Carrier 30GTN040, 30GTN060, 30GTN045, 30GTN050, 30GTN070 Operation And Service Manual

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Controls Start-Up, Operation,

Service, and Troubleshooting

SAFETY CONSIDERATIONS

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.

When working on this equipment, observe precautions in the literature, and on tags, stickers, a nd labels attached to the equipment, and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging, and setting this equipment, and in handling all electrical components.

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out components, or to bypass or otherwise depart from recommended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the electronic modules or electrical components.

To prevent potential damage to heat exchanger tubes always run fluid through heat exchangers when adding or removing refrigerant charge. Use appropriate brine solutions in cooler fluid loops to prevent the freezing of heat exchangers when the equipment is exposed to temperatures below 32 F (0° C).

DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heat ing, Refrigeration and Air Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The a ccumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

30GTN,GTR040-420

30GUN,GUR040-420

Air-Cooled Reciprocating Liquid Chillers

with

Comfort

Link™ Controls

50/60 Hz

DO NOT attempt to unbraze factory joints w hen servicing this equipment. Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines. Cut lines with a tubing cutter as required when performing service. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to system. DO NOT re-use compressor oil.

CONTENTS

Page

SAFETY CONSIDERATIONS GENERAL INTRODUCTION MAJOR SYSTEM COMPONENTS

General Main Base Board (MBB) Expansion Valve (EXV) Board Compressor Expansion Board (CXB) Scrolling Marquee Display Energy Management Module (EMM) Enable/Off/Remote Contact Switch Emergency On/Off Switch Reset Button Board Addresses Control Module Communication Carrier Comfort Network Interface

OPERATING DATA Sensors

• T1 — COOLER LEAVING FLUID SENSOR

• T2 — COOLER ENTERING FLUID SENSOR

• T3,T4 — SATURATED CONDENSING TEMPERATURE SENSORS

• T5,T6 — COOLER SUCTION TEMPERATURE SENSORS

• T7,T8 — COMPRESSOR SUCTION GAS TEMPERATURE SENSORS

• T9 — OUTDOOR-AIR TEMPERA TURE SENSOR

• T10 — REMOTE SPACE TEMPERATURE SENSOR

Thermostatic Expansion Valves (TXV) Compressor Protection Control System

(CPCS) or Control Relay (CR)

Compressor Ground Current Protection Board

(CGF) and Control Relay (CR) Electronic Expansion Valve (EXV) Energy Management Module Capacity Control

• ADDING ADDITIONAL UNLOADERS

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LOADING SEQUENCE

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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 2 Ta b 5 c

PC 903 Catalog No. 563-025 Printed in U.S.A. Form 30GTN-3T Pg 1 3-00 Replaces: 30GTN-2T

CONTENTS (cont)

• LEAD/LAG DETERMINATION

• CAPACITY SEQUENCE DETERMINATION

• CAPACITY CONTROL OVERRIDES

Head Pressure Control

• COMFORTLINK™ UNITS (With EXV)

• UNITS WITH TXV

Pumpout

• EXV UNITS

• TXV UNITS

Marquee Display Usage Service Test Configuring and Operating Dual Chiller

Control Temperature Reset Cooling Set Point (4 to 20 mA) Demand Limit

• DEMAND LIMIT (2-Stage Switch Controlled)

• EXTERNALLY POWERED DEMAND LIMIT

(4 to 20 mA Controlled)

• DEMAND LIMIT (CCN Loadshed Controlled)

TROUBLESHOOTING Compressor Protection Control System

(CPCS) Board Compressor Ground Current (CGF) Board

(30GTN,R and 30GUN,R130-210, 230A-315A,

and 330A/B-420A/B) EXV Troubleshooting

• STEP 1 — CHECK PROCESSOR EXV OUTPUTS

• STEP 2 — CHECK EXV WIRING

• STEP 3 — CHECK RESISTANCE OF EXV MOTOR

WINDINGS

• STEP 4 — CHECK THERMISTORS THAT

CONTROL EXV

• STEP 5 — CHECK OPERATION OF THE EXV

Alarms and Alerts SERVICE

Electronic Components Compressors

• COMPRESSOR REMOV AL

• OIL CHARGE

Cooler

•COOLER REMOVAL

• REPLACING COOLER

• SERVICING THE COOLER

Condenser Coils Condenser Fans Refrigerant Feed Components

• ELECTRONIC EXPANSION VALVE (EXV)

• MOISTURE-LIQUID INDICATOR

• FILTER DRIER

• LIQUID LINE SOLENOID VALVE

• LIQUID LINE SERVICE VALVE

Thermistors

•LOCATION

• REPLACING THERMISTOR T2

• REPLACING THERMISTORS T1,T5,T6,T7, AND T8

• THERMISTORS T3 AND T4

• THERMISTOR/TEMPERATURE SENSOR CHECK

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Page

Safety Devices

• COMPRESSOR PROTECTION

• LOW OIL PRESSURE PROTECTION

• CRANKCASE HEATERS

• COOLER PROTECTION

Relief Devices

• HIGH-SIDE PROTECTION

• LOW-SIDE PROTECTION

• PRESSURE RELIEF VALV ES

Other Safeties PRE-START-UP

System Check START-UP AND OPERATION

Actual Start-Up Operating Limitations

• TEMPERATURES

• VOLTAGE

• MINIMUM FLUID LOOP VOLUME

• FLOW RATE REQUIREMENTS

Operation Sequence Refrigerant Circuit

FIELD WIRING APPENDIX A — CCN TABLES APPENDIX B — FLUID PRESSURE DROP

CURVES

START-UP CHECKLIST

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. . . . . . . . . . . . . . . . .CL-1 to CL-8

GENERAL

The model 30GTN,R chillers are air-cooled chillers uti lizing refrigerant R-22. The model 30GUN,R chillers are aircooled chillers utilizing refrigerant R-134a.

Unit sizes 230-420 are modular units which are shipped as separate sections (modules A and B). Installation instructions specific to these units are shipped inside the individual modules. See T ables 1A and 1B for a listing of unit si zes and modular combinations. For modules 230B-315B, follow all general instructions as noted for unit sizes 080-110. For all remaining modules, follow instructions for unit sizes 130-210.

INTRODUCTION

This publication contains Start-Up, Service, Controls, Operation, and Troubleshooting information for the 30GTN,R040420 and 30GUN,R040-420 liquid chillers with ComfortLink controls.

The 30GTN,R and 30GUN,R040-420 chillers are equipped with electronic expansion valves (EXVs) or, on size 040-110 FIOP (factory-installed option) units, conventional thermostatic expansion valves (TXVs). The size 040-110 FIOP chillers are also equipped with liquid line solenoid valves (LLSV).

NOTE: TXVs are not available on modular units.

Differences in operations and controls between standard and 040-110 FIOP units are noted in appropriate sections in this publication. Refer to the Installation Instructions and the Wiring Diagrams for the appropriate unit for further details.

Table 1A — Unit Sizes and Modular Combinations

(30GTN,R)

UNIT

30GTN,R

040

045 45 — — 050 50 — — 060 60 — — 070 70 — — 080 80 — — 090 90 — — 100 100 — — 110 110 — — 130 125 — — 150 145 — — 170 160 — — 190 180 — — 210 200 — — 230 220 150 080 245 230 150 090 255 240 150 100 270 260 170 100 290 280 190 110 315 300 210 110 330 325 170 170 360 350 190 190/170* 390 380 210 190 420 400 210 210

*60 Hz units/50 Hz units.

NOMINAL

TONS

40 — —

SECTION A

UNIT 30GTN,R

SECTION B

UNIT 30GTN,R

Table 1B — Unit Sizes and Modular Combinations

(30GUN,R)

UNIT

30GUN,R

040 26 — — 045 28 — — 050 34 — — 060 42 — — 070 48 — — 080 55 — — 090 59 — — 100 66 — — 110 72 — — 130 84 — — 150 99 — — 170 110 — — 190 122 — — 210 134 — — 230 154 150 080 245 158 150 090 255 165 150 100 270 176 170 100 290 193 190 110 315 206 210 110 330 219 170 170 360 243 190 190/170* 390 256 210 190 420 268 210 210

*60 Hz units/50 Hz units.

NOMINAL

TONS

SECTION A

UNIT 30GUN,R

SECTION B

UNIT 30GUN,R

MAJOR SYSTEM COMPONENTS

General —

rocating chillers contain the ComfortLink™ electronic control system that controls and monitors all operations of the chiller.

The control system is composed of several components as listed in the sections below. See Fig. 1 for typical control box drawing. See Fig. 2-4 for control schematics.

Main Base Board (MBB) —

the heart of the ComfortLink control system. It contains the major portion of operating software and controls the ope ration of the machine. The MBB continuously monitors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from thermistors T1-T6, T9, and T10. See Table 2. The MBB also receives the feedback

The 30GTN,R and 30GUN,R air-cooled recip-

See Fig. 5. The MBB is

inputs from compressors A1, A2, B1 and B2, and other status switches. See Table 3. The MBB also controls several outputs. Relay outputs controlled by the MBB are shown in Table 4. Information is transmitted between modules via a 3-wire communication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network) bus is also supported. Connections to both LEN and CCN buses are made at TB3. See Fig. 5.

Expansion Valve (EXV) Board —

The electronic expansion valve (EXV) board receives inputs from thermistors T7 and T8. See Table 2. The EXV board communicates with the MBB and directly controls the expansion valves to maintain the correct compressor superheat.

Compressor Expansion Board (CXB) —

The CXB is included as standard on sizes 150-210 (60 Hz) and 130 (50 Hz) and associated modular units. The compressor expansion board (CXB) receives the feedback inputs from compressors A3, B3 and A4. See Table 3. The CXB board communicates the status to the MBB and controls the outputs for these compressors. An additional CXB is required for unit sizes 040110, 130 (60 Hz), 230B-315B with additional unloaders.

Scrolling Marquee Display —

This device is the keypad interface used for accessing chiller information, reading sensor values, and testing the chiller. The marquee display is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an Alarm Status LED. See Marquee Disp lay Us age section on page 29 for further details.

Energy Management Module (EMM) —

The EMM module is available as a factory-installed option or as a field-installed accessory. The EMM module receives 4 to 20 mA inputs for the temperature reset, cooling set point reset and demand limit functions. The EMM module also receives the switch inputs for the field-installed 2-stage demand limit and ice done functions. The EMM module communicates the status of all inputs with the MBB, and the MBB adjusts the control point, capacity limit, and other functions according to the inputs received.

Enable/Off/Remote Contact Switch —

The Enable/Off/Remote Contact switch is a 3-position switch used to control t h e c h il le r. When switched to th e E na b le position the chiller is under its own control. Move the switch to the Off position to shut the chiller down. Move the switch to the Remote Contact position and a field installed dry contact can be used to start the chiller. The contacts must be rated for dry circuit application capable of handling a 24 vac load. In the Enable and Remote Contact (dr y contacts clo sed) position s, the chiller is allowed to operate and respond to the scheduling configuration, CCN configuration and set point data. See Fig. 6.

Emergency On/Off Switch —

The Emergency On/ Off switch should only be used when it is required to shut the chiller off immediately. Power to the MBB, EMM, CXB, and marquee display is interrupted when this switch is off and all outputs from these modules will be turned off. The EXV board is powered separately, but expansion valves will be closed as a result of the loss of communication with the MBB. There is no pumpout cycle when this switch is used. See Fig. 6.

Reset Button —

A reset button is located on the fuse/ circuit breaker panel for unit sizes 130-210 and associated modules. The reset button must be pressed to reset either Circuit Ground Fault board in the event of a trip.

Board Addresses —

The Main Base Board (MBB) has a 3-position Instance jumper that must be set to ‘1.’ All other boards have 4-position DIP switches. All switches are set to ‘On’ for all boards.

Control Module Communication

RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs (lightemitting diodes). When operating correctly, the red status LEDs should be blinking in unison at a rate of once every 2 seconds. If the red LEDs are not blinking in unison, verify that correct power is being supplied to all modules. Be sure that the Main Base Board (MBB) is supplied with the current software. If necessary, reload current software. If the problem still persists, replace the MBB. A red LED that is lit continuously or blinking at a rate of once per second or faster indicates that the board should be replaced.

GREE N LED — The MBB has one green LED. The Local Equipment Network (LEN) LED should always be blinking whenever power is on. All other boards have a LEN LED which should be blinking whenever power is on. Check LEN connections for potential communication errors at the board J3 and/or J4 connectors. Communication between modules is accomplished by a 3-wire sensor bus. These 3 wires run in parallel from module to module. The J4 connector on the MBB provides both power and communication directly to the marquee display only .

YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication.

Carrier Comfort Network (CCN) Interface —

The 30GTN,R chiller units can be connected to the CCN if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is supplied and installed in the field. The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system elements on either side of it. This is also required for the negative and signal ground pins of each system element. Wiring connections for CCN should be made at TB3. Consult the CCN Contractor ’s Manual for further information.

NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 C to 60 C is required. Wire manufactured by Alpha (2413 or 5463), American (A22503), Belden (8772), or Columbia (02525) meets the above mentioned requirements.

It is important when connecting to a CCN communication bus that a color coding scheme be used for the entire network to simplify the installation. It is recommended that red be used for the signal positive, black for the signal negative, and white for the signal ground. Use a similar scheme for cables containing different colored wires.

At each system element, the shields of its communic ation bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only. If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building (one point per building only). To connect the unit to the network:

1. Turn off power to the control box.

2. Cut the CCN wire and strip the ends of the red (+), white (ground), and black (–) conductors. (Substitute appropriate colors for different colored cables.)

3. Connect the red wire to (+) terminal on TB3 of the plug, the white wire to COM terminal, and the black wire to the (–) terminal.

4. The RJ14 CCN connector on TB3 can also be used, but is only intended for temporary connection (for example, a laptop computer running Service Tool).

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, unplug the connector. If conditions return to normal, check the CCN connector and cable. Run new cable if necessary. A short in one section of the bus can cause probl ems with all sys tem elem en ts on th e bu s.

Table 2 — Thermistor Designations

THERMISTOR

NO.

T1 J8-13,14 (MBB) Cooler Leaving Fluid T2 J8-11,12 (MBB) Cooler Entering Fluid

T10

EXV — Electronic Expansion Valve MBB — Main Base Board

LEGEND

CONNECTION

POINT

J8-21,22 (MBB) Saturated Condensing

J8-15,16 (MBB) Saturated Condensing

J8-24,25 (MBB) Cooler Suction Temperature,

J8-18,19 (MBB) Cooler Suction Temperature,

J5-11,12 (EXV) Compressor Suction Gas

J5-9,10 (EXV) Compressor Suction Gas

J8-7,8 (MBB) Outdoor-Air Temperature

J8-5,6 (MBB) Remote Space Temperature

THERMISTOR INPUT

Te m p e ra tu r e, C kt A

Te m p e ra tu r e, C kt B

Ckt A (EXV Only)

Ckt B (EXV Only)

Temperature, Ckt A (EXV Only)

Temperature, Ckt B (EXV Only)

Sensor or Dual Chiller LWT Sensors (Accessory)

Sensor (Accessory)

STATUS SWITCH

Oil Pressure, Ckt B Oil Pressure, Ckt A

Remote On/Off

Compressor Fault

Signal, B3

Compressor Fault

Signal, B2

Compressor Fault

Signal, B1

Compressor Fault

Signal, A4

Compressor Fault

Signal, A3

Compressor Fault

Signal, A2

Compressor Fault

Signal, A1

CPCS — CR — CXB — MBB — OPS —

Compressor Protection Control System Control Relay Compressor Expansion Board Main Base Board Oil Pressure Switch, Circuit A or B

Table 3 — Status Switches

CONNECTION

POINT

J7-1, 2 (MBB) Not Used* OPSB OPSB OPSB OPSB OPSB OPSB J7-3, 4 (MBB) Not Used* OPSA OPSA OPSA OPSA OPSA OPSA

TB5-13, 14 Field-Installed Relay Closure

J5-8, 12 (CXB) Not Used Not Used Not Used Not Used Not Used CR-B3 CR-B3

J9-2, 12 (MBB) Not Used Not Used CPCS-B2 CR-B2 CR-B2 CR-B2 CR-B2

J9-8, 12 (MBB) CR/CPCS-B1† CPCS-B1 CPCS-B1 CR-B1 CR-B1 CR-B1 CR-B1

J5-5, 12 (CXB) Not Used Not Used Not Used Not Used Not Used Not Used CR-A4

J5-11, 12 (CXB) Not Used Not Used Not Used Not Used CR-A3 CR-A3 CR-A3

J9-5, 12 (MBB) Not Used CPCS-A2 CPCS-A2 CR-A2 CR-A2 CR-A2 CR-A2

J9-11, 12 (MBB) CR/CPCS-A1† CPCS-A1 CPCS-A1 CR-A1 CR-A1 CR-A1 CR-A1

LEGEND *The OPS can also be added as an accessory.

040-060 (50 Hz) 040-070 (60 Hz)

070

(50 Hz)

080, 230B

090-110,

245B-315B

†The CPCS can be added as an accessory.

130

(60 Hz)

130 (50 Hz)

150, 230A-

255A

170,190,

270A,290A,

330A/B,

360A/B, 390B

210, 315A,

390A,

420A/B

Table 4 — Output Relay

RELAY

NO.

K1(MBB)

K2 (MBB)

K3 (MBB)

K4 (MBB)

K5 (MBB)

K6 (MBB)

K7 (MBB) K8 (MBB)

K9 (MBB)

K10 (MBB)

K11 (MBB)

K1 (CXB)

K2 (CXB)

K3 (CXB)

K4 (CXB)

K5 (CXB)

K6 (CXB)

OFM —

*And associated modular units. †Field-installed accessory unloader.

Energize Compressor A1 and OFM1 (040-110*) Energize Liquid Line Solenoid Valve for Ckt A (if used) (040-110*) Energize Compressor A1, OFM5, and OFM7 (130-210*)

Energize Compressor B1 and OFM2 (040-110*) Energize Liquid Line Solenoid Valve for Ckt B (if used) (040-110*) Energize Compressor B1, OFM6, and OFM8 (130-210*)

Energize Unloader A1 (040-170*) No Action (190-210*)

Energize Unloader B1 (040-070†, 080-170*) No Action (190,210*)

No Action (040-060, 50 Hz; 040-070, 60 Hz) Energize Compressor A2 (070, 50 Hz; 080-210*)

No Action (040-080*) Energize Compressor B2 (090-210*)

Alarm Cooler Pump Energize First Stage of Condenser Fans:

040-050 —OFM3 060-110* — OFM3, OFM4 130 (60 Hz) — OFM1,OFM2

Energize First Stage of Ckt A Condenser Fans:

130 (50 Hz), 150,170* — OFM1 190,210* —OFM1,OFM11

Energize Second Stage of Condenser Fans:

040-050 — OFM4 060-090* — OFM5, OFM6 100,110* — OFM5,OFM6,OFM7,OFM8 130 (60 Hz) — OFM3,OFM4,OFM9,OFM10

Energize First Stage of Ckt B Condenser Fans:

130 (50 Hz), 150,170* — OFM2

190,210* — OFM2,OFM12 Hot Gas Bypass No Action (040-110*; 130, 60 Hz)

Energize Compressor A3 (130, 50 Hz; 150-210*) No Action (040-150*)

Energize Compressor B3 (170-210*) Energize Compressor A4 (210*)

Energize Accessory Unloader A2 (080-110*) Energize Accessory Unloader B2 (080-110*) Energize Second Stage of Ckt A Condenser Fans:

130 (50 Hz), 150-210* — OFM3,OFM9 Energize Second Stage of Ckt B Condenser Fans:

130 (50 Hz), 150-210* — OFM4,OFM10

LEGEND

Outdoor-Fan Motor

DESCRIPTION

LEGEND FOR FIG. 1-4

C— CB — CCN — CGF — CHT — CKT — CLHR — CPCS — CWFS — CWPI — CR — CXB — EQUIP GND — FB — FC — FCB — FIOP — EMM — EXV — FCB — HPS — LCS — LEN — MBB — NEC — OAT — OPS — PL — PW — SN — SPT — TRAN — SW — TB — TDR — TXV — UL — XL —

Compressor Contactor Circuit Breaker Carrier Comfort Network Compressor Ground Fault Cooler Heater Thermostat Circuit Cooler Heater Relay Compressor Protection and Control System Chilled Water Flow Switch Chilled Water Pump Interlock Control Relay Compressor Expansion Board Equipment Ground Fuse Block Fan Contactor Fan Circuit Breaker Factory-Installed Option Package Energy Management Module Electronic Expansion Valve Fan Circuit Breaker High-Pressure Switch Loss-of-Charge Switch Local Equipment Network Main Base Board National Electrical Code Outdoor-Air Temperature Oil Pressure Switch Plug Par t Wind Sensor (Toroid) Space Temperature Transformer Switch Terminal Block Time Delay Relay Thermostatic Expansion Valve Unloader Across-the-Line

Fig. 1 — Typical Control Box (080-110 and Associated Modular Units Shown)

CCN

LEN

DATA

COMMUNICATION

PORT

Fig. 2 — 24 V Control Schematic, Unit Sizes 040-070

CCN

LEN

DATA

COMMUNICATION

PORT

Fig. 3 — 24 V Control Schematic, Unit Sizes 080-110, 230B-315B

CCN

LEN

DATA

COMMUNICATION

PORT

Fig. 4 — 24 V Control Schematic, Unit Sizes 130-210, 230A-315A, 330A/B-420A/B

RED LED - STATUS GREEN LED -

LEN (LOCAL EQUIPMENT NETWORK)

CEPL130346-01

YELLOW LED CCN (CARRIER COMFORT NETWORK)

INSTANCE JUMPER

LEN

CCN

STATUS

Fig. 5 — Main Base Board

J10

Fig. 6 — Enable/Off/Remote Contact Switch, Emergency On/Off Switch,

RESET BUTTON (SIZES 130-210 AND ASSOCIATED MODULES ONLY)

and Reset Button Locations

EMERGENCY ON/OFF SWITCH

ENABLE/OFF/REMOTE CONTACT SWITCH

GFI-CONVENIENCE OUTLET ACCESSORY ON 208/230V 460 AND 575V ONLY

OPERATING DATA

Sensors —

to sense temperatures for controlling chiller operation. See Table 2. These sensors are outlined below. See Fig. 7-10 for thermistor locations. Thermistors T1-T9 are 5 kΩ at 77 F (25 C). Thermistors T1, T2, T3-T6 and T7-T 9 have different temperature versus resistance and voltage drop performance. Thermistor T10 is 10 kΩ at 77 F (25 C) and has a different temperature vs resistance and voltage drop performance. See Thermistors section on page 59 for temperature-resistance-voltage drop characteristics.

T1 — COOLER LEAVING FLUID SENSOR — This thermistor is located in the leaving fluid nozzle. The thermistor probe is inserted into a friction-fit well.

T2 — COOLER ENTERING FLUID SENSOR — This thermistor is located in the cool er shel l in th e first ba ffle spac e in close proximity to the cooler tube bundle.

The electronic control uses 4 to 10 thermistors

T3, T4 — SATURATED CONDENSING TEMPERATURE SENS O RS — These 2 thermistors are clamped to the outside of a return bend of the condenser coils.

T5, T6 — COOLER SUCTION TEMPERATURE SENSORS — These thermistors are located next to the refrigerant inlet in the cooler head, and are insert ed into a friction-fit well. The sensor well is located directly in the refrigerant path. These thermistors are not used on units with TXVs.

T7, T8 — COMPRESSOR SUCTION GAS TEMPERATURE SENSORS — These thermistors are located in the lead compressor in each circuit in a suction passage aft er the refrigerant has passed over the motor and is about to enter the cylinders. These thermistors are ins erted into frict ion-fit wells. T he sensor wells are located directly in the refrigerant path. These thermistors are not used on units with TXVs.

T9 — OUTDOOR-AIR TEMPERATURE SENSOR — Sensor T9 is an accessory sensor that is remotely mounted and used for outdoor-air temperature reset.

MIN. 6” OF 22 AWG WIRES WITH ENDS STRIPPED BACK .25” ±1/8”

1/2 NPT MALE THREADED ADAPTER

REF.

1.81

(46.0)

1/2” PVC SHIELD

3/16” DIA. THERMOWELL (S.S.)

REF.

5.75

(146.1

040-110*

130-210*

REF. .83 D

(21.1)

LEGEND

AWG — EXV —

*And associated modular units.

American Wire Gage Electronic Wire Gage

Fig. 7 — Cooler Thermistor Locations and Accessory Outdoor-Air Temperature Sensor Detail

040-070

080-110 AND ASSOCIATED MODULAR UNITS* 130-210 AND ASSOCIATED MODULAR UNITS*

*When thermistor is viewed from perspective where the compressor is on the left and the cooler is on the right.

Fig. 8 — Thermistor T3 and T4 Locations

Electronic Expansion Valve

EXV —

Fig. 9 — Compressor Thermistor Locations (T7 and T8)

LEGEND

Fig. 10 — Typical Thermistor Location (30GTN,R and 30GUN,R 210, 315A, 390A, 420A/B Shown)

T10 — REMOTE SPACE TEMPERA TURE SENSOR —

Fig. 11 — Typical Space Temperature

Sensor Wiring

Fig. 12 — CCN Communications Bus Wiring

to Optional Space Sensor RJ11 Connector

Sensor T10 (part no. HH51BX006) is an accessory sensor that is remotely mounted in the controlled space and used for space temperature reset. The sensor should be installed as a wall-mounted thermostat would be (in the conditioned space where it will not be subjected to either a cooling or heating source or direct exposure to sunlight, and 4 to 5 ft above the floor). The push button override button is not supported by the ComfortLink™ Controls.

Space temperature sensor wires are t o be connected to terminals in the unit main control box. The space temperature sensor includes a terminal block (SEN) and a RJ11 female connector. The RJ1 1 connector is used to tap into the Carrier Comfort Network (CCN) at the sensor.

T o connect the space temperature sensor (Fig. 11):

1. Using a 20 AWG (American Wire Gage) twisted pair conductor cable rated for the application, connect 1 wire of the twisted pair to one SEN terminal and connect the other wire to the other SEN terminal located under the cover of the space temperature sensor.

2. Connect the other ends of the wires to terminals 5 a nd 6 on TB5 located in the unit control box.

Units on the CCN can be monitored from the space at the sensor through the RJ11 connector, if desired. To wire the RJ11 connector into the CCN (Fig. 12):

2. Insert and secure the red (+) wire to terminal 5 of the space temperature sensor terminal block.

3. Insert and secure the white (ground) wire to terminal 4 of the space temperature sensor.

4. Insert and secure the black (–) wire to terminal 2 of the space temperature sensor.

5. Connect the other end of the communication bus cable to the remainder of the CCN communication bus.

SPT (T10) PART NO. HH51BX006

SENSOR

SEN

TB5

IMPORTANT: The cable selected for the RJ11 connector wiring MUST be identical to the CCN communication bus wire used for the entire network. Refer to table below for acceptable wiring.

MANUFACTURER

Alpha American Belden Columbia Manhattan Quabik

Regular Wiring Plenum Wiring

1895 —

A21451 A48301

8205 884421

D6451 —

M13402 M64430

6130 —

PART NO.

1. Cut the CCN wire and strip ends of the red (+), white (ground), and black (–) conductors. (If another wire color scheme is used, strip ends of appropriate wires.)

TO CCN TERMINALS ON TB3 AT UNIT

CCN+

CCN GND

CCN-

T-55 SPACE SENSOR

Thermostatic Expansion Valves (TXV) —

Fig. 13 — Compressor Protection Control

System Module — Sizes 040-110

Fig. 14 — Compressor Ground Fault Module

— Sizes 130-210

30GTN,R and 30GUN,R 040-110 units are available from the factory with conventional TXVs with liquid line solenoids. The liquid line solenoid valves are not intended to be a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system.

NOTE: This option is not available for modular units.

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 metering the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless abso- lutely necessary. When TXV is used, thermistors T5, T 6, T7, and T8 are not required.

The TXV is designed to limit the cooler saturated suctio n temperature to 55 F (12.8 C). This makes it possible for unit to start at high cooler fluid temperatures without overloading the compressor.

Compressor Protection Control System (CPCS [CPCS — Standard on Sizes 080-110 and Optional on Sizes 040-070]) or Control Relay (CR) — 30GTN,R and 30GUN,R 040-110 —

compressor has its own CPCS module or CR. See Fig. 13 for CPCS module. The CPCS or CR is used to control and protect the compressors and crankcase heaters. The CPCS and CR provide the following functions:

• compressor contactor control/crankcase heater

• crankcase heater control

• compressor ground current protection (CPCS only)

• status communication to processo r board

• high-pressure protection

One large relay is located on the CPCS board. This relay controls the crankcase heater and compressor contactor, and also provides a set of signal contacts that the microprocessor monitors to determine the operating status of the compressor. If the processor board determines that the compressor is not operating properly through the signal contacts, it will lock the compressor off by deenergizing the proper 24-v control relay on the relay board. The CPCS board contains logic that can detect if the current-to-ground of any compressor winding exceeds

2.5 amps. If this condition occurs, the CPCS shuts down the compressor.

A high-pressure switch is wired in series between the MBB and the CR or CPCS. On compressor A1 and B1 a loss-ofcharge switch is also wired in series with the high-pressure switch. If the high-pressure switch opens during operation of a compressor, the compressor will be stopped, the failure will be detected through the signal contacts, and the compressor will be locked off. If the le ad compressor in eithe r circuit is shut down by the high-pressure switch, loss-of-charge switch, ground current protector, or oil safety switch, all compressors in that circuit are shut down.

NOTE: The CR operates the same as the CPCS, except the ground current circuit protection is not provided.

Compressor Ground Current Protection Board (CGF) and Control Relay (CR) —

30GTN,R and 30GUN,R 130-210, and associated modular units (see T a ble 1) contain one compressor ground current protection board (CGF) (see Fig. 14) for each refrigeration circuit. The CGF contains logic that can detect if the current-to-ground

Model

Each

The

of any compressor winding exceeds 2.5 amps. If this occurs, the lead compressor in that circuit is shut down along with other compressors in that circuit.

A high-pressure switch is wired in series between the MBB and the CR. On compressor A1 and B1 a loss-of-charge switch is also wired in series with the high-pressure swit ch. The lead compressor in each circuit also has the CGF contacts described above. If any of these switches open during operation of a compressor, the CR relay is deenergized, stopping the compressor and signaling the processor at the MBB-J9 inputs to lock out the compressor. If the lead compressor in either circuit is shut down by high-pressure switch, compressor ground fault, oil pressure switch, or the loss-of-charge switch, all compressors in that circuit are also shut down.

Electronic Expansion Valve (EXV) (See

Fig. 15 — Electronic Expansion Valve (EXV)

Fig. 15) —

EXV. This device eliminates the use of the liquid line solenoid pumpdown at unit shutdown. An O-ring has been added t o bottom of orifice a ssem bly to com plete a se al i n the v alve on s hutdown. This is not a mechanical shut-off. When service is required, use the liquid line service val ve to pump down the system.

High pressure refrigerant enters bottom of val ve where it passes through a group of machined slots in side of orifice assembly. As refrigerant passes through the orifice, it drops in pressure. To control flow of refrigerant, the sleeve slides up and down along orifice assembly, modulating the size of orifice. The sleeve is moved by a linear stepper motor that moves in increments controlled directly by the processor. As stepper motor rotates, the moti on is translated into li near movement of lead screw. There are 1500 discrete steps with this combination. The valve orifice begins to be exposed at 320 steps. Since there is not a tight seal with the orifice and the sleeve, the minimum position for operation is 120 steps.

Two thermistors are used to determine suction superheat . One thermistor is located in the cooler and the othe r is locat ed in the cylinder end of the compressor after refrigerant has passed over the motor. The difference between the 2 thermistors is the suction superheat. These machines are set up to provide approximately 5 to 7 F (2.8 to 3.9 C) superheat leaving the cooler. Motor cooling accounts for approximately 22 F (12.2 C) on 30GTN,R units and 16 F (8.9 C) on 30GUN,R units, resulting in a superheat entering compressor cylinders of approximately 29 F (16.1 C) for 30GTN,R units and 23 F (12.8 C) for 30GUN,R units.

Because the valves are controlled by the EXV module, it is possible to track the position of the valve. Valve position can be used to control head pressure and system refrigerant charge.

During initial start-up, the EXV module will drive each valve fully closed. After initialization period, valve position is controlled by the EXV module and the MBB.

The EXV is used to limit the maximum cooler saturated suction temperature to 55 F (12.8 C). This makes it possible for the chiller to start at high cooler fluid temperatures without overloading the compressor.

Energy Management Module (Fig. 16) —

factory-installed option or field-installed accessory is used for the following types of temperature reset, demand limit, and/or ice featu res :

• 4 to 20 mA leaving fluid temperature reset (requires

field-supplied 4 to 20 mA generator)

• 4 to 20 mA cooling set point reset (requires field-

supplied 4 to 20 mA generator)

• Discrete inputs for 2-step demand limit (requires field-

supplied dry contacts capable of handling a 5 vdc, 1 to 20 mA load)

• 4 to 20 mA demand limit (requires field-supplied 4 to

20 mA gener ator)

• Discrete input for Ice Done switch (requires field-

supplied dry contacts capable of handling a 5 vdc, 1 to 20 mA load)

See Demand Limit and Temperature Reset sections on pages 46 and 43 for further details.

Capacity Control —

pressors, unloaders, and hot gas bypass solenoids to maintain the user-configured leaving chilled fluid temperature set point. Entering fluid temperature is used by the Main Base Board (MBB) to determine the temperature drop across the cooler and is used in determining the optimum time to add or subtract capacity stages. The chilled fluid temperature set point can be automatically reset by the return tem perature reset or space and outdoor-air temperature reset features. It can also be reset from

Standard units are equipped with a bottom seal

This

The control system cycles com-

STEPPER MOTOR (12 VDC)

LEAD SCREW

PISTON SLEEVE

ORIFICE ASSEMBLY (INSIDE PISTON SLEEVE)

an external 4 to 20 mA signal (requires Energy Management Module FIOP/accessory).

With the automatic lead-lag feature i n the unit, the control determines which circuit will start first, A or B. At the first call for cooling, the lead compressor crankcase heater will be deenergized, a condenser fan will start, and the compressor will start unloaded.

NOTE: The automatic lead-lag feature is only operative when an even number of unloaders is present. The 040-070 units require an accessory unloader to be installed on the B1 compressor for the lead-lag feature to be in effect.

If the circuit has been off for 15 minutes, and the unit is a TXV unit, liquid line solenoid will remain closed during startup of each circuit for 15 seconds while the cooler and suction lines are purged of any liquid refrigerant. For units with EXVs, the lead compressor will be signaled to start. The EXV will remain at minimum position for 10 seconds before it is allowed to modulate.

After the purge period, the EXV will begin to meter the refrigerant, or the liquid line solenoid will open allowing the TXV to meter the refrigerant to the cooler. If the off-time is less than 15 minutes, the EXV will be opened as soon as the compressor starts.

The EXVs will open gradually to provide a controlled startup to prevent liquid flood-back to the compressor. During startup, the oil pressure switch is bypassed for 2 minutes to allow for the transient changes during start-up. As additional stages of compression are required, the processor control will add them. See Tables 5A and 5B.

If a circuit is to be stopped, the control will first start to close the EXV or close the liquid line solenoid valve.

For units with TXVs

, the lag compressor(s) will be shut down and the lead compressor will continue to operate for 10 seconds to purge the cooler of any refrigerant.

For units with EXVs

, the lag compressor(s) will be shut down and the lead compressor will continue to run. After t he lag compressor(s) has shut down, the EXV is signaled to close. The lead compressor will remain on for 10 seconds after the EXV is closed.

During both algorithms (TXV and EXV), all diagnostic conditions will be honored. If a safety trip or alarm condition is detected before pumpdown is complete, the circuit will be shut down.

CEBD430351-0396-01C

PWR

J4 J3

RED LED - STATUS

LEN

STATUS

GREEN LED LEN (LOCAL EQUIPMENT NETWORK)

Fig. 16 — Energy Management Module

ADDRESS DIP SWITCH

TEST 1

CEPL130351-01

TEST 2

The capacity control algorithm runs every 30 seconds. The algorithm attempts to maintain the leaving chilled water temperature at the control point. Each time it runs, the control reads the entering and leaving fluid temperatures. The control determines the rate at which conditions are changing and calculates 2 variables based on these conditions. Next, a capacity ratio is calculated using the 2 variables to determine whether or not to make any changes to the current stages of capacity. This ratio

value ranges from –100 to + 100%. If the next stage of capacity is a compressor, the control starts (stops) a compressor when the ratio reaches +100% (–100%). If the next stage of capacity is an unloader, the control deenergizes (energizes) an unloader when the ratio reaches +60% (–60%). Unloaders are allowed to cycle faster than compressors, to minimize the number of starts and stops on each compressor. A delay of 90 seconds occurs after each capacity step change.

Table 5A — Part Load Data Percent Displacement, Standard Units

UNIT

30GTN,R

30GUN,R

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz) 050 (60 Hz)

050 (50 Hz) 060 (60 Hz)

060 (50 Hz) 070 (60 Hz)

070 (50 Hz)

080, 230B (60 Hz)

080, 230B (50 Hz)

090, 245B (60 Hz)

090, 245B (50 Hz)

100, 255B,

270B (60 Hz)

*Unloaded compressor. NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

125A1*—— 250A1—— 375A1*, B1—— 4 100 A1,B1 ——

124A1*—— 247A1—— 376A1*,B1—— 4 100 A1,B1 ——

131A1*—— 244A1—— 387A1*,B1—— 4 100 A1,B1 ——

128A1*—— 242A1—— 387A1*,B1—— 4 100 A1,B1 ——

133A1*—— 250A1—— 383A1*,B1—— 4 100 A1,B1 ——

119A1*—— 227A1—— 365A1*,B1—— 473A1,B1—— 5 92 A1*,A2,B1 —— 6 100 A1,A2,B1 ——

1 22 A1* 30 B1* 234A144B1 3 52 A1*,B1* 52 A1*,B1* 4 67 A1*,B1 63 A1,B1* 5 78 A1,B1 78 A1,B1 6 89 A1*,A2,B1 85 A1,A2,B1* 7 100 A1,A2,B1 100 A1,A2,B1

1 17 A1* 25 B1* 225A138B1 3 42 A1*,B1* 42 A1*,B1* 4 54 A1*,B1 50 A1, B1* 5 62 A1,B1 62 A1,B1 6 79 A1*,A2,B1* 79 A1*,A2,B1* 7 92 A1*,A2,B1 88 A1,A2,B1* 8 100 A1,A2,B1 100 A1,A2,B1

1 18 A1* 18 B1* 227A127B1 3 35 A1*,B1* 35 A1*,B1* 4 44 A1*,B1 44 A1,B1 5 53 A1,B1 53 A1,B1 6 56 A1*,A2,B1* 62 A1*,B1*,B2 7 65 A1*,A2,B1 71 A1,B1*,B2 8 74 A1,A2,B1 80 A1,B1,B2

9 82 A1*,A2,B1*,B2 82 A1*,A2,B1*,B2 10 91 A1*,A2,B1,B2 91 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

114A114B1*

221A121B1

3 29 A1*,B1* 29 A1*,B1*

4 36 A1*,B1 36 A1,B1*

5 43 A1,B1 43 A1,B1

6 61 A1*,A2,B1* 53 A1*,B1*,B2

7 68 A1*,A2,B1 60 A1,B1*,B2

8 75 A1,A2,B1 67 A1,B1,B2

9 86 A1*,A2,B1*,B2 86 A1*,A2,B1*,B2 10 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

1 16 A1* 16 A1*

223A123A1

3 31 A1*,B1* 31 A1*,B1*

4 39 A1*,B1 39 A1*,B1

5 46 A1,B1 46 A1,B1

6 58 A1*,A2,B1* 58 A1*,A2,B1*

7 66 A1*,A2,B1 66 A1*,A2,B1

8 73 A1,A2,B1 73 A1,A2,B1

9 85 A1*,A2,B1*,B2 85 A1*,A2,B1*,B2 10 92 A1*,A2,B1,B2 92 A1*,A2,B1,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

Table 5A — Part Load Data Percent Displacement, Standard Units (cont)

UNIT 30GTN,R 30GUN,R

100, 255B

270B (50 Hz)

110, 290B,

315B (60 Hz)

110, 290B,

315B (50 Hz)

130 (60 Hz)

130 (50 Hz)

150, 230A, 245A,

255A (60 Hz)

*Unloaded compressor. NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

1 13 A1* 13 B1* 220A120B1 3 26 A1*,B1* 26 A1*,B1* 4 33 A1,B1 33 A1,B1 5 40 A1,B1 40 A1,B1 6 57 A1*,A2,B1* 57 A1*,B1*,B2 7 63 A1*,A2,B1 63 A1,B1*,B2 8 70 A1,A2,B1 70 A1,B1,B2

9 87 A1*,A2,B1*,B2 87 A1*,A2,B1*,B2 10 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

1 14 A1* 14 B1*

221A121B1

3 29 A1*,B1* 29 A1*,B1*

4 36 A1*,B1 36 A1,B1*

5 43 A1,B 43 A1,B1

6 61 A1*,A2,B1* 53 A1*,B1*,B2

7 68 A1*,A2,B1 60 A1,B1*,B2

8 75 A1,A2,B1 67 A1,B1,B2

9 86 A1*,A2,B1*,B2 86 A1*,A2,B1*,B2 10 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

1 17 A1* 17 B1*

225A125B1

3 33 A1*,B1* 33 A1*,B1*

4 42 A1*,B1 42 A1,B1*

5 50 A1,B1 50 A1,B1

6 58 A1*,A2,B1* 58 A1*,B1*,B2

7 67 A1*,A2,B1 67 A1,B1*,B2

8 75 A1,A2,B1 75 A1,B1,B2

9 83 A1*,A2,B1*,B2 83 A1*,A2,B1*,B2 10 92 A1*,A2,B1,B2 92 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

1 14 A1* 14 B1*

221A121B1

3 28 A1*,B1* 28 A1*,B1*

4 35 A1*,B1 35 A1,B1*

5 42 A1,B1 42 B1,B1

6 58 A1*,A2,B1* 58 A1*,B1*,B2

7 64 A1*,A2,B1 64 A1,B1*,B2

8 71 A1,A2,B1 71 A1,G1,B2

9 87 A1*,A2,B1*,B2 87 A1*,A2,B1*,B2 10 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 11 100 A1,A2,B1,B2 100 A1,A2,B1,B2

1 10 A1* 16 B1*

214A125B1

3 26 A1*,B1* 26 A1*,B1*

4 35 A1*,B1 31 A1,B1*

5 39 A1,B1 39 A1,B1

6 44 A1*,A2,B1* 51 A1*,B1*,B2

7 53 A1*,A2,B1 56 A1,B1*,B2

8 57 A1,A2,B1 64 A1,B1,B2

9 69 A1*,A2,B1*,B2 69 A1*,A2,B1*,B2 10 78 A1*,A2,B1,B2 75 A1,A2,B1*,B2 11 82 A1,A2,B1,B2 82 A1,A2,B1,B2 12 87 A1*,A2,A3,B1*,B2 87 A1*,A2,A3,B1*,B2 13 96 A1*,A2,A3,B1,B2 91 A1,A2,A3,B1*,B2 14 100 A1,A2,A3,B1,B2 100 A1,A2,A3,B1,B2

1 11 A1* 18 B1*

215A127B1

3 29 A1*,B1* 29 A1*,B1*

4 38 A1*,B1 33 A1,B1*

5 42 A1,B1 42 A1,B1

6 44 A1*,A2,B1* 55 A1*,B1*,B2

7 53 A1*,A2,B1 60 A1,B1*,B2

8 58 A1,A2,B1 69 A1,B1,B2

9 71 A1*,A2,B1*,B2 71 A1*,A2,B1*,B2 10 80 A1*,A2,B1,B2 75 A1,A2,B1*,B2 11 85 A1,A2,B1,B2 85 A1,A2,B1,B2 12 86 A1*,A2,A3,B1*,B2 86 A1*,A2,A3,1*,B2 13 95 A1*,A2,A3,B1,B2 91 A1,A2,A3,B1*,B2 14 100 A1,A2,A3,B1,B2 100 A1,A2,A3,B1,B2

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

Table 5A — Part Load Data Percent Displacement, Standard Units (cont)

UNITT

30GTN,R

30GUN,R

150, 230A, 245A,

255A (50 Hz)

170, 270A,

330A/B (60 Hz)

170, 270A,

330A/B,

360B (50 Hz)

190, 290A, 360A/B,

390B (60 Hz)

190, 290A, 360A,

390B (50 Hz)

210, 315A, 390A,

420A/B (60 Hz)

210, 315A, 390A,

420A/B (50 Hz)

*Unloaded compressor. NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14

9 10 11 12 13 14 15 16 17

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

13 20 26 33 40 46 53 60 66 73 80 86 93

100

11 17 23 28 33 39 45 50 56 61 67 73 78 83 89 95

100

9 14 19 23 28 33 37 42 52 57 61 72 76 81 91 96

100

13 25 41 56 78

100

17 33 50 67 83

100

11 25 36 56 67 86

100

9 26 35 51 67 84

100

Compressors

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1*

% Displacement

(Approx)

13 20 26 33 40 46 53 60 66 73 80 86 93

100

11 17 23 28 33 39 45 50 56 61 67 73 78 83 89 95

100

9 14 19 23 28 38 43 47 52 57 61 72 76 81 91 96

100

13 25 41 56 78

100

17 33 50 67 83

100

14 25 44 56 75 86

100

16 26 42 51 67 84

100

Compressors

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders

UNIT 30GTN,R 30GUN,R

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz) 050 (60 Hz)

050 (50 Hz) 060 (60 Hz)

060 (50 Hz) 070 (60 Hz)

070 (50 Hz)

080, 230B (60 Hz)

080, 230B (50 Hz)

090, 245B (60 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

NOTE: Some control steps will be skipped if they do not increase chiller capacity when staging up or decrease chiller capacity when staging down.

CONTROL

STEPS

1 25 A1* 25 B1* 250A150B1 3 75 A1*,B1 75 A1,B1* 4 100 A1,B1 100 A1,B1

1 24 A1* 21 B1† 247A137B1* 345A1*,B1† 53 B1 4 61 A1*,B1* 45 A1*,B1† 5 84 A1,B1* 61 A1*,B1* 6 100 A1,B1 84 A1,B1* 7 ——100 A1,B1

118A1† 20 B1† 2 31 A1* 38 B1* 344A156B1 438A1†,B1† 38 A1†,B1† 551A1*,B1† 51 A1*,B1† 6 69 A1*,B1* 69 A1*,B1* 7 82 A1,B1* 82 A1,B1* 8 100 A1,B1 100 A1,B1

115A1† 18 B1† 2 28 A1* 38 B1* 342A158B1 433A1†,B1† 33 A1†,B1† 547A1*,B1† 47 A1*,B1† 6 67 A1*,B1* 67 A1*,B1* 7 80 A1,B1* 80 A1,B1* 8 100 A1,B1 100 A1,B1

116A1† 16 B1† 2 33 A1* 33 B1* 350A150B1 431A1†,B1† 31 A1†,B1† 549A1*,B1† 49 A1*,B1† 6 66 A1*,B1* 66 A1*,B1* 7 83 A1,B1* 83 A1,B1* 8 100 A1,B1 100 A1,B1

111A1† 15 B1† 2 19 A1* 31 B1* 327A147B1 425A1†,B1† 25 A1†,B1† 533A1*,B1† 33 A1*,B1† 6 49 A1*,B1* 49 A1*,B1* 7 57 A1,B1* 57 A1,B1* 8 73 A1,B1 73 A1,B1

984A1†,A2,B1 68 A1,A2,B1† 10 92 A1*,A2,B1 84 A1,A2,B1* 11 100 A1,A2,B1 100 A1,A2,B1

111A1† 15 B1†

2 22 A1* 30 B1*

334A144B1

441A1†,B1* 48 A1,B1†

555A1†,B1 63 A1,B1*

6 67 A1*,B1 78 A1,B1

7 78 A1,B1 85 A1,A2,B1*

8 89 A1*,A2,B1 100 A1,A2,B1

9 100 A1,A2,B1 ——

18A1† 13 B1†

2 17 A1* 25 B1*

325A138B1

433A1†,B1* 50 A1,B1*

546A1†,B1 62 A1,B1

6 54 A1*,B1 67 A1*,A2,B1†

7 62 A1,B1 75 A1,A2,B1†

871A1†,A2,B1* 88 A1,A2,B1*

984A1†,A2,B1 100 A1,A2,B1 10 92 A1*,A2,B1 —— 11 100 A1,A2,B1 ——

19A1† 9B1†

2 18 A1* 18 B1*

327A127B1

435A1†,B1 35 A1,B1†

5 44 A1*,B1 44 A1,B1*

6 53 A1,B1 53 A1,B1

756A1†,A2,B1 62 A1,B1†,B2

8 65 A1*,A2,B1 71 A1,B1*,B2

9 74 A1,A2,B1 80 A1,B1,B2 10 82 A1†,A2,B1,B2 82 A1,A2,B1†,B2 11 91 A1*,A2,B1,B2 91 A1,A2,B1*,B2 12 100 A1,A2,B1,B2 100 A1,A2,B1,B2

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)

UNIT

30GTN,R

30GUN,R

090, 245B (50 Hz)

100, 255B,

270B (60 Hz)

100, 255B,

270B (50 Hz)

110, 290B,

315B (60 Hz)

110, 290B,

315B (50 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

17A1† 7B1† 2 14 A1* 14 B1* 321A121B1 429A1†,B1 29 A1,B1† 5 36 A1*,B1 36 A1,B1* 6 43 A1,B1 43 A1,B1 749A1†,A2,B1† 46 A1*,B1†,B2 854A1†,A2,B1* 53 A1,B1†,B2

961A1†,A2,B1 60 A1,B1*,B2 10 68 A1*,A2,B1 67 A1,B1,B2 11 75 A1,A2,B1 72 A1†,A2,B1†,B2 12 79 A1†,A2,B1*,B2 79 A1*,A2,B1†,B2 13 86 A1†,A2,B1,B2 86 A1,A2,B1†,B2 14 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 15 100 A1,A2,B1,B2 100 A1,A2,B1,B2

18A1† 8B1†

2 16 A1* 16 B1*

323A123B1

431A1†,B1 31 A1,B1†

5 39 A1*,B1 39 A1,B1*

6 46 A1,B1 46 A1,B1

750A1†,A2,B1* 50 A1*,B1†,B2

858A1†,A2,B1 58 A1,B1†,B2

9 66 A1*,A2,B1 66 A1,B1*,B2 10 73 A1,A2,B1 73 A1,B1,B2 11 77 A1†,A2,B1*,B2 77 A1*,A2,B1†,B2 12 85 A1†,A2,B1,B2 85 A1,A2,B1†,B2 13 92 A1*,A2,B1,B2 92 A1,A2,B1*,B2 14 100 A1,A2,B1,B2 100 A1,A2,B1,B2

17A1† 7B1†

2 13 A1* 13 B1*

320A120B1

426A1†,B1 26 A1,B1†

5 33 A1*,B1 33 A1,B1*

6 40 A1,B1 40 A1,B1

743A1†,A2,B1† 43 A1†,B1†,B2

850A1†,A2,B1* 50 A1*,B1†,B2

957A1†,A2,B1 57 A1,B1†,B2 10 63 A1*,A2,B1 63 A1,B1*,B2 11 70 A1,A2,B1 70 A1,B1,B2 12 74 A1†,A2,B1†,B2 74 A1†,A2,B1†,B2 13 80 A1†,A2,B1*,B2 80 A1*,A2,B1†,B2 14 89 A1†,A2,B1,B2 87 A1,A2,B1†,B2 15 93 A1*,A2,B1,B2 93 A1,A2,B1*,B2 16 100 A1,A2,B1,B2 100 A1,A2,B1,B2

17A1† 7B1†

2 14 A1* 14 B1*

321A121B1

429A1†,B1 29 A1,B1†

5 36 A1*,B1 36 A1,B1*

6 43 A1,B1 43 A1,B1

747A1†,A2,B1† 46 A1*,B1†,B2

854A1†A2,B1* 53 A1,B1†,B2

18A1† 8B1†

2 17 A1* 17 B1*

325A125B1

433A1†,B1 33 A1,B1†

5 42 A1*,B1 42 A1,B1*

6 50 A1,B1 50 A1,B1

758A1†,A2,B1 58 A1,B1†,B2

8 67 A1*,A2,B1 67 A1,B1*,B2

9 75 A1,A2,B1 75 A1,B1,B2 10 83 A1†,A2,B1,B2 83 A1,A2,B1†,B2 11 92 A1*,A2,B1,B2 92 A1,A2,B1*,B2 12 100 A1,A2,B1,B2 100 A1,A2,B1,B2

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

Table 5B — Part Load Data Percent Displacement, with Accessory Unloaders (cont)

UNIT 30GTN,R 30GUN,R

130 (60 Hz)

130 (50 Hz)

150, 230A, 245A,

255A (60 Hz)

150, 230A, 245A,

255A (50 Hz)

*Unloaded compressor. Two unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

9 10 11 12 13 14 15 16 17 18 19

9 10 11 12 13 14 15 16 17

9 10 11 12 13 14 15

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

8 14 21 22 28 35 42 44 51 58 64 71 73 80 87 93

100

6 10 14 22 31 35 39 40 49 53 57 65 74 78 82 83 91 96

100

6 11 15 24 33 38 42 49 53 58 66 75 80 85 91 95

100

6 13 20 26 33 40 46 53 60 66 73 80 86 93

100

Compressors

A1†,A2,B1† A1†,A2,B1*

A1†,A2,B1†,B2 A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,B1*

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†

A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1,A2,B1

A1,A2,B1†

A1†

A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1†

A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1†

A1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

% Displacement

(Approx)

8 14 21 22 28 35 42 44 51 58 64 71 73 80 87 93

100

8 16 25 31 39 43 47 56 64 65 74 82 83 91

100

— — — —

9 18 27 33 42 46 51 60 69 75 86 91

100

— — — —

6 13 20 26 33 40 46 53 60 66 73 80 86 93

100

Compressors

B1†

B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1 A1†,B1†,B2 A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2 A1†,A2,B1†,B2 A1*,A2,B1†,B2

A1,A2,B1†,B2

A1,A2,B1*,B2

A1,A2,B1,B2

B1†

B1*

A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1†,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1†,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

— — — —

B1†

B1*

A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

— — — —

B1†

B1*

B1 A1,B1† A1,B1*

A1,B1

A1,B1†,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1†,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1†,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)

UNIT

30GTN,R

30GUN,R

170, 270A,

330A/B (60 Hz)

170, 270A,

330A/B, 360B (50 Hz)

190, 290A, 360A/B,

390B (60 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

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

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

9 10 11 12 13 14 15 16 17

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

6 11 17 17 23 28 33 34 39 45 50 51 56 61 67 67 73 78 83 84 89 95

100

9 14 14 19 23 28 28 33 37 42 43 48 52 57 61 63 67 72 76 81 82 87 91 96

100

9 13 18 21 25 33 37 41 49 53 56 71 74 78 93 96

100

Compressors

A1†,B1*

A1†,B1 A1*,B1

A1,B1

A1†,A2,B1*

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,A3,B1*,B2,B3

A1†,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1†,B1*

A1†B1

A1*,B1

A1,B1

A1†,A2,B1*

A1†,A2,B1

A1*,A2,B1

A1,A2,B1 A1†,A2,B1†,B2 A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†A2,A3,B1†,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2 A1†,A2,A3,B1†,B2,B3 A1†,A2,A3,B1*,B2,B3

A1†,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1†

A1*

A1†

A1*

% Displacement

(Approx)

6 11 17 17 23 28 33 34 39 45 50 51 56 61 67 67 73 78 83 84 89 95

100

9 14 14 19 23 28 29 34 38 43 47 48 52 57 61 63 67 72 76 81 82 87 91 96

100

9 13 18 21 25 33 37 41 49 53 56 71 74 78 93 96

100

Compressors

B1†

B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2 A1,B1*,B2

A1,B1,B2

A1*,A2,B1†,B2

A1,A2,B1†,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1†,B2,B3

A1,A2,B1†,B2,B3 A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1†,B2,B3

A1,A2,A3,B1†,B2,B3 A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

B1†

B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1 A1†,B1†,B2 A1*,B1†,B2

A1,B1†,B2 A1,B1*,B2

A1,B1,B2

A1*,A2,B1†,B2

A1,A2,B1†,B2

A1,A2,B1*,B2

A1,A2,B1,B2 A1†,A2,B1†,B2,B3 A1*,A2,B1†,B2,B3

A1,A2,B1†,B2,B3 A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3 A1†,A2,A3,B1†,B2,B3 A1*,A2,A3,B1†,B2,B3

A1,A2,A3,B1†,B2,B3 A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B3,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)

UNIT

30GTN,R

30GUN,R

190, 290A, 360A,

390B (50 Hz)

210, 315A, 390A,

420A/B (60 Hz)

210, 315A, 390A,

420A/B (50 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

9 10 11 12 13 14 15 16 17 18 19 20

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

11 11 22 28 33 39 44 50 55 61 67 72 78 83 89 94

100

8 11 17 22 25 28 33 36 48 52 56 59 63 67 78 83 86 92 97

100

9 17 23 26 27 32 35 43 48 51 59 65 67 75 81 84 92 97

100

Compressors

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

% Displacement

(Approx)

11 17 22 28 33 39 44 50 55 61 67 72 78 83 89 94

100

9 14 17 21 25 37 40 44 48 51 56 67 71 75 78 82 86 92 96

100

11 16 17 20 26 34 36 42 43 46 51 59 62 67 75 78 84 92 94

100

Compressors

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

ADDING ADDITIONAL UNLOADERS — See Table 6 below for required hardware.

Follow accessory instructions for installation. Connect unloader coil leads to P INK wir es in com pr essor A1 /B1 ju ncti on box. Configuration items CA.UN and CB.UN in the OPT1 sub-mode of the configuration mode must be changed to match the new number of unloaders. Two unloaders cannot be used with hot gas bypass on a single circuit.

MINUTES LEFT FOR START — This value is displayed only in the network display tables (using Service Tool or ComfortWORKS® software) and represents the amount of time to elapse before the unit will start its initialization routine. This value can be zero without the machine running in many situations. This can include being unoccupied, ENABLE/OFF/ REMOTE CONTACT switch in the OFF position, CCN not allowing unit to start, Demand Limit in effect, no call for cooling due to no load, and alarm or alert conditions pre se nt. If the machine should be running and none of the above are true, a minimum off time (DELY, see below) may be in effect. The machine should start normally once the time limit has expired.

MINUTES OFF TIME (DELY, Configuration Mode under OPT2) — This user configurable time period is used by the control to determine how long unit operation is delayed after power is applied/restored to the unit. T ypically, this time period is configured when multiple machines are located on a single site. For example, this gives the user t he ability to prevent all the units from restarting at once after a power failure. A val ue of zero for this variable does not mean that the unit should be running.

LOADING SEQUENCE — The 30GTN,R and 30GUN,R compressor efficiency is greatest at par tial lo ad. Th erefore, t he following sequence list applies to capacity control.

The next compressor will be started with unloaders energized on both lead compressors.

All valid capacity combinations using unloaders will be used as long as the total capacity is increasing.

LEAD/LAG DETERMINATION (LLCS, Configuration Mode under OPT2) — This is a configurable choice and is factory set to be automatic (for sizes 080-420) or Circuit A leading (for 040-070 sizes). For 040-070 sizes, the value can be changed to Automatic or Circuit B only if an accessory unloader is added to compressor B1. For 080-420 sizes, the value can be changed to Circuit A or Circuit B leading, as desired. Set at automatic, the control will sum the current number of logged circuit starts and one-quarter of the current operating hours for each circuit. The circuit with the lowest sum is started first. Changes to which circuit is the lead circuit and which is the lag are also made when total machine capacity is at 100% or when

there is a change in the direction of capacity (increase or decrease) and each circuit’s capacity is equal.

CAPACITY SEQUENCE DETERMINATION (LOAD, Configuration Mode under OPT2) — This is configurable as equal circuit loading or staged circuit loading with the default set at equal. The control determines the order in which the steps of capacity for each circuit are changed. This control choice does NOT have any impact on machines with only 2 compressors.

CAPACITY CONTROL OVERRIDES — The following overrides will modify the normal operation of the routine.

Deadband Multiplier

— The user configurable Deadband Multiplier (Z.GN, Configuration Mode under SLCT) has a default value of 1.0. The range is from 1.0 to 4.0. When set to other than 1.0, this factor is a pplied to the capacity Load/Unload Factor. The larger this value is set, the longer the control will delay between adding or removing stages of capacity. Figure 17 shows how compressor starts can be reduced over time if the leaving water temperature is allowed to drift a larger amount above and below the set point. This value should be set in the range of 3.0 to 4.0 for systems with small loop volumes.

First Stage Override

— If the current capa city stage is zero, the control will modify the routine with a 1.2 factor on adding the first stage to reduce cycling. This factor is also applied when the control is attempting to remove the last stage of capacity.

Slow Change Override

— The control prevents the capacity stages from being changed when the leaving fluid temperature is close to the set point (within an adjustable de adband) and moving towards the set point.

Ramp Loading

(CRMP, Configuration Mode under SLCT) — Limits the rate of change of leaving fluid temperature. If the unit is in a Cooling mode and configured for Ramp Loading, the control makes 2 comparisons before deciding to change stages of capacity. The control calculates a temperature difference between the control point and leaving fluid temperature. If the difference is greater than 4° F (2.2° C) and the rate of change (°F or °C per minute) is more than the configured Cooling Ramp Loading value (CRMP), the control does not allow any changes to the current stage of capacity.

Low Entering Fluid Temperature Unloading

— When the entering fluid temperature is below the control point, the control will attempt to remove 25% of the current stages bei ng used. If exactly 25% cannot be removed, the control re moves an amount greater than 25% but no more than necessary. The lowest stage will not be removed.

Table 6 — Required Hardware for Additional Unloaders

UNIT

30GTN,GTR,GUN,GUR

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz)

050-070

080-110**

130 (60 Hz)

130 (50 Hz)

150-210**

CBX — Compressor Expansion Board

LEGEND

COMP.

A1 1 0 N/A N/A B1 0 1 06EA-660---138 EF19ZE024 A1 1 0 N/A N/A

B1 0

A1 1 1

B1 0

A1 1 1 B1 1 1 A1 1 1 B1 1 1

FACTO RY

STANDARD

ADDITIONAL UNLOADERS

1 2 Not Required 30GT-911---031

UNLOADER PAC K AGE *

06EA-660---138

06EA-660---138 Not Required 30GT-911---031

06EA-660---138 EF19ZE024 Not Required

*Requires one per additional unloader.

†2 solenoid coils are included in the CXB Accessory.

**And associated modular units.

SOLENOID

COIL

EF19ZE024

EF19ZE024 Not Required

CXB ACCESSORY†

Not Required

LEGEND

Leaving Water Temperature

LWT —

WT (C) L

DEADBAND EXAMPLE

WT (F)

0 200 400 600 800 1000

TIME (SECONDS)

STANDARD DEADBAND

2 STARTS

MODIFIED DEADBAND

3 STARTS

Fig. 17 — Deadband Multiplier

Low Cooler Suction Temperature

— To avoid freezing the cooler, the control will compare the circuit Cooler Suction temperature (T5/T6) with a predetermined freeze point. If the cooler fluid selected is Water, the freeze point is 34 F (1.1 C ). If the cooler fluid selected is Brine, the freeze point i s 8° F (4.4 ° C) below the cooling set point (or lower of two cooling set points in dual set point configurations). If the cooler suction temperature is 24° to 29° F (13.3° to 16.1° C) below the cooler leaving water temperature and is also 2° F (1.1° C) less than the freeze point for 5 minutes, Mode 7 (Circuit A) or Mode 8 (Circuit B) is initiated and no additional capacity increase is allowed. The circuit will be allowed to run in this condition. If the cooler suction temperature is more than 30° F (16.7° C) below the cooler leaving water temperature and is also 2° F (1.1° C) below the freeze point for 10 minutes, the circuit will be stoppe d without going through pumpdown.

Cooler Freeze Protection

— The control will try to prevent shutting the chiller down on a Cooler Freeze Protection alarm by removing stages of capacity. The control uses the same freeze point logic as described in the Low Cooler Suction Temperature section above. If the cooler leaving fluid temperature is less than the freeze point plus 2.0° F (1.1° C), the control will immediately remove one stage of capacity. This can be repeated once every 30 seconds.

MOP (Maximum Operating Pressure) Override

— The control monitors saturated condensing and suction temperature for each circuit. Based on a maximum operating set point (saturated suction temperature), the control may lower the EX V position when system pressures approach the set parameters.

Head Pressure Control

COMFORTLINK™ UNITS (With EXV) — The Main Base Board (MBB) controls the condenser fans to maintain the lowest condensing temperature possible, and thus the highest unit efficiency. The fans are controlled by the saturated condensing temperature set from the factory. The fans can also be controlled by a combination of the saturated condensing temperature, EXV position and compressor superheat. Fan control is a configurable decision and is determined by the Head Pressure Control Method (HPCM) setting in the Configuration Mode under the OPT1 sub-mode. For EXV control (HPCM = 1), when the position of the EXV is fully open, T3 and T4 are less than 78 F (25.6 C), and superheat is greater than 40 F (22.2 C), fan stages will be removed. When th e valve is less than 40% open, or T3 and T4 are greater than 113 F (45 C), fan stages will be added. At each change of th e fan stage, the system will wait one minute to allow the head pressure to stabilize unless either T3 or T4 is greater than 125 F (51.6 C), in which case all MBB-controlled fans will start immediately. This method allows the unit to run at very low condensing temperatures at part load.

During the first 10 minutes after circuit start-up, MBBcontrolled fans are not turned on until T3 and T4 a re greater than the head pressure set point plus 10 F (5.6 C). If T3 and T4 are greater than 95 F (35 C) just prior to circuit start-up, all MBB-controlled fan stages are t urned on to prevent excessive discharge pressure during pull-down. Fan sequences are shown in Fig. 17.

UNITS WITH TXV — The logic to cycle MBB-controlled fans is based on saturated condensing temperature only, as sensed by thermistors T3 and T4 (see Fig. 8 and 10). When either T3 or T4 exceeds the head pressure set point, the MBB will turn on an additional stage of fans. For the first 10 minutes of each circuit operation, the head pressure set point is raised by 10° F (5.6° C). It will turn off a fan stage when T3 and T4 are both below the head pressure set point by 35° F (19.4° C). At each change of a fan stage the control will wait for one minute for head pressure to stabilize unless T3 and T4 is greater than 125 F (51.6 C), in which case all MBB-controlled fans start immediately. If T3 and T4 are greater than 95 F (35.0 C) just prior to circuit start-up, all MBB-controlled fan stages are turned on to prevent excessive discharge pressure during pulldown. Fan sequences are shown in Fig. 18.

Motormaster® Option

— For low-ambient operation, the lead fan(s) in each circuit can be equipped with the Motormaster III head pressure controller option or accessory. Wi nd baffles and brackets must be field-fabricated for all units using accessory Motormaster III controls to ensure proper cooling cycle operation at low-ambient temperatures. The fans controlled are those that are energized with the lead compres sor in each circuit. All sizes use one controller per circuit. Refer to Fig. 18 for condenser fan staging information.

Pumpout

EXV UNITS — When the lead compressor in each circ uit is started or stopped, that circuit goes through a pumpout cycle to purge the cooler and refrigerant suction lines of refrigerant. If a circuit is starting within 15 minutes of the last shutdown, the pumpout cycle will be skipped.

The pumpout cycle starts immediately upon starting the lead compressor and keeps the EXV at minimum position for 10 seconds. The EXV is then opened an additional percentage and compressor superheat control begins. At this point, the EXV opens gradually to provide a controlled start-up to prevent liquid flood-back to the compressor.

At shutdown, the pumpout cycle continuously closes the EXV until all lag compressors are off and the EXV is at 0%. The lead compressor continues to run for an additional 10 seconds and is then shut off.

TXV UNITS — Pumpout is based on timed pumpout. On a command for start-up, the lead compressor starts. After 15 seconds, the liquid line solenoid opens. At shutdown, the liquid line solenoid closes when the lead compressor has stopped.

FAN ARRANGEMENT

30GTN,R040-050 30GUN,R040-050

30GTN,R060-090, 230B, 245B 30GUN,R060-090, 230B, 245B

30GTN,R100,110, 255B-315B 30GUN,R100,110, 255B-315B

30GTN,R130 (60 Hz), 30GUN,R130 (60 Hz)

POWER

FAN

NO.

1 — Compressor No. A1

2 — Compressor No. B1

3 1 First Stage of Condenser Fans

4 2 Second Stage of Condenser Fans

1 — Compressor No. A1

2 — Compressor No. B1

3, 4 1 First Stage of Condenser Fans

5, 6 2 Second Stage of Condenser Fans

1 — Compressor No. A1

2 — Compressor No. B1

3, 4 1 First Stage of Condenser Fans

5, 6, 7, 8 2 Second Stage of Condenser Fans

5, 7 — Compressor No. A1

6, 8 — Compressor No. B1

1, 2 1 First Stage of Condenser Fans

FAN RELAY NORMAL CONTROL

3, 4, 9, 10 2 Second Stage of Condenser Fans

30GTN,R130 (50 Hz), 150-210, 230A-315A, 330A/B-420A/B† 30GUN,R130 (50 Hz), 150-210, 230A-315A, 330A/B-420A/B†

*Control box. †Fan numbers 11 and 12 do not apply to 30GTN,R and 30GUN,R 130-170 and associated modular units (see Table 1).

POWER

5, 7 — Compressor No. A1

6, 8 — Compressor No. B1

1, 11 1 First Stage of Condenser Fans, Circuit A

3, 9 2 Second Stage of Condenser Fans, Circuit A

2, 12 3 First Stage of Condenser Fans, Circuit B

4, 10 4 Second Stage of Condenser Fans, Circuit B

Fig. 18 — Condenser Fan Sequence

Marquee Display Usage (See Fig. 19 and

ENTER

Tables 7-25) —

user interface to the ComfortLink™ control system. The dis- play has up and down arrow keys, an key, and an

ENTER

key. These keys are used to navigate through the dif-

ferent levels of the display structure. See Table 7. Press the

ESCAPE

key until the display is blank to move through the top 11 mode levels indicated by LEDs on the left side of the display .

Pressing the and keys simultaneously will scroll a clear language text description across the display indicating the full meaning of each display acronym. Pressing the and keys when the display is blank

ESCAPE ENTER (Mode LED level) will return the Marquee display to its default menu of rotating display items. In addition, the password will be disabled requiring that it be entered again before changes can be made to password protected items.

Clear language descriptions in English, Spanish, French, or Portuguese can be displayed when properly configuring the LANG variable in the Configuration mode, under DISP submode. See Table 16.

NOTE: When the LANG variable is cha nged to 1, 2, or 3, all appropriate display expansions will immediately change to the new language. No power-off or control reset is required when reconfiguring languages.

When a specific item is located, the display will flash showing the operator, the item, followed by the item value and then followed by the item units (if any). Press the key to stop the display at the item value. Items in the Configuration and Service Test modes are password protected. The display will flash PA SS and WORD when required. Use the and arrow keys to enter the 4 digits of the password. The default password is 1111. The password can only be changed through CCN devices such as ComfortWORKS® and Service T ool.

Changing item values or testing outputs is accomplished in the same manner. Locate and display the desired item. Press

ENTER ENTER

to stop the display at the item value. Press the key again so that the item value flashes . Use the ar-

row keys to change the value or state of an i tem and press t he

ENTER ESCAPE

key to accept it. Press the key and the item, value, or units display will resume. Repeat the process as required for other items.

See Tabl es 7-25 for further details.

Service Test (See Table 9) —

control cir cuit power must be on.

Run Status

Service Test

Temperature

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

Fig. 19 — Scrolling Marquee Display

The Marquee display module provides the

ESCAPE

ESCAPE ENTER

Both main power and

MODE

Alarm Status

ESCAPE

ENTER

The Service Test function should be used to verify proper operation of compressors, unloaders, hot gas bypass (if installed), cooler pump and remote alarm relays, EXVs and condenser fans. To use the Service Test mode, the Enable/Off/ Remote Contact switch must be in the OFF position. Use the display keys and Table 9 to enter the mode and display TEST. Press twice so that OFF flashes. Enter the password if required. Use either arrow key to change the TEST value to the On position and press . Switch the Enable/Off/Re-

ENTER mote Contact switch to the Enable position (Version 2.3 and later). Press and the button to ent er the OUTS

ESCAPE

or COMP sub-mode.

Test the condenser fan, cooler pump, and alarm relays by changing the item values from OFF to ON. These discrete outputs are turned off if there is no keypad activity for 10 minutes. Use arrow keys to select desired percentage when testing expansion valves. When testing compressors, the lead compressor must be started first. All compressor outputs can be turned on, but the control will limit the rate by staging one compressor per minute. Compressor unloaders and hot gas bypass relays/ solenoids (if installed) can be tested with compressors on or off. The relays under the COMP sub-mode will stay on for 10 minutes if there is no keypad activity. Compressors will stay on until they are turned off by the operator. The Service Test mode will remain enabled for as long as there is one or more compressors running. All safeties are monitored during this test and will turn a compressor, circuit or the machine off if required. Any other mode or sub-mode can be accessed, viewed, or changed during the TEST mode. The MODE item (Run Status mode under sub-mode VIEW) will display “0” as long as the Service mode is enabled. The TEST sub-mode value must be changed back to OFF before the chiller can be switched to Enable or Remote contact for normal operation.

Configuring and Operating Dual Chiller Control (See Table 18) —

able for the control of two units supplying chilled fluid on a common loop. This control is designed for a parallel fluid flow arrangement only. One chiller must be configured as the master chiller, the other as the slave chiller. An additional leaving fluid temperature thermistor (Dual Chiller LWT) must be installed as shown in Fig. 20 and connected to the master chiller. See Field Wiring section for Dual Chiller L WT sensor wiring.

To configure the two chillers for opera tion, follow the example shown in Table 18. The master chiller will be configured with a slave chiller at address 6. Also in this example, the master chiller will be configured to use Lead/Lag Balance to even out the chiller runtimes weekly. The Lag Start Delay feature will be set to 10 minutes. The master and slave chillers cannot have the same CCN address (CCNA, Configuration mode under OPT2). Both chillers must have the control method variable (CTRL, Configuration mode under OPT2) set to ‘3.’ In addi- tion, the chillers must both be connected together on the sam e CCN bus. Connections can be made to the CCN screw terminals on TB3 in both chillers. The master chiller will determine which chiller will be Lead and which will be Lag. The master chiller controls the slave chiller by forcing the slave chiller’s CCN START/STOP variable (CHIL_S_S), control point (CTPT) and demand limit (DEM_LIM).

The master chiller is now configured for dual chiller operation. To configure the slave chiller, only the LLEN and MSSL variables need to be set. Enable the Lead/ Lag chiller enable variable (LLEN) as shown Table 18. Similarly, set the M aster/ Slave Select variable (MSSL) to SLVE. The variables LLBL, LLBD, an LLDY are not used by the slave chiller.

Refer to Field Wiring section on page 67 for wiring information.

The dual chiller routine is avail-

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