troubleshooting SYMPTOMS COMPRESSOR DOES NOT RUN CAUSE Power line open Control fuse open High-Pressure Switch (HPS) tripped Tripped power breaker Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective COMPRESSOR CYCLES OFF ON LOW PRESSURE COMPRESSOR SHUTS DOWN ON HIGH PRESSURE CONTROL UNIT OPERATES LONG OR CONTINUOUSLY SYSTEM NOISES Seized compressor Loss of charge Bad transducer Low refrigerant charge High-pressure control erratic in action Compresso
5. Using test function, check unloaders. Press pad display reads OUTPUTS. Press reads UNA2 OFF. Press b. Log into the processor and enter the service function using the keypad and display module. . Keyuntil display Press . Relay energizes. Press and relay deenergizes. Press . The keypad LCD will display ‘‘PASSWORD.’’ Enter , and the keypad LCD will display ‘‘LOGGEDON.’’ c. To change the configuration, press , and the keypad LCD will display ‘‘FLD CFG.
*Or HGBPR-A. †Or HGBPR-B. LEGEND C CB COMM HGBPR — — — — Contactor Circuit Breaker Communications Bus Hot Gas Bypass Relay PWR SW TRAN U — — — — Power Switch Transformer Unloader Fig. 23 — Accessory Unloader Control Wiring, All Units COM HGBPR NO SNB — — — — LEGEND Communications Bus TB — Terminal Block Hot Gas Bypass Relay TRAN — Transformer Normally Open U — Unloader Snubber Fig.
FIELD WIRING Refer to Fig. 25-35 for field wiring. NOTE: Contacts must be rated for dry circuit application, capable of reliably switching a 5 vdc, 1 mA to 20 mA load. Fig. 25 — Demand Limit — Two External Switch Inputs Fig. 26 − Demand Limit — 4-20 mA Signal (Externally Powered) Fig. 30 — Remote Reset from 4-20 mA Signal (Internally Powered) TB — Terminal Block NOTE: Contacts must be rated for dry circuit application, capable of reliably switching a 5 vdc, 1 mA to 20 mA load. Fig.
TB — Terminal Block Fig. 34 — Remote Alarm CWP1 — Chilled Water (Fluid) Pump Interlock CWFS — Chilled Water (Fluid) Flow Switch (not required — low flow protection is provided by Flotronic™ II controls) TB — Terminal Block Fig. 35 — Interlocks REPLACING DEFECTIVE PROCESSOR MODULE The replacement part number is printed on a small label on the front of the PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior corner post.
Copyright 1995 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No. 563-079 Printed in U.S.A.
