Carrier 30GX125, 30GX080, 30GX115, 30GX150, 30GX136 Controls, Start-up, Operation, Service, And Troubleshooting

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ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers

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, and labels attached to the equipment, and any other safety precautions that apply. Follow all safety codes. W ear 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 and condenser 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/Ame rican Society of Heating, Refrigeration and Air Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The accumulation 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.

30GX080-350

30HXA,HXC076-271

50/60 Hz

Series 3

DO NOT attempt to unbraze factory joints when 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

SAFETY CONSIDERATIONS GENERAL MAJOR SYSTEM COMPONENTS Processor Module (PSIO-1) DSIO-HV Relay Module Electronic Expansion Device Module Compressor Protection Module (CPM) PSIO-2 (8052) Module Keypad and Display Module

(Also Called HSIO-II) Control (LOR) Switch OPERATION D ATA Electronic Expansion Device (EXD)

• EXV OPERATION

• ECONOMIZER OPERATION

Oil Pumps Motor Cooling Back Pressure Valve (30GX and 30HXA only) Sensors Compressor Protection Module (CPM)

• OUTPUTS

• INPUTS

Wye-Delta vs Across-the-Line (XL)

Starting Option Capacity Control

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LOADING SEQUENCE

• CLOSE CONTROL

• LEAD/LAG DETERMINATION

• CAPACITY SEQUENCE DETERMINATION

• MINIMUM LOAD VALVE

• CAPACITY CONTROL OVERRIDES

Head Pressure Control

• GENERAL

• AIR-COOLED UNITS (30GX)

• WATER-COOLED UNITS (30HXC)

• CONDENSERLESS UNITS (30HXA)

• 09DK CONDENSING UNITS

• ADJUSTING PID ROUTINES

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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. 533-095 Printed in U.S.A. Form 30G,H-5T Pg 1 8-99 Replaces: 30G,H-4T

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CONTENTS (cont)

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Cooler and Condenser (30HXC) Pump Control

• COOLER PUMP CONTROL

• CONDENSER PUMP CONTROL

Cooler Heater Control Oil Heater Control Keypad and Display Module

(Also Called HSIO-II)

• ACCESSING FUNCTIONS

AND SUBFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . 15

• AUTOMATIC DEFAULT DISPLAY . . . . . . . . . . . . . . 15

• STATUS FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 19

• TEST FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

• HISTORY FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . 27

• SET POINT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 27

• SERVICE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . 32

• SCHEDULE FUNCTION. . . . . . . . . . . . . . . . . . . . . . . 39

Temperature Reset

• EXTERNAL TEMPERATURE RESET

• EXTERNALLY POWERED RESET

• RETURN FLUID TEMPERATURE RESET

Demand Limit

• DEMAND LIMIT (Switch Controlled, 30GX Only)

• EXTERNALLY POWERED DEMAND LIMIT

• DEMAND LIMIT (CCN Loadshed Controlled)

TROUBLESHOOTING Checking Display Codes Unit Shutoff Complete Unit Stoppage Single Circuit Stoppage Restart Procedure

• POWER FAILURE EXTERNAL TO THE UNIT

Alarms and Alerts Compressor Alarm/Alert Circuit EXD Troubleshooting Procedure

• INSPECTING/OPENING ELECTRONIC EXPANSION VALVES

• INSPECTING/OPENING ECONOMIZERS

SERVICE Servicing Coolers and Condensers

• TUBE PLUGGING

• RETUBING

• TIGHTENING COOLER/CONDENSER HEAD BOLTS

Inspecting/Cleaning Heat Exchangers

•COOLERS

• CONDENSERS (30HX Only)

Water Treatment Condenser Coils (30GX Only)

• COIL CLEANING

Condenser Fans (30GX Only) Refrigerant Charging/Adding Charge Oil Charging/Low Oil Recharging Oil Filter Maintenance

• REPLACING THE EXTERNAL OIL FILTER

• REPLACING THE INTERNAL OIL FILTER

Compressor Changeout Sequence

• BURNOUT CLEAN-UP PROCEDURE

Moisture-Liquid Indicator Filter Drier Liquid Line Service Valve Thermistors

•LOCATION

• THERMISTOR REPLACEMENT

Pressure Transducers

• PRESSURE TRANSDUCER CALIBRATION

• TROUBLESHOOTING

Safety Devices

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• COMPRESSOR PROTECTION

• OIL SEPARATOR HEATERS (30GX)

• COOLER PROTECTION

Relief Devices

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• PRESSURE RELIEF VALVES

Control Modules

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• PROCESSOR MODULE (PSIO-1), COMPRESSOR PROTECTION MODULE (CPM), HIGH VOLTAGE RELAY MODULE (DSIO-HV), AND EXV DRIVER MODULE (DSIO-EXV), 12/6 MODULE (PSIO-2)

• RED LED

• GREEN LED

• CONTROL MODULE BATTERY REPLACEMENT

Carrier Comfort Network (CCN) Interface

. . . . . . . . 66

• PROCESSOR MODULE (PSIO-1)

• HIGH VOLTAGE RELAY MODULE (DSIO-HV)

Replacing Defective Processor Module Winter Shutdown Preparation PRE-START-UP PROCEDURE System Check

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START-UP AND OPERATION Actual Start-up Operating Sequence FIELD WIRING

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APPENDIX A

(Compressor Must Trip Amps)

. . . . . . . . . . . . . 76-80

APPENDIX B

(Capacity Loading Sequence) APPENDIX C (Available Accessories) APPENDIX D (Building Interface)

. . . . . . . . . . . . . . 81-85

. . . . . . . . . 86,87

. . . . . . . . . . . . . 88-92

APPENDIX E (Cooler and

Condenser Pressure Drop)

. . . . . . . . . . . . . . . . . 93-96

APPENDIX F

(Typical System Components) INDEX START-UP CHECKLIST

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

. . . . . . . . . . . . . 97,98

GENERAL

IMPORTANT: The 30GX,HX units use refrigerant R-134a. Compressor oil used with R-134a is Polyolester oil.

This publication contains Start-Up, Service, Controls, Operation and Troubleshooting data for the 30GX080-350 and 30HXA,C076-271 screw chillers.

Circuits are identified as circuits A and B, and compressors are identified as A1 or A2 in circuit A, and B1 or B2 in circuit B.

The 30GX,HX Series chillers feature microprocessor-based electronic controls and electronic expansion devices (EXD) in each refrigeration circuit.

The control system cycles compressor loaders and/or compressors to mai ntain the se lected lea ving fluid te mperature s et point. The system automatically positions the EXD to maintain the specified refrigerant level in the cooler. The system also has capabilities to control a condenser water valve to maintain suitable leaving-water temperature for the 30HXC unit. Safeties are continuously monitored to prevent the unit from operating under unsafe conditions. A scheduling function can be programmed by the user to control the unit’s occupied and unoccupied schedules. The control also operates a test function and a manual control function that allows the operator to check output signals and ensure components are operable.

The control system consists of a processor module (PSIO-1), an EXD driver module (DSIO-EXV), a high voltage relay module on 30GX units (DSIO-HV), 2 six-pack relay boards, a keypad and display module (also called HSIO-II), 2 electronic expansion devices (EXDs), 1 compressor protection module (CPM) per pair of compressors, a PSIO-2 module,

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6 thermistors, and up to 10 transducers. A remote enhanced display is available as an accessory.

MAJOR SYSTEM COMPONENTS

Processor Module (PSIO-1) —

upgrade to the original PSIO (8088) module, with superior electrical noise immunity capability. It contains the operating software and controls the operation of the machine. It has 12 input channels and 6 output channels.

The PSIO-1 continuously monitors input/output channel information received from all the modules and controls all output signals for all output channels. It also controls the relays on the six-pack relay board. The processor module also controls the EXD driver module, commanding it to open or close each EXD in order to maintain the proper cooler level. Information is transmitted between the processor module, CPM modules, the EXD driver module, and the HSIO-II standard display module through a 3-wire communications bus called COMM3. The remote enhanced display (accessory) is connected to the PSIO-1 module through a 3-wire communications bus, but uses a different communication bus called COMM1. The COMM1 bus is also used to communicate to other CCN (Carrier Comfort Network) devices when the unit is installed in a network application.

DSIO-HV Relay Module —

4 inputs and 8 outputs and is installed on 30GX units only. The module communicates the status of the inputs with the PSIO-1 module and operates the oil heater, outdoor fan, and minimum load control outputs.

Electronic Expansion Device Module —

electronic expansion device module has 4 inputs and 2 outputs. It receives signals from the PSIO-1 module and operates the electronic expansion devices. The electronic expansion device module also sends the PSIO-1 module the status of its 4 input channels.

Compressor Protection Module (CPM) —

compressor protection module monitors the high pressure switch status, running current, and motor temperature for each compressor. Each CPM controls up to 2 compressors. The CPM also controls the motor cooling solenoid, oil solenoid, and contactor outputs. A pre-punched configuration header for each compressor determines the must trip amps setting. Each CPM sends the PSIO-1 each compressor’s motor temperature, relay status, and running current as a percentage of the must trip amps value. The CPM als o communic ates any al arm conditions as the feedback value.

PSIO-2 (8052) Module —

put/output module only, as there is no unit software loaded in the module. This module has 12 input channels and 6 output channels.

This module is an

The DSIO-HV module has

The

This module is used as an in-

Keypad and Display Module (Also Called HSIO-II) —

keys, 4 operative keys, 12 numeric keys, and a 2-line 24-character alphanumeric LCD (liquid crystal display). Key usage is explained in the Accessing Functions and Subfunctions section on page 15.

Control (LOR) Switch —

fined by the position of the LOCAL/OFF/REMOTE (LOR) switch. This is a 3-positi on manual swit ch th at allow s th e chiller to be put under the control of its own controls (LOCAL ), manually stopped (OFF), or controlled through a set of remote contacts (REMOTE). This switch i s different than the switch

This device consists of a keypad with 8 function

Control of the chiller is de-

that is used in the Flotronic™ II controls configuration. The CCN control is enabled through the H SIO-II. The switch allows unit operation as shown in T able 1.

In the LOCAL position, the c hiller i s allowed to ope rate and respond to the scheduling configuration, CCN configuration, and set point data. In the remote position, the unit operates similarly to the LOCAL position, except the remote contacts must be closed for the unit to operate.

Table 1 — Unit Mode from LOR Switch

and CCN State

SWITCH

POSITION

LOCAL

OFF

REMOTE

CCN — NR —

NOTE: If the unit is configured for a clock, then the unit is under clock control if it is in an ON mode.

REMOTE

CONTACTS

NR NR NR LOCAL OFF

OPEN NR NR LOCAL OFF

CLOSED

LEGEND Carrier Comfort Network

Input Not Read by Processor

CCN

CONFIGURATION

DISABLE NR LOCAL ON

ENABLE

DISABLE NR LOCAL ON

ENABLE

CCN

STATE

RUN CCN ON

STOP CCN OFF

RUN CCN ON

STOP CCN OFF

UNIT

MODE

OPERATION DATA

Electronic Expansion Devi ce (EXD) —

processor controls the EXD through the EXD driver module . The EXD will either be an EXV (electronic expansion valve) or an economizer. Inside both these devices is a linear actuator stepper motor.

EXV OPERATION — High-pressure liquid refrigerant enters the valve through the bottom. A series of calibrated slots are located inside t he orifice assembly. As refrigerant passes through the orifice, the pressure drops and the refrigerant changes to a 2-phase condition (liquid and vapor). To control refrigerant flow for different operating conditions, the sleeve moves up and down over the orifice, thereby changing orifice size. The sleeve is moved by a linear stepper motor. The stepper motor moves in increments and is controlled directly by the processor module. As the stepper motor rotates, motion is transferred into linear movement by the lead screw. Through the stepper motor and lead screw, 1500 discrete steps of motion are obtained. The large number of steps and long stroke result in very accurate control of refrigerant flow.

Each circuit has a liquid level sensor mounted vertically in the top of the cooler shell. The level sensor consists of a small electric resistance heater and 3 thermi stors wire d in s eries , positioned at different heights inside the body of the well. The heater is designed so that the thermistors read approximately 200 F (93.3 C) in dry air . As the refrigerant level ris es (falls) in the cooler, the resistance of the closes t thermistor(s) will increase (decrease) as it is cooled by the rising liquid refrigerant (heated by the heater). This large resistance difference allows the control to accurate ly maint ain a spe cified le vel.

The level sensor monitors the refrigerant liquid level in the cooler and sends this infor mation to the PSIO-1. At initia l startup, the EXV position is at zero. After that, the microprocessor keeps accurate track of the valve position in order to use this information as input for the other control functions. The processor does this by initializing the EXVs at start-up. The processor sends out enough closing pulses to the valve to move it from fully open to fully closed, then resets the position counter to zero. From this point on, until the next initialization, the processor counts the total number of open and closed steps it has sent to each valve.

The micro-

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ECONOMIZER OPERATION — Economizers are factory installed on 30GX105-350 units and 30HXA,C161-271 units. All other sizes use standard EXVs. The economizer improves both the chiller capacity and efficiency as well as providing compressor motor cooling. Inside the economizer are both a linear stepper motor (same as standard EXV motor) and a float valve. The stepper motor is controlled by the processor to maintain the desired liquid level in the cooler (as is done for chillers without economizers). The float valve maintains a liquid level in the bottom of the economizer.

Liquid refrigerant is supplied from the condenser through the end to the bottom of the economizer. A bubbler tube supplies a small amount of discharge gas to ensure that the float will be able to work properly. As the refrigerant passes through the EXD, its pr essure is reduced to an inter mediate level of about 75 psig (517 kPag). This pressure is maintained inside the economizer shell. Next, the refrigerant flows through the float valve where its pressure is further reduced to slightly above the pressure in the cooler.

The increase in performance is achieved when some of the refrigerant passing through the EXD flashes to vapor, further subcooling the liquid that is maintained at the bottom of the economizer. This increase in subcooling provides additional capacity. Also, since the additional power required to accomplish this is minimal, the efficiency of the m achine improves. The vapor that flashes rises to the top of the economizer where it passes to the compressor and is used to provide motor cooling. After passing over the motor windings, the refrigerant reenters the cycle at an intermediate port i n the compression cycle.

Oil Pumps —

nally mounted prelubricating oil pump per circuit. This pump is operated as part of the start-up sequence. On 30GX units, the pumps are mounted to the base rails on the oil separator side of the unit. The pumps are mounted to a bracket on the condensers of 30HXC units and to the oil separator on 30HXA units.

When a circuit is required to start, the controls energize the oil pump first and read the oil pressure transducer reading. The pump is operated for a period of 20 seconds, after which the oil solenoid is energized to open the oil inlet valve at the compressor. The control again reads the pressure from the oil pressure transducer. If the pump has built up sufficient oil pressure, the compressor is allowed to start.

Once the compressor has started, the oil pump is turned off within 10 seconds. If the pump is not able to build up enough oil pressure, the pump is turned off. Within 3 seconds, the pump is re-energized and makes one additio nal attempt to build oil pressure. The control generates an alarm if the second attempt fails.

The oil pump is also used to supplement system pressure under certain operating conditions. The oil flow requirements of the compressor vary based on pressure differential across the compressor. The oi l pump is designed to provi de differential oil pressure during low pressure differential conditions. It is not designed to overcome high pressure drop across filters during high pressure differential conditions.

If the differential oil pressure (oil pressure – economizer pressure) for a compressor is less than 13 psi then the oil pump will be started. Just before the oil pump is started the control measures the pressure differential between the discharge pressure and oil pressure (oil system pressure drop). The oil system pressure drop is saved and used to determine when the oil pump should be shut off.

When the oil pump is operating, it is capable of increasing oil pressure from 0 psi to 50 psi depending on the oil flow

The 30GX,HX screw chillers use one exter-

requirements of the compressor. For example, if the compressor needs 2 gpm (high pressure differential condition) and the oil pump is capable of 1.2 gpm, there is no pressure rise and the oil flow will bypass the check valve and supply the 2 gpm to the compressor. If the compressor requires .75 gpm, the oil pump will increase pressure to satisfy the oil pressure requirement.

The pump will continue to operate until the discharge pressure minus economizer pressure is greater then 17 psi plus the oil system pressure drop.

Example:

Discharge pressure 80 psi

Oil pressure 65 psi

Oil system pressure drop80 –65 = 15 psi

Economizer pressure 55 psi

Suction pressure 42 psi

Based on the above conditions the oil pump will be started because differential oil pressure equals 10 psi.

The oil pump will continue to operate until the discharge pressure minus economizer pressure (which equals 25) is greater than 17 plus 15 (oil system loss before pump was started). The only way this can be satisfied is if the discharge pressure increases or the compressor unloads at which point the oil pump will be shut off.

Motor Cooling —

tures are controlled to a set point of 200 F (93.3 C). The control accomplishes this by cycling the motor cooling solenoid valve to allow liquid refrigerant to flow across the motor windings as needed. On units equipped with economizers, flash gas leaves the top of the economizer and continually flows to the motor windings. All refrigerant used for motor cooling re-enters the rotors through a port located midway along the compression cycle and is compressed to discharge pressure.

Compressor motor winding tempera-

Back Pressure Valve (30GX and 30HXA only) —

30GX units and mounted on the oil separator shell of 30HXA units. The valve’s function is to ensure that there is sufficient system differential pressure to allow for oil to be driven back to the compressor. A small copper line (economizer pressure) is connected to the top of the valve, which contains an internal spring that closes a piston if the pressure in the oil separator is not at least 15 psig greater than the economizer pressure.

Sensors —

Flotronic™ II chiller control system) gathers information from sensors to control the operation of the chiller. The units use up to 10 standard pressure transducers, up to 8 standard thermistors (including 4 motor temperature thermistors), and 2 liquid level thermistors to monitor and control system operation. The sensors are listed in Table 2.

Compressor Protection Module (CPM) —

CPM controls up to 2 compressors. The CPM provides the following functions:

• compressor main contactor control|

• Wye-Delta contactor transition

• compressor ground current protection

• motor temperature reading

• high-pressure protection

• reverse rotation protection

• current imbalance protection

• compressor oil solenoid control

• motor cooling solenoid contro l

• sensor bus communications

• starting and running overcurrent protection

This valve is located on the oil separator outlet on

The 30GX,HX control system (based on the

One

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The CPM has the following 4 output relays and 4 inputs:

OUTPUTS:

• compressor contactor

• compressor oil solenoid

• compressor motor cooling soleno id

• Wye-Delta transition relay INPUTS:

• motor temperature

• three-phase current

• high-pressure switch A diagram of the CPM board is (HN67LM101) shown in

Fig. 1. One CPM board is installed on 30GX080-176 and 30HXA,C076-186 units, and 2 CPM boards are installed on 30GX205-350 and 30HXA,C206-271 units. The address for

switches 3 and 4. For CPM1 (compressors A1 and B1), both DIP switches should be set to 0. For CPM2 (compressor A2, for 30GX205-265 and 30HXA,C206-271 units only and compressors A2 and B2 for 30GX281-350 only), both switches should be set to 1. See Table 3 for CPM board connections. The CPM has a reset button located between the DIP switch and the J10 connector. Pressing the reset button on the CPM will clear any current CPM alarms, but will not turn off any outputs from the CPM. Pressing the reset button on the CPM will NOT cause the board to go through initialization. Initialization period only occurs during power-up and lasts for approximately 2 minutes. Each compressor’s MTA (must trip amps) setting is communicated to the PSIO-1 during the initialization period. Switches 1 and 2 should be set to 0. See Table 4 for DIP switch settings.

each CPM board is set using DIP (dual in-line package)

Table 2 — Thermistor and Transducer Locations

Sensor Description Location Connection Terminals T1 T2 Motor Temp A1 Motor Temp A2* Motor Temp B1 Motor Temp B2† T5 T6 LL-A (T3) LL-B (T4) T7 (optiona l)* * STP (optional)** T8 (optiona l)* * T9 (optiona l)* *

Sensor Description Location Connection Terminals DPT-A SPT-A EPT-A OPT-A1 OPT-A2* DPT-B SPT-B EPT-B OPT-B1 OPT-B2†

*30HX206-271 and 30GX205-265 only. †Sensors are available as accessories for field installation.

Cooler Leaving Fluid Temp Cooler Head Leaving Fluid Side PSIO-2, J7 pins 2,3 Cooler Entering Fluid Temp Cooler Head Entering Fluid Side PSIO-2, J7 pins 5,6 Motor Temperature A1 Compressor A1 Junction Box CPM1, plug J5 Motor Temperature A2 Compressor A2 Junction Box CPM2, plug J5 Motor Temperature B1 Compressor B1 Junction Box CPM1, plug J9 Motor Temperature B2 Compressor B2 Junction Box CPM1, plug J9 Discharge Gas Temp A Top of Oil Separator Circuit A PSIO-2, J7 pins 8,9 Discharge Gas Temp B Top of Oil Separator Circuit B PSIO-2, J7 pins 11,12 Liquid Level Circuit A Top of Cooler Circuit A PSIO-1, J7 pins 5,6 Liquid Level Circuit B Top of Cooler Circuit B PSIO-1, J7 pins 8,9 Outdoor Air Thermistor Outside Air Stream PSIO-2, J7 pins 20,21 Space Temperature Conditioned Space PSIO-2, J7 pins 23,24 Condenser Entering Water Thermistor Condenser Entering Fluid Line PSIO-2, J7 pins 14,15 Condenser Leaving Water Thermistor Condenser Leaving Fluid Line PSIO-2, J7 pins 17,18

Discharge Pressure Circuit A Top of Condenser Separator Circuit A PSIO-1, J7 pin 22 Suction Pressure Circuit A Top of Cooler Circuit A PSIO-1, J7 pin 19 Economizer Pressure Circuit A Economizer Line Entering Comp A PSIO-1, J7 pin 10 Oil Pressure Compressor A1 Compres sor A1 Oil Connection PS IO-1, J7 pin 25 Oil Pressure Compressor A2 Compres sor A2 Oil Connection PS IO-1, J7 pin 1 Discharge Pressure Circuit B Top of Oil Separator Circuit B PSIO-1, J7 pin 16 Suction Pressure Circuit B Top of Cooler Circuit B PSIO-1, J7 pin 31 Economizer Pressure Circuit B Economizer Line Entering Comp B PSIO-1, J7 pin 13 Oil Pressure Compressor B1 Compres sor B1 Oil Connection PS IO-1, J7 pin 28 Oil Pressure Compressor B2 Compres sor B1 Oil Connection PS IO-1, J7 pin 16

THERMISTORS

PRESSURE TRANSDUCERS

Table 3 — Compressor Protection Module

(CPM) Plug Connections

CPM PLUG DESCRIPTION

J2, J6 J3, J7 J4, J8

J5, J9

J10, J11

NOTE: Plugs J2-J5 are for compressors A1 (CPM1) or A2 (CPM2). Plugs J6-J9 are for compressor B1 (CPM1) or B2 (CPM2).

24-vac Power Input Compressor Contactor(s) High Pressure Switch, Oil and Motor Cooling

Solenoids Current Sensor Input Compressor Motor Temperature Input Communication Connections

30GX080-176 30HXA076-186 30HXC076-186

30GX205-350 30HXA206-271 30HXC206-271

Table 4 — CPM Address DIP Switch Settings:

UNIT

CPM1 CPM2

1234 1 2 3 4

0000————

0000 0 0 1 1

Page 6

To verify proper must trip amps header configuration, press

and use the up arrow key on the HSIO to locate the must trip amp values. Press the reset button on the control panel to update these values. See Appendix A. If the values do not match those in Appendix A, verify that the configuration headers have been properly punched out.

The CPM communicates on the COMM3 communic ation bus to the PSIO-1 module. Proper operation of the CPM board can be verified by observing the 2 LEDs (light-emitting diodes) located on the board. The red LED blinks at a rate of once every 1 to 2 seconds. This indicates that the module is powered and operating correctly. The green LED blinks when the module is satisfactorily communicating with the PSIO-1 module. The CPM communicates the status of its inputs and outputs, and reports 15 different alarm conditions to the PSIO-1. The alarms are listed in Table 5.

The CPM module has many features that are specifically designed to protect the compressor, including reverse rotation protection. Do not attempt to bypass or alter any of the factory wiring. Any compressor operation in the reverse direction will result in a compressor failure that will require compressor replacement.

The PSIO-1 will generate an alert when it receives an alarm input from the CPM. The alert will be generated in a y.xx format, where “y” refers to the compre ssor and “xx” to the alarm value in Table 5 (decimal point removed). For example, the HSIO might display Alarm 1.75 for a contactor failure occurring on compressor A1. Similarly, the display would read 5.85 for a motor overtemperature condition on compressor B1. Alerts for compressors A2 and B2 (if present) would be generated as “2.xx” and “6.xx,” respectively. Alarm codes 3 and 4 would not be used. Ending zeros are not displayed.

The high-pressure switch is wired in series with the relay coils of the 8 relays on the CPM. If this switch opens during operation, all relays on the CPM are deenergized and the compressor is stopped. The failure is reported to the PSIO-1 and the processor module locks off the compressor from restarting until the alarm is manually reset.

SW1

LEGEND

LED — MTA —

NOTES:

1. The red LED blinks continuously when the module is operating properly.

2. The green LED blinks continuously when communicating properly with PSIO-1.

3. On all plugs, pin 1 is identified by a “●.’’

SW2

Light-Emitting Diode Must Trip Amps

SW3 SW4

COMP 2 MTA HEADER

DIP SWITCH

RESET BUTTON

J10

J11

3 2 1

1 2 3 4

GREEN LED

RED LED

COMP 1 MTA HEADER

2 3

1 2

1 2 3 4

1 2

1 2 3

Fig. 1 — Compressor Protection Module (HN67LM101)

Page 7

Table 5 — Compressor Protection Module

Feedback Codes

High Pressure Switch Trip 1.0 No Motor Current 2.0 Current Imbalance Alarm 10% 2.5 Current Imbalance Warning 10% 2.7 Current Imbalance 25% 3.0 Single Phase Current Loss 3.5 High Motor Current 4.0 Ground Fault 5.0 Contactor Failure 7.5 Current Phase Reversal 8.0 Motor Overtemperature 8.5 Open Thermistor 9.0 Configuration Header Fault 9.5 Shorted Thermistor 10.0 No Error 0

ALARM CONDITION VALUE

Wye-Delta vs Across-the-Line (XL) Starting Option —

208/230-3-60 or 230-3-50 (5 or 8 at Position 12 in model number) are supplied with factory installed Wye-Delta starters. All other voltage options can be ordered with either Wye-Delta or XL starting options. The XL starting method is the most cost effective and simply starts the compressor motor in a Delta configuration (the motors are designed for continuous operation in this configuration) using a single contactor. See Fig. 2. This is the simplest starting method to use and is ideal where starting current does not require limiting.

Where current limitations exist, the Wye-Delta option may be used. See Fig. 3. This option uses a factory-installed starter assembly for each compressor, which consists of 3 contactors labelled 1M, 2M, and S. As the compressor is started, the CPM module energizes contactors 1M and S, which connects and energizes the motor windings in a Wye configuration. The starting current required will be approximately 60% less than that required for an XL start due to the higher impedance of the motor windings when W ye connected. The compressor will attain about 100% of its normal operating speed (approximately 3 to 5 seconds) before the CPM module deenergizes the S contactor and energizes the 2M contactor, switching the compressor windings to a Delta wiring configuration. The S and 2M contactors in the starter assembly are both mechanic ally and electrically interlocked so that they will not both be energized at the same time.

Do not alter the factory-installed power wiring from the control box terminal block to the compressor junction block.

Doing so will cause permanent damage t o the compress or and will require that the compressor be replaced.

Capacity Control —

pressors, loaders, and minimum load control valves to maintain the user-configured leaving chilled fluid temperature set point. Entering fluid temperature is used by the microprocessor 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 temperature reset or space and outdoor-air temperature reset features. It can also be reset from an ext ernal 4 to 20 mA signal (requires field-supplied 500-ohm, sistor), or from a network signal.

The capacity control algorithm runs every 30 seconds. The algorithm attempts to maint a in the Control Point at the desired set point. Each time it runs, the control reads the e ntering and leaving fluid temperatures. The control determines the rate at which conditions are changing and calculates 2 variables based

All 30GX,HX chillers operating at voltages of

The control system cycles com-

/2 watt re-

on these conditions. Next, a capacity ratio (Load/Unload Factor under ) 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 start s (stops) a compressor when the ratio reaches + 100% (–100%). If the next stage of capacity is a loader, the control energizes (deenergizes) a loader when the ratio reaches + 60% (–60%). Loaders are allowed to cycle faster than com pressors, to minimize the number of starts and stops on each compressor. A delay of 90 seconds occurs after each capacity step change.

MINUTES LEFT FOR START — This value is displayed in the Status subfunction and represents the amount of time to elapse before the unit is started. This value can be zero without the machine running in many situations. This can include being unoccupied, LOR 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 present. If the machine should be running and none of the above are true, a minimum off time may be in effect. The machine should start normally once the time limit has expired.

MINUTES OFF TIME ( ) — 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. It is also used to delay compressor restarts after the unit has shut off its lowest stage of capacity. Typically, this time period is configured when multiple machines are located on a single site. For example, this gives the user the ability t o prevent all the units from restarting at once afte r a power fa ilure. A val ue of zero for this variable does not mean that the unit should be running.

LOADING SEQUENCE — The 30GX,HX compressor efficiency is greatest at full load. Therefore, the following sequence list applies to capacity control.

1. The next compressor is not started until all others are running at 100%.

2. The second unloading stage is only used during initial capacity staging of the unit at start-up.

3. Whenever a compressor is started i n a c ircuit , th e loaders in the circuit are deenergized for 15 seconds before the compressor is started. The loaders are energized 90 seconds after the compressor is started.

CLOSE CONTROL ( ) — When configured for Close Control, the control is allowed to use any loading/capacity control devices required to maintain better leaving fluid temperature regulation. All stages of unloading are available. See Appendix B for an example.

LEAD/LAG DETERMINATION ( ) — This is a configurable choice and is factory set to be automatic. 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 made when shutting off compressors.

On 30HX206-271 and 30GX205-350 units set for staged loading, the control fully loads the lead circuit before starting the lag circuit and unloads the lag circuit first. When these units are set for equal loading, the control maintains nearly equal capacities in each circuit when the chiller is loading and unloading.

Page 8

TERMINAL BLOCK

COMPRESSOR CONTACTOR

JUMPER BARS

COMPRESSOR JUNCTION BOX

Fig. 2 — Across-the Line (XL) Compressor Wiring

TERMINAL BLOCK

COMPRESSOR STARTER ASSEMBLY

Fig. 3 — Wye-Delta Compressor Wiring

CAPACITY SEQUENCE DETERMINATION ( ) — This is configurable as equal circuit loading or staged circuit loading with the default set at staged. 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.

MINIMUM LOAD VALVE ( ) — When this option is installed and configured, the first stage of capacity is altered by energizing the Minimum Load valve relay. Once the control requires more capacity, the minimum load valve is deenergized and normal capacity staging resumes with loaders and compressors. Similarly, the Minimum Load valve relay will be energized for the last stage of capacity to be used before t he circuit is shut down.

Configure Unit for Minimum Load Control

— The chiller must be configured for minimum load control operation. This may be done using the unit keypad (HSIO-2). Set the LOCAL/ OFF/REMOTE (LOR) switch in the OFF position.

COMPRESSOR JUNCTION BOX

1. Press on the keypad.

2. Press the down arrow until the display reads: MIN. LOAD V AL V E SELECT DISABLE

3. T o enable the minimum load valve feature, press

ENTER

4. The display may read as follows. (If not, skip to Step 7.) P ASSWORD PROTECTED FUNCTION ENTER P ASSWORD

5. Press .

ENTER

6. The HSIO-2 again displays the following: MIN. LOAD V AL V E SELECT DISABLE

7. Press . The display changes to:

ENTER

MIN. LOAD V AL V E SELECT ENABLE

Page 9

The chiller is now configured for minimum load valve

control. Test Minimum Load Relay Outputs

— After the unit is reconfigured, test the operation of the relay and solenoid valve using the Quick Test software function. Test Circuit A as follows (the LOCAL/OFF/REMOTE (LOR) switch must be in the OFF position):

1. Press on the HSIO-2 keypad.

2. Press the down arrow until the display reads:

MIN. LOAD V AL VE A RELA Y IS OFF

3. Press .

ENTER

4. The display may read as follows. (If not, skip to Step 7.)

P ASSWORD PROTECTED FUNCTION ENTER P ASSWORD

5. Press .

ENTER

6. The HSIO-2 again displays the following:

MIN. LOAD V AL VE A RELA Y IS OFF

7. Press to energize the relay. The display reads:

ENTER

MIN. LOAD V AL VE A RELA Y IS ON An audible click will be heard. Verify that the solenoid valve for Circuit A is energized.

8. Press to turn off the minimum load valve relay for

ENTER

Circuit A.

To check the operation of the solenoid valve on Circuit B, follow the same procedure as the preceding, but enter in Step 1, instead of . The display screens will be fo r Circuit B instead of A.

Adjust Setting of Minimum Load Ball Valve

— The minimum load ball valve must be adjusted to suit the application. Calibrate one circuit at a time as follows:

1. Adjust the ball valve so that it is approximately half open.

2. Operate the chiller in Manual Control mode, with one circuit

operating, and all compressor loaders deenergized. See Manual Control Mode section on page 32 for further information.

3. Record the cooler ∆T (the difference between cooler enter-

ing fluid temperature and cooler leaving fluid temperature) at this fully unloaded condition.

4. Use the Manual Control feature to enable the minimum load

valve for the circuit that is operating.

5. Observe and record the cooler ∆T with the minimum load

valve energized.

6. Adjust the minimum load ball valve until the cooler temper-

ature difference reading from Step 5 is equal to half of the temperature difference reading from Step 3.

7. Open the ball valve to decrease the temperature difference or

close the ball valve to increase the temperature difference (∆T). When the valve is adjusted correctly, the difference between cooler entering and leaving fluid temperatures when the minimum load control is energized must be at least half of the temperature difference when the minimum load control is deenergized. For example, if the difference between the cooler entering and leaving water temperature is 3° F with the valve deenergized, then the difference between cooler entering and leaving water temperature must be at least 1.5° F with the valve energized.

Once the outputs have been tested and the ball valve adjusted, the installation is complete. Disable manual control and return chiller to desired operational status.

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

Deadband Multiplier

— The user configurable Deadband Multiplier ( ) 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 applied 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 4 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 capacity 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 deadband) and moving towards the set point.

Ramp Loading

( ) — 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 betw een the control point and leaving fluid temperature. If the difference is greater tha n 4° F (2.2° C) and the rate of change (°F or °C per minute) is more than the configured Cooling Ramp Loading value ( ), 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 being used. If exactly 25% cannot be removed, the control removes an amount greater than 25%, but no more than necessary. The lowest stage will not be removed.

Low Discharge Superheat

— If a circuit’s discharge superheat

is less than 15° F (8.3° C), the control does not increase the current capacity stage. If the discharge superheat is le ss than 5° F (2.8° C) and decreasing, the circuit is unloaded every 30 seconds until the superheat is greater than 5° F (2.8° C). The final capacity stage is not unloaded unless an alarm condition exists. This override is ignored for the first 3 minutes after a compressor is started.

Low Saturated Suction Temperature

— To avoid freezing the cooler, the control will compare the cir cuit Saturated Suction temperature with a pre determined freeze point. If the cooler fluid selected is water, the freeze point is 28 F (–2.2 C). If the cooler fluid selected is bri ne, the freeze poi nt is 8° F (4.4 ° C) below the cooling set point (lower of 2 cooling set points for dual configuration). If the saturated suction temperature is below the freeze point, the unit capacity is not allowed to increase.

For brine applications, the freeze point (Brine Freeze Point) can be entered by pressing and scrolling 12 items down. The cont rol will use the B rine Freeze Point va lue less 6° F (3.3° C) as the freeze point to compare with the Saturated Suction temperature. The default for t he Brine Freez e Point is 34 F (1.1 C) which means the control will use 28 F (–2.2 C) as the freeze point. The brine freeze point is adjustable from –15 F to 34 F (–26.1 to 1.1 C).

Page 10

For water [brine] circuits, if t he Sat urat ed Suct ion tempera ture falls below 34 F (1.1 C) [th e Brine F reeze Poi nt], the unit capacity will not increase. If the Saturated Suction temperature falls below 28 F (–2.2 C), [the Brine Freeze Point minus 6° F (3.3° C)], for 90 seconds, all loaders in the circuit are turned off. If this condition continues for a total of 3 minutes, the circuit will alarm and shut down.

High Condensing Temperature Unloading

— Every 10 seconds the control checks for the conditions below. Loaders will be cycled as needed to control the saturated condensing temperature below the configured maximum condensing temperature. Configured maximums are 154 F (67.8 C) for 30GX, 152 F (66.7 C) for 30HXA, and 122 F (50 C) for 30HXC units. If a circuit’s saturated condensing temperature is more than 12° F (6.7° C) below the maximum condensing temperature, the circuit capacity is not allowed to increase. If the saturated condensing temperature is more than 2° F (1.1° C) above the maximum condensing temperature for 60 seconds, a loader is turned off. If the saturated condensing temperature rises to more than 5° F (2.8° C) above the maximum condensing temperature during the 60 seconds, a loader is turned off immediately. If all the loaders were already off, the compressor is shut down and an alarm is generated.

MOP (Maximum Operating Pressure) Override

— The control monitors saturated condensing and suction temperature for each circuit as well as differential oil pressure. Based on a configurable maximum operating set point (saturated suction temperature), set maximum condensing temperature, and minimum differential oil pressure, the control may reduce the number of capacity stages being used and/or may lower the EXD position when system pressures approach the set parameters.

Head Pressure Control

GENERAL — The microprocessor controls the condenser fans (30GX) or water val v e (30HX C ) to maintain the saturated condensing temperature to a configurable set point. The 30HXA condenserless units with a 09DK condenser use a combination of factory-supplied fan cycling pressure switches (shipped in the 30HXA control box), temperature switches, and an accessory Motormaster 50DJ902811) or Motormaster III (part no. 30GT910-079) control to control head pressure independent of 30HXA unit control. The fans are staged or speed varied (30GX) or water valve controlled (30HXC) based on each circuit’s saturated condensing temperature and compressor status. Water cooled units (30HXC) operating at less than 70 F (21.1 C) for entering condenser water require the use of head pressure control.

The chiller must be field configured for the options shown

in T able 6. Fan stage settings are shown in Table 7.

(part no. 50DJ902801 or

AIR-COOLED UNITS (30GX) — See Fig. 5 for condenser fan locations.

Without Motormaster® Control

— The first stage of fans are turned on based on compressor status or a Head Pressure Set Point based on Saturated Condensing Temperature (SCT). Additional fan stages are added when the SCT exceeds the Head Pressure Set Point. The Head Pressure Se t Point is configurable in the Set Point subfunction. The default is 113 F (45 C). Once a fan stage has been added, the software temporarily modifies the head pressure set point by adding 15° F (8.3° C) for 35 seconds. A fan stage will be removed when the Saturated Condensing Temperature has been less than the Head Pressure Set Point minus 35 F (19.4 C) for 2 minutes. The control uses the higher of the 2 Saturated Condensing Temperature values for 30GX080-150 and 160 units. For the 30GX151 and 161-350 units, each circuit’s fan stages are independently controlled based on the circuit Saturated Condensing Temperature. Refer to Table 7 for condenser fan control information. See Fig. 6A.

With Motormaster Control

— For low-ambient operation, the lead fan in each circuit can be equipped with the optional or accessory Motormaster III head pressure controller. If factory installed, the controller will be configured for 4 to 20 mA control. With the Motormaster III option enabled, the PSIO-1 module calculates the required output based on Saturated Condensing temperature, Head Pressure set point, and a PID (proportional integral derivative) loop calculation. This 4 to 20 mA output is driven through the PSIO-2 module. Proportional, Integral, and Derivative gain parameters for air cooled controls are adjustable and can be found in the Service subfunction. Checkout and adjustment of the PID loop should only be performed by certified Carrier Comfort Network technicians. To obtain this accessory for field installation, order by part number 30GX-900---012 for a single controller package (30GX080-150 and 160). Order part number 30GX-900---014 for a dual controller package (30GX151 and 161-350). These packages contain all the hardware required to install the accessory . See Fig. 6B.

The control will use the higher of the 2 Saturated Condensing Temperature values for 30GX080-150 and 160 units. For the 30GX151 and 161-350 units, each circuit’s fan stages are independently controlled based on the circuit Saturated Condensing Temperature. Refer to Table 8 for condenser fan staging information.

LWT (C)

LEGEND

LWT —

Leaving Water Temperature

46 45 44

LWT (F)

42 41

0 200 400 600 800 1000

STANDARD DEADBAND

DEADBAND EXAMPLE

TIME (SECONDS)

Fig. 4 — Deadband Multiplier

2 STARTS

3 STARTS

MODIFIED DEADBAND

Page 11

Table 6 — Field Configured Chiller Options

UNIT CONFIGURATION OPTION DESCRIPTION HSIO LOCATION FACTORY CONFIGURED?

Fan Staging Select Air cooled staging method Yes. See Table 7

30GX

30HXC

Motormaster® Control Select Applies to air cooled units only

Water Valve Type Applies to water cooled unit only

Set to 1 to enable (Motormaster only)

Set to 1 = 4 to 20 mA, 2 = 2 to 10 V,

Yes. 0 = None

3 = 20 to 4 mA, 4 = 10 to 2 V

Table 7 — Fan Staging Settings for Air Cooled (30GX) Units

UNIT 30GX DESCRIPTION OPTION NUMBER HSIO DISPLAY

080-105 106-125

136, 150, 160

151, 161, 175,

205, 225

176

206, 226, 250

251-350

LEGEND

SCT —

Saturated Condensing Temperature

1st stage compressor status and SCT set point 2nd stage common control based on highest SCT

1st stage compressor status and SCT set point 2nd and 3rd stage common control based on highest SCT

1st stage compressor status and SCT set point 2nd through 4th stage common control based on highest SCT

1st stage each circuit, compressor status 2nd stage Circuit B independent 2nd and 3rd stage Circuit A independent

1st stage each circuit, compressor status 2nd and 3rd stage each circuit independent

1st stage each circuit, compressor status 2nd stage Circuit B independent 2nd, 3rd and 4th stage Circuit A independent

1st stage each circuit, compressor status 2nd, 3rd and 4th stage each circuit independent

12 Com_1cmp 14 Com_2cmp 16 Com_3cmp

7 A2B1_stg

3 Ind_2stg

9 A3B2_cmp

5 Ind_3stg

WATER-COOLED UNITS (30HXC) — The 30HXC chillers can be configured to control direct or reverse-acting water valves that are controlled by a 4 to 20 mA signal. A 2 to10 vdc signal can be used by installing a 500-ohm

/2 watt resistor across the 2 output terminals of the 4 to 20 mA signal. The 4 to 20 mA control scheme reads the saturated condensing temperature and uses a PID (proportional integral deriative) loop to control the head pressure. Proportional, Integral and Derivative gain parameters for the water cooled controls are adjustable and can be found in the Service subfunction. Checkout and adjustment of the PID loop should only be performed by certified Carrier Comfort Network technicians.

CONDENSERLESS UNITS (30HXA) — The remote condenser fans are controlled by 2 relays with the 30HXA control box. See Field Wiring section on page 73 for wiring details. The 30HXA control must be configured to turn the 09DK fans on and/or off. To set the 30HXA control for this configuration Unit T ype under must be changed to 3 (Split System). Next, under , Head Pressure Control Type must be changed to 1 (Air Cooled), and Condenser Pump control must be set to 0 (Not Controlled).

The 30HXA control does not support a 4 to 20 mA or a 2 to 10 vdc output for fan speed control. Instead, head pressure control is accomplished with fan cycling pressure switches (09DK054-094), temperature switches (09DK044, 074-094) and Motormaster control. Motormaster and Motormaster III control is used with temperature sensor input to control condenser fan speed. See accessory installation instructions for further information.

09DK CONDENSING UNITS 09DK044 Units

— The 09DK044 units have accessory provision for fully automatic intermediate-season head pressure control through condenser fan cycling. Fan number 2 and 3 cycling is controlled by outdoor-air temperature through air temperature switches (ATS) 1 and 2.

The air temperature switches are located in the low er divider panel underneath the coil header. The sensing element is exposed to air entering the no. 1 fan compartment through a hole in the panel. Fan no. 1 is non-cycling.

The air temperature switch controls the fans as shown in Table 9.

09DK054-094

— The capacity of an air-cooled condenser increases with increased temperature difference (defined as saturated condenser temperature minus entering outdoor-air temperature) and decreases with decreased temperature difference. A drop in entering outdoor-air temperature results in a lower saturated condensing temperature. When outdoor-air temperature drops below the minimum temperature for standard units, additional head pressure control is required.

Model 09DK units have fully automatic intermediateseason head pressure control through condenser fan cycling using electromechanical fan cycling controls. Standard head pressure controls regulate the 100 and 50/50% condenser capacity applications. Head pressure can also be controlled by fan cycling controls supplemented by the accessory Motormaster III solid-state head pressure control. See Motormaster

III installation instructions for more information.

In the standard control scheme, fans 1 and 2 are on when there is a call for cooling from the respective coil circuits. Fans 1 and 2 are non-cycling. On 054 and 064 units, fans 3 and 4 are controlled by using a fan cycling pressure switch on each of the primary coil circuits in response to condensing pressure. On 074-094 units, fans 3 and 4 are controlled using a fan cycling pressure switch in each of the primary coil circuits in response to condensing pressure. Fans 5 and 6 are controlled by using two air temperature switches, which respond to the outdoor ambient temperature. The air temperature swit ches are locat ed on the control box shelf.

Page 12

Table 8 — 30GX080-350 Condenser Fan Staging (PSIO-1 Controlled)

30GX UNIT SIZE FAN TYPE FAN CONTACTOR FANS CONTROLLED FAN RELAY NO.*

080-105

106-125

136, 150, 160

151, 161, 175, 205, 225

176

206, 226, 250

251, 265

281-350

LEGEND

Comp. — FC —

*Fan Relay number displayed when using

Compressor Fan Contactor

Standard

High Static

Standard

High Static

Standard

High Static

Standard

High Static

Standard

High Static

Standard

High Static

Standard

High Static

Standard

High Static

to test fans.

FC-1 1, 2 5

FC-2 3, 4 1 FC-1, 1A 1, 2 5 FC-2, 2A 3, 4 1

FC-1 1, 2 5

FC-2 3, 4 1

FC-3 5, 6 2 FC-1, 1A 1, 2 5 FC-2, 2A 3, 4 1 FC-3, 3A 5, 6 2

FC-1 1, 2 5

FC-2 3, 4 1

FC-3 5, 6 2

FC-4 7, 8 2 FC-1, 1A 1, 2 5 FC-2, 2A 3, 4 1 FC-3, 3A 5, 6 2 FC-4, 4A 7, 8 2

FC-1 1, 2 Comp. B1 contactor†

FC-2 3, 4 3

FC-3 5, 6 2

FC-4 7, 8 Comp. A1/A2 contactor†

FC-5 9, 10 1 FC-1, 1A 1, 2 Comp. B1 contactor† FC-2, 2A 3, 4 3 FC-3, 3A 5, 6 2 FC-4, 4A 7, 8 Comp. A1/A2 contactor† FC-5, 5A 9, 10 1

FC-1 1, 2 Comp. B1 contactor†

FC-2 3, 4 3

FC-3 5, 6 4

FC-4 7, 8 Comp. A1 contactor†

FC-5 9, 10 1

FC-6 11, 12 2 FC-1, 1A 1, 2 Comp. B1 contactor† FC-2, 2A 3, 4 3 FC-3, 3A 5, 6 4 FC-4, 4A 7, 8 Comp. A1 contactor† FC-5, 5A 9, 10 1 FC-6, 6A 11, 12 2

FC-1 1, 2 Comp. B1 contactor†

FC-2 3, 4 3

FC-3 5, 6 1

FC-4 7, 8 Comp. A1/A2 contactor†

FC-5 9, 10 2

FC-6 11, 12 2 FC-1, 1A 1, 2 Comp. B1 contactor† FC-2, 2A 3, 4 3 FC-3, 3A 5, 6 1 FC-4, 4A 7, 8 Comp. A1/A2 contactor† FC-5, 5A 9, 10 2 FC-6, 6A 11, 12 2

FC-1 2, 4 1

FC-2 6, 8 2

FC-3 1 Comp. B1 contactor†

FC-4 3 3

FC-5 5, 7 4

FC-6 9, 10 Comp. A1/A2 contactor†

FC-7 11, 12 2

FC-8 13, 14 2 FC-1, 1A 2, 4 1 FC-2, 2A 6, 8 2

FC-3 1 Comp. B1 contactor†

FC-4 3 3 FC-5, 5A 5, 7 4 FC-6, 6A 9, 10 Comp. A1/A2 contactor† FC-7, 7A 11, 12 2 FC-8, 8A 13, 14 2

FC-1 1, 2 Comp. B1/B2 contactor†

FC-2 3, 4 3

FC-3 5, 6 4

FC-4 7, 8 4

FC-5 9, 10 1

FC-6 11, 12 Comp. A1/A2 contactor†

FC-7 13, 14 2

FC-8 15, 16 2 FC-1, 1A 1, 2 Comp. B1/B2 contactor† FC-2, 2A 3, 4 3 FC-3, 3A 5, 6 4 FC-4, 4A 7, 8 4 FC-5, 5A 9, 10 1 FC-6, 6A 11, 12 Comp. A1/A2 contactor† FC-7, 7A 13, 14 2 FC-8, 8A 15, 16 2

†Proper rotation of these fans to be checked when compressor(s) is running. See Fig. 5 for

condenser fan locations when viewing from the control box end.

NOTE: For 30GX151, 161-350 units, fan relays 1 and 2 energize Circuit A fans. Fan relays 3 and 4 energize Circuit B fans.

Page 13

Table 9 — Air Temperature Switch Control

(09DK044 Units)

FAN FAN SWITCH TEMPERATURE

FAN 2

OFF

FAN 3

OFF

Above 65 ± 3 F (18.3 ± 1.7 C) Between 55 and 65 F (12.8 and 18.3 C)

and temperature falling Below 55 ± 3 F (12.8 ± 1.7 C) Between 55 and 65 F (12.8 and 18.3 C)

and temperature rising Above 80 ± 3 F (26.7 ± 1.7 C) Between 70 and 80 F (21.1 and 26.7 C)

and temperature falling Below 70 ± 3 F (21.1 ± 1.7 C) Between 70 and 80 F (21.1 and 26.7 C)

and temperature rising

The fan cycling pressure switch controls the fans as follows:

Fans 3 and 4 are on above 185 ± 10 psig (1276 ± 69 kPa) and off below 97 ± 10 psig (669 ± 69 kPa). If pressure is rising between 97 psig (669 kPa) and 185 psig (1276 kPa), fans 3 and 4 are off. If pressure is falling from 185 psig (1276 kPa) to 97 psig (669 kPa) fans 3 and 4 are on.

30GX080-105 30GX106-125 30GX136,150,160

CONTROL BOX END

The 09DK054-094 condensers are supplied with fan cycling pressure switches suitable for use with R-22 refrigerant. Fan cycling pressure switches that are compatible with R-134a refrigerant pressures are shipped with the 30HXA chillers. These fan cycling pressure switches must be installed in place of the 09DK factory-installed switches before charging to ensure proper head pressure control.

The air temperature switch controls th e fans as foll ows: On the 074-094 condensers, below 70

3 F (21.1 ± 1.7 C) outdoor ambient, fans 5 and 6 are off; above 80 ± 3 F (26.7 ± 1.7 C) fans 5 and 6 are on. Between 70 F (21.1 C) and 80 F (26.7 C), whether fans 5 and 6 are on or off depends on whether temperature is rising or falling. If the temperature is rising from 70 F (21.1 C) to 80 F (26.7 C), fans 5 and 6 are off. If the temperature is falling from 80 F (26.7 C) to 70 F (21.1 C), fans 5 and 6 are on.

CONTROL BOX END

24 6 8

CONTROL BOX END

13 5 7

30GX151,161,175,205,225 30GX176

CONTROL BOX END

7911

30GX206,226,250 30GX251,265

30GX281-350

6810

CONTROL BOX END

Fig. 5 — 30GX Condenser Fan Locations

CONTROL BOX END

Page 14

30GX UNITS — MOTORMASTER III CONTROL NOT INSTALLED

LEGEND

Saturated Condensing Temper ature

SCT —

Fig. 6A — 30GX Head Pressure Control Without Motormaster

30GX UNITS — MOTORMASTER III CONTROL INSTALLED

READ CIRCUIT SATURATED CONDENSING TEMPERATURE AND CURRENT FAN STAGE

IS SCT GREATER THAN HEAD PRESSURE SET POINT PLUS 15°F (8.3°C)?

YES

INCREASE CURRENT FAN STAGE BY ONE

Fig. 6B — 30GX Head Pressure Control Without Motormaster III Control

ADJUSTING PID ROUTINES — The 30GX and 30HXC head pressure control routines use PID (proportional integral derivative) loops to maintain a user-configurable head pressure set point. Gain defaul t values are located in the Service function. See page 32. The current values can be read under

from the HSIO. The control calculates a new fan speed (30GX) or water valve position (30HXC) every 5 seconds based on these gain values and an error term equal to saturated condensing temperature minus head pressure set point. If the control routine is not responding fast enough to large changes (circuit starting, for example), increase the proportional term.

When the routine is making too great a change to valve position or fan speed, decrease the proportional term. To minimize hunting, keep the integral term positive and as low as possible. This value is used to control “droop,” which is common in master/submaster control schemes. The default for the derivative term is zero. The value should not need to be changed.

Cooler and Condenser (30HXC) Pump Control —

cooler and condenser (30HXC) pump control. Inputs for a

The 30GX and 30HX chillers can be configured for

III Control

CALCULATE NEW PID VALUE. DOES OUTPUT REQUIRE MORE FANS?

YES

INCREASE CURRENT FAN STAGE BY ONE

OUTPUT NEW mA SIGNAL TO CONTROLLER

DOES PID OUTPUT REQUIRE LESS FANS?

YES

DECREASE CURRENT FAN STAGE BY ONE

cooler flow switch or interlock and condenser flow switch are also provided.

COOLER PUMP CONTROL — Proper configuration of the cooler pump control and cooler pump interlock is required to prevent possible cooler freeze-up. The cooler pump interlock should always be enabled. This prevents the chiller from operating unless chilled water flow is detected. See page 73 of the Field Wiring section for proper connection of the chilled water flow switch and cooler pump interlock.

The factory default setting for cooler pump control is “0” (not controlled). It is recommended for 30GX packaged aircooled chillers that the cooler pump control be utilized unless the chilled water pump runs continuously or the chilled water system contains a suitable anti-freeze solution. The cooler pump relay is energized when the chiller enters an occupied mode. In the event a freeze protection alarm is generated t he cooler pump relay is also energized. If the cooler heater is being used and has been on for more than 15 minutes during saturated suction freeze protection, the cooler pump relay is energized.

When the cooler pump control is set to “0” and the cooler pump interlock is set to “1” an alarm 53 will be generated if flow is not proven within one minute after the unit is enabled and in an occupied mode.

Page 15

When the cooler pump control is set to “1” and the cooler

CLEAR

ENTER

STAT

SET

SCHD

EXPN EDIT

SRVC

HIST

ALGO

TEST ALRM

TWENTY-FOUR CHARACTER TWO-LINE LCD DISPLAY

LEGEND

LCD —

Liquid Crystal Display

Fig. 7 — Keypad and Display Module

pump interlock is set to “1” an alarm 53 will be generated if flow is not proven within one minute after the cooler pump relay is energized. An alarm 55 will be generated if the interlock contacts remain closed when the cooler pump relay is off. In either cooler pump control configuration, alarm 54 will be generated whenever the cooler pump interlock is open for at least 5 seconds during operation.

CONDENSER PUMP CONTROL ( ) — Factory defaults for both condenser pump control and condenser flow switch are set to “Not Controlled” and “Disabled,” respectively. The condenser pump can be controlled in one of two ways: In the first method, the pump can be controlled like the cooler pump — it is turned on whenever the machine is in the on state and turned off otherwise (set to “1” using the Service function). The second method of control is to turn the pump on when the fir st compresso r is started and off when the last compressor is turned off (set to “2” using the Service function). With the flow switched enabled, the control checks the status of the input one minute after starting the pump. An alarm 49 is generated if the flow switch input is not closed.

Cooler Heater Control —

Accessory cooler heaters can be ordered for the 30GX chillers. If installed and e nabled, these heaters are turned on only when the machine is in the off state and the chiller is in a saturated suction temperature freeze condition.

Oil Heater Control —

Standard feature that controls oil temperature based on Saturated Condensing Temperature (SCT). Heaters turn on at <105 F (40.6 C) SCT, and turn off at >110 F (43.3 C) SCT.

Keypad and Display Module (Also Called HSIO-II) —

cate with the processor. It is used to enter configurations and set points and to read data, perform tests, and set schedules. The device consists of a keypad with 7 function keys, 5 operative keys, 12 numeric keys (0 to 9, •, and -), and a 2-line, 24-character alphanumeric liquid crystal display . See Fig. 7.

ACCESSING FUNCTIONS AND SUBFUNCTIONS — Table 10 shows a brief description of the keypad buttons. Table 11A shows the 6 functions (identified by name) and the subfunctions (identified by number). Table 11B shows the 6 functions (identified by name) and the subfunctions (identified by number) when using the optional remote enhanced display controller. Table 12 shows a brief example on how to access subfunctions.

NOTE: It is not necessary to use the through every item in a subfunction. For example, if you wanted to read the oil pressure for the A1 compressor, press , then

procedure to view an item near the bottom of a subfunction. To view Condenser Pump Flow Switch status, press ,

, and . This procedure is available in all functions

except the TEST function. AUTOMATIC DEF AULT DISPLAY — When the keypad has

not been used for 10 minutes, the display automatically switches to the rota tin g a uto ma ti c defa u lt d isp la y. This display contains the 5 parts shown below .

Entering Fluid T emp

Leaving Fluid T emp

Percent Total Capacity

This module allows the operator to communi-

press to go directly to A1 Oil Pre ssure. Use a similar

xx.x° F xx.x° F

xxx.x%

Table 10 — Keypad and Display Module Usage

FUNCTION

KEYS

OPERATIVE

KEYS

CLEAR

ENTER

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 configur ation information and enabling manual control function.

SCHEDULE — For entering occupied/unoccupied schedules for unit operation.

ALGORITHM — Not used. SET POINT — For entering operating set points

and daytime information. TEST — For testing operating of the analog and

discrete outputs.

EXPAND — For displaying a non-abbreviated expansion of the display.

CLEAR — For clearing the screen of all displays. UP ARROW — For returning to previous display

position. DOWN ARROW — For advancing to next display

position. ENTER — For entering data.

USE

T ota l Num ber of A larm s

MODES : MODE_TBL Current active modes

All functions are made up of a group of subfunctions. To enter a subfunction, first press the subfunction number desired. Then press the function key in which the subfunction resides. To move within that subfunction, press the up or down arrow keys. Another subfunction may be entered at any time by pressing the subfunction number, then the function key. Depending on system type and configuration, all displays may not be shown.

Page 16

SUBFUNCTION NO.

Table 11A — HSIO Functions and Subfunctions

FUNCTIONS

Status Test Schedule Service History Set Point

Alarm Display Circuit A

General Pa r ameters Circuit B

Circuit A Analog Values

Circuit A Discrete Inputs/ Outputs Table

Circuit B Analog Values

Circuit B Discrete Inputs/ Outputs Table Unit Analog Parameters Miscellaneous Inputs/Outputs Operating Modes — Holiday 06

Capacity Control — Holiday 07

Dual Chiller — Holiday 08

Ice Build Occupancy Schedule

Local/Normal Occupancy Schedule Remote CCN Occupancy Schedule

Holiday 01 Configuration

Configuration

Configuration*

Discrete Outputs

Unit Discrete Outputs

Valves and Motormaster Control

—Holiday 02

—Holiday 03

—Holiday 04

—Holiday 05

Factory Configuration

Options Configuration1

Options Configuration 2

Reset/Demand Limit Configuration

Machine Configuration Codes

———

Transducer Calibration

Manual Control — —

Master /Slave Configuration

———

Operating Hours Set Point s

Alarm History English/Metric

— Bus Address

— Time/Date

Configuration

— CCN

Enable/Disable

——

*Subfunctions through are for configuring Holidays 09 through 30.

Page 17

Table 11B — Functions and Subfunctions Cross-Reference for the

Optional Remote Enhanced Display Controller

The optional Remote Enhanced Display controller cross reference table below can be used as a guide to access the same information outlined in the HSIO functions and subfunctions table (see Table 11A). For example, in Table 11A, the alarm history is accessed through the HSIO by pressing 2 and the History button on the keypad (see Table 10). The Remote Enhanced Display cross reference table lists the menu item from

the Remote Enhanced Display which contains the alarm history information. In another example, from Table 11A, pressing 3 and the Status button on the HSIO keypad will access the circuit A analog values. In the table below, the circuit A analog values are accessed by selecting STATUS CIRCA_AN from the appropriate Remote Enhanced Display menu.

HSIO SUBFUNCTION

NO.

HSIO FUNCTION KEY

Status Test Schedule Service History Set Point

STATUS A_UNIT_1

STATUS CIRCA_AN

STATUS CIRA_DIO

STATUS CIRCB_AN

STATUS CIRB_DIO

STATUS UNIT_2

STATUS UNIT_3

STATUS MODE_TBL

SERVICE CONTROL ALGORITHM STATUS LOADFACT

SERVICE CONTROL ALGORITHM STATUS LEADLAG

SERVICE CONTROL TEST

SERVI C E CONTROL TEST

—

SCHEDULE OCCPC01S

SCHEDULE OCCPC02S

SCHEDULE OCCPC65S

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_01

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_02

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_03

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_04

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_05

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_06

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_07

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_08*

SERVICE EQUIPMENT CONFIGURATION

SERVICE EQUIPMENT CONFIGURATION OPTIONS1

SERVICE EQUIPMENT CONFIGURATION OPTIONS2

SERVICE EQUIPMENT CONFIGURATION RESETCON

SERVICE EQUIPMENT CONFIGURATION CONCODES

SERVICE EQUIPMENT CONFIGURATION EXV TESTS

SERVICE EQUIPMENT SERVICE CALIBRTE

SERVICE EQUIPMENT SERVICE MAN_CTRL

SERVICE EQUIPMENT CONFIGURATION MSTR_SL V

———

SERVIC E EQUIPMENT CONFIGURATION STRTHOUR

SERVIC E ALARM HISTORY

—

——

SETPOINT

SERVICE LID CONFIGURATION

SERVICE CONTROLLER IDENTIFICATION

SERVICE EQUIPMENT SERVICE TIME AND DATE

STATUS A_UNIT_1

*Subfunctions through are for configuring Holidays 09 through 30

NOTE: The optional Remote Enhanced Display controller uses the same password (1111) as the HSIO.

, and are also found under Service, Equipment Configuration.

Page 18

Table 12 — Accessing Functions and Subfunctions

OPERATION KEYPAD ENTRY 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.

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. Press function name key to advance display through all subfunctions within a function and then back to the first.

Circuit A Discrete Outputs Loader A1

Relay is OFF Loader A2

Relay is OFF Minimum Load Valve A

Relay is OFF Circuit A Oil Heater

Relay is OFF A1 Mtr. Cooling Solenoid

Relay is OFF A2 Mtr. Cooling Solenoid

Relay is OFF Circuit A Oil Pump

Relay is OFF Oil Solenoid A1

Relay is OFF Oil Solenoid A2

Relay is OFF Loader A1

Relay is OFF Circuit B Discrete Outputs Unit Discrete Outputs Valves and Motor Master Circuit A Discrete Outputs

To move to another function, either depress function name key for desired function (display shows the first subfunction), or Access a specific subfunction by using the subfunction number and the function name key.

Alarms : xx Reset Alarms : 1 <ENTER>

CIR. A DISCRETE OUTPUTS

Page 19

ST ATUS 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, analog inputs, and switch inputs. Refer to Table 13 for a complete description of the function.

Alarms/Alerts

— Alarms and alerts are mess ages that one or more faults have been detected. The alarms and alerts indicat e failures that cause the unit to shut down, terminate an option (such as reset) or result in the use of a default value such as a set point. Refer to the Troubleshooting section for more information.

Up to 10 alarms/alerts can be stored at once. To view them, press . The control will display the current total number of alarms/alerts. Use the arrow keys to scroll through the list. Press the key when needed to view the full description of an alarm or alert. Press to clear all the alarms. Se e

ENTER

T able 14.

IMPORTANT: Do not clear the alarms without first

reviewing the full list and investigating and correcting

the cause of t he a lar ms .

When an alarm or alert is s tored in the display and the machine automatically resets, the al arm/alert is deleted. Codes for safeties which do not automatically reset are not deleted until the problem is corrected and the machine is reset. To clear manual reset alarms from the CPM modules, the reset button on the HSIO bracket must be pressed. Next, switch the LOR switch to OFF and back to Local or Remote position (default alarm clearing method). Press and then to

ENTER

clear the alarm from the PSIO if the default LOR reset function has been disabled.

General Parameters

— General operating parameters are displayed including control mode, run status, CCN status, and the 5 most current alarms. Press to display these and the other values as shown in T able 13.

Circuit A and B Analog and Discrete Information

— Circuit A Analog Values can be vie wed by pre ssing and scrolling down to see current system operating conditions such as pressures and temperatures. Pressing will bring up Circuit A Discrete Inputs and Outputs. Scroll down to view the On/Off status of the compressor(s), loaders, solenoids, and pumps. Oil switch and feedback inputs are also displayed. Press and to view the identical ana log values and discrete inputs and outputs for Circuit B. See Table 13 for a complete display.

Unit Analog Parameters and Temperature Reset

— Press

and scroll down to display the unit entering and leaving fluid temperatures as well as the temperature reset signal and calculated values.

Miscellaneous Inputs and Outputs

— Pressing and scrolling down will reveal the On/Off status of the condenser fans (30GX only). Also found here are the Demand Limit settings, pump relay and switch status, and miscellaneous items such as Heat/Cool and Dual Set Point switch positions. See Table 13 for a complete list.

— The operating modes are displayed to indicate the

Modes operating status of the unit at a given time. See Table 15 for a complete list of all mode s.

To enter the MODES subfunction, press and use the key to view all current modes of operation. See Table 16.

Capacity Control

— Pressing , this subfunction displays the load/unload factor, control point, and leaving water temperature. Scrolling down will also reveal the liquid level sensor values in degrees format.

Dual Chiller

— Pressing will access the dual chiller control status. This subfunction will display whether or not the chiller is operating as a Master or Slave, any alarm conditions present for dual chiller control, and lead/lag information for changeover. Dual chiller control is configured under

Page 20

Table 13 — Status Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Alarms

Alarms : xx Reset Alarms : 1 <ENTER>

All current alarms are displayed

Use as needed

2 General Parameters

3 Circuit A Analog Values

See Legend on page 25.

GENERAL PARAMETERS Control Mode Run Status

Off/On Occupied ?

Yes/ No CCN Enable

Off/On CCN Chiller Start/Stop

Start/Stop Alarm State

Normal/Alarm Current Alarm 1

x.xx Current Alarm 2

x.xx Current Alarm 3

x.xx Current Alarm 4

x.xx Current Alarm 5

x.xx Active Demand Limit

xxx.x% Percent Total Capacity

xxx.x% Water/Brine Setpoint

xx.x dF Control Point

xx.x dF Entering Fluid Temperature

xx.x dF Leaving Fluid Temperature

xx.x dF Emergency Stop

Emstop Minutes Left for Start

xx min Heat-Cool Status

Heat/Cool CIRCUIT A ANALOG VALUES Total Capacity

xxx.x% Available Capacity

xxx.x% Discharge Pressure

xxx.x PSI Suction Pressure

xxx.x PSI A1 Oil Pressure Diff.

xxx.x PSI A2 Oil Pressure Diff.

xxx.x PSI A1 Oil Pressure

xxx.x PSI A2 Oil Pressure

xxx.x PSI Discharge Gas Temperature

xxx.x dF A1 Motor Temperature

xxx.x dF A2 Motor Temperature

xxx.x dF

Displays LOCAL ON/OFF or CCN ON/OFF

Force/clear value with HSIO or CCN device. Must be ON for CCN clock control.

Percentage of total circuit capacity currently in use.

Percentage of Total Capacity value not in an alarm or fault condition.

Page 21

Table 13 — Status Function and Subfunction Directory (cont)

3 Circuit A Analog Values (cont) SAT Condensing Temp

4 Circuit A Discrete Inputs/Outputs

5 Circuit B Analog Values

SUBFUNCTION KEYPAD ENTR Y DISPLAY COMMENT

xxx.x dF Saturated Suction Temp

xxx.x dF EXV Percent Open

xxx.x% Motormaster Speed

xxx.x% Water Valve Position

xxx.x% Cooler Level Indicator

x.xx CPM A1 Feedback

x.x Volts CPM A2 Feedback

x.x Volts Circuit A Econ Pressure

xxx.x PSI CIR. A DISCRETE OUTPUTS Compressor A1

Off/On Compressor A2

Off/On Loader A1

Off/On Loader A2

Off/On Minimum Load Valve A

Off/On Circuit A Oil Heater

Off/On A1 Mtr Cooling Solenoid

Off/On A2 Mtr Cooling Solenoid

Off/On Circuit A Oil Pump

Off/On Oil Solenoid A1

Off/On Oil Solenoid A2

Off/On CIR. A DISCRETE INPUTS

Circuit A Oil Switch Open/Close

Compressor A1 Feedback Off/On

Compressor A2 Feedback Off/On

CIRCUIT A ANALOG VALUES Total Capacity

xxx.x% Available Capacity

xxx.x% Discharge Pressure

xxx.x PSI Suction Pressure

xxx.x PSI B1 Oil Pressure Diff.

xxx.x PSI B2 Oil Pressure Diff.

xxx.x PSI B1 Oil Pressure

xxx.x PSI B2 Oil Pressure

xxx.x PSI Discharge Gas Temperature

xxx.x dF

See Table 5. See Table 5.

Percentage of total circuit capacity currently in use.

Percentage of To tal Capacity value not in an alarm or fa ult condition.

Page 22

5 Circuit B Analog Values (cont)

SUBFUNCTION KEYPAD ENTR Y DISPLAY COMMENT

6 Circuit B Discrete Inputs/Outputs

7 Unit Analog Parameters

Table 13 — Status Function and Subfunction Directory (cont)

B1 Motor Temperature xxx.x dF

B2 Motor Temperature xxx.x dF

SAT Condensing Temp xxx.x dF

Saturated Suction Temp xxx.x dF

EXV Percent Open xxx.x%

Motormaster Speed xxx.x%

Water Valve Position xxx.x%

Cooler Level Indicator x.xx

CPM B1 Feedback x.x Volts

CPM B2 Feedback x.x Volts

Circuit B Econ Pressure xxx.x PSI

CIR. B DISCRETE OUTPUTS Compressor B1

Off/On Compressor B2

Off/On Loader B1

Off/On Loader B2

Off/On Minimum Load Valve B

Off/On Circuit B Oil Heater

Off/On B1 Mtr Cooling Solenoid

Off/On B2 Mtr Cooling Solenoid

Off/On Circuit B Oil Pump

Off/On Oil Solenoid B1

Off/On Oil Solenoid B2

Off/On CIR. B DISCRETE INPUTS

Circuit B Oil Switch Open/Close

Compressor B1 Feedback Off/On

Compressor B2 Feedback Off/On

UNITS ANALOG PARAMETERS Cooling Entering Fluid

xx.x dF Cooling Leaving Fluid

xx.x dF Condenser Entering Fluid

xx.x dF Condenser Leaving Fluid

xx.x dF Reclaim Entering Fluid

xx.x dF Reclaim Leaving Fluid

xx.x dF 5 Volt Supply

x.x Volts

See Table 5. See Table 5.

See Legend on page 25.

Page 23

7 Unit Analog Parameters (cont)

SUBFUNCTION KEYPAD ENTR Y DISPLAY COMMENT

8 Misc. Inputs/Outputs

9 Operating Modes

Table 13 — Status Function and Subfunction Directory (cont)

TEMPERATURE RESET 4-20 mA Reset Signal

xx.x mA Return Reset Signal

xx.x dF External Reset Signa l

xx.x dF Outdoor Air Temp

xx.x dF Calculated Reset

xx.x dF MISC INPUTS/OUTPUTS

FAN_1 Off/On

FAN_2 Off/On

FAN_3 Off/On

FAN_4 Off/On

FAN_5 Off/On

FAN_6 Off/On

DEMAND LIMIT 4-20 mA Demand Signal

x.xx mA Demand Switch 1

Off/On Demand Switch 2

Off/On CCN Loadshed Signal

Normal/Alarm Max Allowable CAP

xxx.x% PUMPS

Cooler Pump Relay Off/On

Cooler Pump Flow Switch Off/On

Condenser Pump Relay Off/On

Condenser Pump Flow Switch Off/On

MISCELLANEOUS Ice Valve

Off/On Ice Build Complete

Yes/N o Heat/Cool Switch

Heat/Cool Dual Set point Switch

Off/On Cooler Heater

Off/On Options Temperature 1

xx.x dF Options Temperature 2

xx.x dF MODES :MODE_TBL

mode name ON/OFF LOCAL OFF

CCN OFF

Not Used Not Used

Only active modes displayed Scroll with down arrow key to display

Page 24

9 Operating Modes (cont)

SUBFUNCTION KEYPAD ENTR Y DISPLAY COMMENT

Table 13 — Status Function and Subfunction Directory (cont)

CLOCK OFF LOCAL ON CCN ON CLOCK ON DUAL SP ACTIVE (1st SP) DUAL SP ACTIVE (2nd SP) TEMPERATURE RESET

ACTIVE DEMAND LIMIT ACTIVE

LOAD LIMIT ACTIVE LOW SOURCE TEMP PROTECT RAMP LOADING ACTIVE TIMED OVERRIDE ACTIVE LOW COOLER SUCTION TEMP WSM CONTROLLING SLOW CHANGE OVERRIDE OFF TO ON DELA Y ACTIVE FSM CONTROLLING 2 CHILLR LEAD LAG ACTIVE 2 CHILLR LL COMM FAILURE CIR A LOW DISCHG SUPERHT CIR B LOW DISCHG SUPERHT CIR A HIGH SDT CIR B HIGH SDT

10 Capacity Control

See Legend on page 25.

CAPACITY CONTROL Load/Unload Factor

xxx.x% Control Point

xx.x dF Leaving Water Temp

xx.x dF MISC. INDICATORS

Liquid Lvl Sensor Cir. A xx.x dF

Liquid Lvl Sensor Cir. B xx.x dF

Page 25

11 Dual Chiller

Table 13 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTR Y DISPLAY COMMENT

DUAL CHILLER Unit Master/Slave

0 / 1 / 2 Master / Slave Ctrl Active

Yes / N o Lead Chiller

1 / 2

0 = Neither 1 = Master 2 = Slave

1 = Master 2 = Slave

0 = Chiller OFF 1 = Valid Run State in CCN Mode 3 = Chiller in Local Mode 5 = Shutdown on Alarm 6 = Communications Failure

Yes if Lead / Lag Balance Enabled 1 = Master / S lave Have Same Address

2 = Master / Slave Communication Failure 3 = Chiller in Local Mode 4 = Slave Shutdown on Alarm(s) 5 = Master Configured for Heating 6 = No Slave Configured

CCN — Carrier Comfort Network CPM — Compressor Protection Module dF — Degrees Fahrenheit EXV — Electronic Expansion Valve FSM — Flotronic™ System Manager LL — Lead/Lag MTA — Must Trip Amps SAT — Saturated SDT — Saturated Discharge Temperature SP —Set Point WSM — Water System Manager

LEGEND

Slave Chiller State 0 / 1 / 3 / 5 / 6

Slave Chiller Total Cap xxx.x%

Lead / Lag Changeover Master / Slave Error

1 / 2 / 3 / 4 / 5 / 6

Table 14 — Reading and Clearing Alarms

KEYPAD ENTRY DISPLAY COMMENT

ENTER

Alarm: 02 Reset Alarms: 1 <ENTER>

Comp A1 F ail - 1.80 Curr Alarm: 15:12 04/15/96

Comp A1 Fail - 1. 80 Cur rent Phase Reversal Alarm: 15:12 04/15/96

Compressor A1 Low Oil Pr Alarm: 10:34 04/15/96

Compressor A1 Low Oil Pressure Alarm: 10:34 04/15/96

Alarm: 02 Reset Alarms: 1 <ENTER>

Alarm: 00 Reset Alarms: 1 <ENTER>

Entering Fluid Temp xx.x dF

Leaving Fluid Temp xx.x dF

Percent Total Capacity xxx.x%

Total Number of Alarms xx

MODES: MODE_TBL List of All Curren t Modes

Press CPM Reset button first

Alarms reset and cleared

Returns to rotating default display

Page 26

Table 15 — Operational and Mode Display Codes

CODE DESCRIPTION

LOCAL OFF Unit is off. LOCAL/OFF/REMOTE switch is in OFF

CCN OFF Unit is off. LOCAL/OFF/REMOTE switch is in

CLOCK OFF Unit is off due to internal clock schedule. LOR

LOCAL ON Unit is on. LOR switch is in LOCAL position and

CCN ON Unit is on due to CCN command. LOR switch is in

CLOCK ON Unit is on due to internal clock schedule or occu-

DUAL SP ACTI VE (1st SP)

DUAL SP ACTI VE (2nd SP)

TEMPERATURE RESET ACTIVE

DEMAND LIMIT ACTIVE

FSM CONTROLLING

RAMP LOADING ACTIVE

TIMED OVERRIDE ACTIVE

WSM CONTROLLING

SLOW CHANGE OVERRIDE

position or LOCAL/OFF/REMOTE switch is in REMOTE position and remote contacts are open.

LOCAL position and CCN control is enabled (Stop state) or CCN is enabled (Stop state) with LOR switch in REMOTE position and remote contacts closed.

switch is in LOCAL position.

CCN is disabled or LOR switch is in REMOTE position with contacts closed and CCN is disabled.

LOCAL position and CCN is enabled (Run state) or LOR switch is in REMOTE position with contacts closed and CCN is enabled (Run state).

pied override function. LOR switch is in LOCAL position.

Dual set point is in effect. In this mode, unit continues to run in an occupied condition, and leaving fluid set point is automatically controlled to the CSP1 set point in the SET POINT function.

Dual set point is in effect. In this mode, unit continues to run in unoccupied condition, but leaving fluid set point is automatically increased to a higher level (CSP2 set point is in SET POINT function).

Temperature reset is in effect. In this mode, unit is using temperature reset to adjust leaving fluid set point upward, and unit is currently controlling to the modified set point. The set point can be modified based on re turn flu id, outdoor -air temp erat ure, space temperature, or 4 to 20 mA signal.*

Demand limit is in effect. This indicates that capacity of unit is being limited by demand limit control option. Because of this limitation, the unit may not be able to produce the desired leaving fluid temperature. Demand limit can be controlled by a switch or 4 to 20 mA signal.*

Flotronic™ System Manager (FSM) is controlling the chiller.

Ramp load (pulldown) limiting is in effect. In this mode, the rate at which leaving fluid temperature is dropped is limited to a predetermined value to prevent compressor overloading. See CRAMP set point in the SET POINT function (page 27). The pulldown limit can be modified, if desired, to any rate from 0.2° F to 2° F (0.1° to 1° C)/minute.

Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed sche dul e, forcing unit to occupied mode. Override can be implemented with unit und er LOCA L/ R EMOTE or CCN control. Override expires after each use.

Water System Manager is controlling the chiller.

Slow change override is in effect. The leaving fluid temperature is close to and moving towards the control point.

CODE DESCRIPTION

OFF TO ON DELA Y ACTIVE

LOAD LIMIT ACTIVE

2 CHILLR LEAD LAG ACTIVE

2 CHILLR LL COMM FAILURE

CIRCUIT A LOW DISCHARGE SUPERHT

CIRCUIT B LOW DISCHARGE SUPERHT

CIRCUIT A HIGH SCT

CIRCUIT B HIGH SCT

LOW COOLER SUCTION TEMPERATURE

Chiller is being held off by Minutes Off Time found by keying . Also, normal operation of the chiller

includes a minimum 1.5 minute delay after a capacity stage change has been made. This delay is adjustable from 1.5 to 6 minutes.

This function determines the maximum allowable capacity that can be running and is accomplished through the Flotronic System Manager. The unit may not be able to produce the desired leaving fluid temperature.

This mode indicates that Master and Slave chillers have been configured and are operating using the Dual Chiller control. This is a series water flow arrangement where chilled fluid is piped to the Slave Chiller first and then through the Master Chiller. Leaving Fluid Temperature control is performed based on Master Chiller Leaving Fluid Temperature.

This mode indicates that communication has been lost between the Master and Slave chillers. Both chillers will return to a stand-alone mode of operation until communication is restored.

If the discharge superheat is less than 5° F (2.8° C) and falling, a circuit loader will be deenergized every 30 seconds. The final stage will not be unloaded unless an alarm condition is present.

See description for Circuit A above.

If the circuit is running and the Saturated Condensing Temperature (SCT) is greater than the Maximum Condensing Temperature Set point (MCT_SP) minus 12° F (6.7° C), the control will not add any stages.

If the SCT is greater than the MCT_SP plus 5° F (2.8° C), the circuit will be unloaded and shut down if necessary. If the SCT is greater than the MCT_SP plus 2° F (1.1° C) for one minute, a loader will be deenergized.

If the SCT is greater than the MCT_SP minus 4° F (2.2° C), the control will compare the maximum operatin g pressure set point (MOP_SP) with the modified MOP_SP (MOP_CTRL).

If the MOP_CTRL is greater than the MOP_SP, the mode will be cleared. Otherwise the control will display the high SCT override mode. The capacity control routine will not add any stages. If the circuit is at its lowest capacity, this mode will be ignored.

See description for Circuit A above.

Circuit A and/or B low saturated suction condition exists. Control will not increase capacity on affected circuits. The EXV of the affected circuit(s) will be opened until the condition does not exist.

CCN — Carrier Control Network CSP — Cooling Set Point CRAMP — Cooling Ramp Loading EXV — Electronic Expansion Valve LOR — Local/Off/Remote SP —Set Point WSM — Water System Manager

*A field-supplied 500 Ohm 1/

the input terminals when using a 4 to 20 mA signal.

LEGEND

W resistor must be installed across

Table 16 — Reading Current Operating Mode

KEYP AD ENTR Y DISPL AY

MODES :MODE_TBL CCN ON

DEMAND LIMIT ACTIVE

Page 27

TEST FUNCTION — The test function operates the diagnos-

ENTER

tic program. To initiate the test function, the LOCAL/OFF/ REMOTE switch must be in the OFF position.

To reach a particular test, press its subfunction number followed by the key then scroll to the desired test by pressing the down arrow key. Refer to Ta ble 17 for a complete description of the test function.

To start a test of discrete outputs, press . To end the test, simply press the key or press . Pressing

ENTER

the key after a test has started advances the system to the next test, whether the current test is operating or has timed out. Circuit A discrete outputs can be tested in and include loaders, minimum load valve, oil heater (if equipped), motor cooling solenoids, oil pump, and oil solenoi ds. Similarly, Circuit B discrete outputs can be tested in . Additional discrete outputs, including condenser fans, cooler heater, water pumps, and remote alarms can be tested in .

Press to access Valves and Motormaster

control analog outputs. Scroll down to display Circuit A EXV Valve with a target percent of 0%. Press to step the EXV to 25%. Pressing three additional times will move the

ENTER

EXV to 50%, 75%, and 100% The EXV may be closed in 25% steps by pressing for each desired step. Wait 30 sec-

ENTER

onds between each step when opening and closing for the valve to stop moving. Pressing the down arrow will display Circuit B EXV Valve and it is tested in the same manner as Circuit A. Also available for test are Circuit A water valve (if equipped) and the Circuit A and B Fan speed % (direct control Motormaster device) outputs for 30GX chillers. These are tested in the same manner as the EXV valves. Note that condenser fan motors are NOT started during fan speed quick tests. Measure 4 to 20 mA dc output using meter in series with violet wire to controller. See pages 74 and 75 of Field W iring section.

While the unit is in test, you can leave the test function and access another display or function by pressing the appropriate keys. However, a component that is operating when another function is accessed remains operating. You must re-enter the test function and press to shut down the component.

ENTER

Components with a timed operating limit time out normally even if another function is accessed.

Since the Test function checks only certain outputs, it is a good practice to also check all inputs and outputs accessible through the Status function. These can be located by pressing

through . If keypad is not used for 10 minutes, the unit automa tically l eave s the tes t functi on and res umes t he normal rotating display . See Table 18.

HISTORY FUNCTION — Pressing displays total machine operating hours. Scroll down to display machine run time and starts, and total run time and starts for each compressor. Refer to Table 19 for a complete description of the function. When the PSIO-1 module is replaced or downloaded with Version 4.0 or later software, the number of starts and run hours may be changed one time. Record the current values from the PSIO before removing the module or downloading new software. The number of starts and hours may be changed

by entering the desired value at the HSIO and pressing the

key.

Pressing displays the last 10 alarms along with a description and time and date of occurrence of each alarm.

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. Refer to Tabl e 20 for a complete description of the function.

Cooling Set Point 1 and 2

Water:

38 to 70 F

(3.3 to 21.1 C)

Medium

T emp erature Brine:

14 to 70 F

(–10 to 21.1 C)

Temperature Brine:

Low

–13 to 70 F

(–25 to 21.1 C)

Reset Set Points

Maximum

Reset Range:

–30 to 30 F

(–17 to 17 C)

External Signal Reset: 4 to 20 mA (2 to 10 vdc with

External

T emp erature Reset:

–40 to 240 F

(–40 to 118 C)

500 Ohm

/2 watt resistor)

Chiller Fluid ∆:

0° to 15 F

(0° to 8 C)

Demand Limit Set Points Switch Input: Step 1 — 0 to 100% Capacity Reduction

Step 2 — 0 to 100% Capacity Reduction

External Signal: Maximum Demand Limit 4 to 20 mA

(2 to 10 vdc with 500 Ohm Minimum Demand Limit 4 to 20 mA (2 to 10 vdc with 500 Ohm

/2 watt resistor)

/2 watt resistor) Loadshed Demand Delta: 0 to 60% Maximum Loadshed Time: 0 to 120 min.

Head Pressure Set Points Air cooled chillers (30GX): 80 to 135 F (26.7 to 57.2 C) W ater cooled chill ers (30HX): 80 to 128 F (26.7 to 53.3 C) Set Point Table

— The unit operating set points can be found under . Use the down arrow key to scroll through the set points. The first set point is Cool Set Point 1. This is the occupied chilled fluid set point. Scroll down to Cool Set Point 2 and then to the Cooling Ramp load multiplier which is configurable from 0.2 to 2.0° F/min. (0.11 to 1.1° C/min.). This value is the maximum rate at which the leaving fluid temperature is allowed to drop without adding a stage. Cooling Set Point 2 is used in conjunction with the dual set point switch function. This is used as the low temperature set point for ice duty or as the unoccupied set point. Press the down arrow key to display the Circuit A and B head pressure set points. The remaining set points in this subfunction include demand limit, LCW (leaving chilled water) delta alarm limit, minutes off time, and motor temperature set point.

Display Units

— Press to display the units of mea-

sure being used. Type 0 is for Engli sh and type 1 is for Metric. Address

— For CCN configurations, press and scroll

down to display the address and bus number of the chiller.

— Press and scroll down to read and change the

Time unit day of week, time, day of month, m onth of year a nd year of century . See the examples in Table 20 for making changes to these value s.

Page 28

Table 17 — Test Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Circuit A Discrete Outputs

2 Circuit B Discrete Outputs

Circuit A Discrete Output Loader A1 Relay is OFF

Loader A1

ENTER

Relay is ON Loader A2

Minimum Load Valve A Circuit A Oil Heater A1 Mtr. Cooling Solenoid A2 Mtr. Cooling Solenoid Circuit A Oil Pump Oil Solenoid A1 Oil Solenoid A2

Circuit B Discrete Output Loader B1 Relay is OFF

Loader B1

ENTER

Relay is ON Loader B2

Minimum Load Valve B

Similarly, use to test remaining outputs. Press the down arrow key or to turn an output off.

NOTE: Output will display Rela y is ABSENT when not configured

Similarly, use to test remaining outputs. Press the down arrow key or to turn an

output off.

ENTER

3 Unit Discrete Outputs

Circuit B Oil Heater B1 Mtr. Cooling Solenoid B2 Mtr. Cooling Solenoid Circuit B Oil Pump Oil Solenoid B1 Oil Solenoid B2

NOTE: Output will display Rela y is ABSENT when not configured

Unit Discrete Output Fan 1 Relay is OFF

Fan 1

ENTER

Relay is ON Fan 2

Similarly, use to test remaining outputs.

ENTER

Press the down arrow key or to turn an

Fan 3

output off.

Fan 4 Fan 5 Energizes Circuit A fans for 30HXA units. Fan 6 Energizes Circuit B fans for 30HXA units. Cooler Pump

ENTER

Condenser Pump Cooler Heater Alarm Remote Alarm 1 Currently not supported.

Page 29

Table 17 — Test Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLA Y COMMENT

3 Unit Discrete Outputs (cont)

4 Valves and Motormaster

ENTER

Remote Alarm 2 Currently not supported. Remote Alarm 3 Currently not supported.

Remote Alarm 4 Currently not supported. Remote Alarm 5 Currently not supported. Remote Alarm 6 Currently not supported. Remote Alarm 7 Currently not supported. Remote Alarm 8 Currently not supported. Remote Alarm 9 Currently not supported. Remote Alarm 10 Currently not supported. Remote Alarm 11 Currently not supported. Remote Alarm 12 Currently not supported. Remote Alarm 13 Currently not supported. Remote Alarm 14 Currently not supported. Remote Alarm 15 Currently not supported. Remote Alarm 16 Currently not supported.

Valves and Motor Master Circuit A EXV Valve Target Percent = 0% Circuit A EXV Valve

Step in 25% increments.

Target Percent = 25% Circuit A EXV Valve

Target Percent = 50% Circuit A EXV Valve

Target Percent = 75%

Wait 30 seconds between each step for valv e to stop moving.

Valve may be closed in 25% increments by keying in . Wait 30 seconds between

ENTER

each step for valve to stop moving. Circuit A EXV Valve Target Percent = 100%

Circuit B EXV Valve Target Percent = 0%

Circuit A Water Valv e Target Percent = 0%

Test same method as for Circuit A.

Test same method as for EXV valves. Circuit A% Fan Speed Test same method as for EXV valves.

EXV — Electronic Expansion Valve

LEGEND

KEYPAD ENTRY DISPLAY RESPONSE COMMENTS

ENTER

EXV — Electronic Expansion Valve

ENTER

LEGEND

Circuit A Discrete Output Loader A1 Relay is OFF Loader A1 Relay is ON

Loader A1 Relay is OFF

Valves and Motor Master Circuit A EXV Valve Target Percent = 0% Circuit A EXV Valve Target Percent = 25%

Circuit A EXV Valve Target Percent = 0

Circuit B% Fan Speed Test same method as for EXV valves.

Table 18 — Using Test Function

Appears on screen momentarily, then will switch to Loader A1.

Compressor Loader A1 solenoid energized Compressor Loader A1 solenoid deenergized

Continue pressing to step to 50%, 75%, and 100%. Wait 30 seconds between each step for valve to stop moving. Continue pressing to step closed.

ENTER

Page 30

Table 19 — History Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Operating Hours

Machine Operating Hours xxx.x hours

Machine St arts xxx

Circuit A

Number of hours unit has at least 1 compressor running

Number of unit starts from zero capacity

2 Alarm History

Operating Hours xxx.x hours

Compressor A1 Hours xxx.x hours

Compressor A2 Hours xxx.x hours

Starts Compressor A1 Starts

xxx Compressor A2 Starts

xxx Circuit B

Compressor B1 Hours xxx.x hours

Compressor B2 Hours xxx.x hours

Starts Compressor B1 Starts

xxx Compressor B2 Starts

xxx Previous Alarm 1 - description

Alarm description, time/day of occurrence

Previous Alarm 2 - description Alarm description, time/day of occurrence

Previous Alarm 3 - description Alarm description, time/day of occurrence

Previous Alarm 4 - description Alarm description, time/day of occurrence

Previous Alarm 5 - description Alarm description, time/day of occurrence

Previous Alarm 6 - description Alarm description, time/day of occurrence

Previous Alarm 7 - description Alarm description, time/day of occurrence

Previous Alarm 8 - description Alarm description, time/day of occurrence

Previous Alarm 9 - description Alarm description, time/day of occurrence

Previous Alarm 10 - description Alarm description, time/day of occurrence

These values may be changed once, when new software is downloaded or when the PSIO-1 module is replaced (Version 4.0 and later)

List 10 most recent alarms. Use when necessary.

Page 31

Table 20 — Set Point Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Set Point Table

COOLING Cool Setpoint 1

Default: 44.0

x.xx dF Cool Setpoint 2

xx.x dF Cooling Ramp Loading

Default: 44.0

Default: 0.5

xx.x dF HEATING NOT SUPPORTED

Heat Setpoint 1 xx.x dF

Heat Setpoint 2 xx.x dF

Heating Ramp Loading xx.x dF

NOT SUPPORTED Default: 98.0

NOT SUPPORTED Default: 0.5

HEAD PRESSURE

2 Units

3 Address

4 Time

5 CCN Disable

CCN — Carrier Comfort Network dF — Degrees Fahrenheit LCW — Leaving Chilled Water

LEGEND

ENTER

Head Pressure Setpoint A xxx.x dF

Head Pressure Setpoint B xxx.x dF

DEMAND LIMIT Demand Switch 1 Setpoint

xxx.x% Demand Switch 2 Setpoint

xxx.x% LCW Delta Alarm Limit

xxx.x dF Minutes Off Time

xxx min Motor Temp Set Point

xxx.x dF US IMPERIAL/METRIC

0 TARGET ADDRESS

x TARGET BUS NUMBER

x Day of Week

Monday Day of Week

Wednsday TIME (HOUR/MIN)

00:00 TIME (HOUR/MIN)

10:30 DAY OF MONTH

xx DAY OF MONTH

20 MONTH OF YEAR

xx MONTH OF YEAR

05 YEAR OF CENTURY

xx YEAR OF CENTURY

96 Disable CCN Control

Default: 113.0 (GX)

100.0 (HXA) 85.0 (HXC) Default: 113.0 (GX)

100.0 (HXA) 85.0 (HXC)

Default: 80.0%

Default: 50.0%

Default: 50.0 dF

Default: 0 min

Default: 200.0 dF

0 = English (Default) 1 = Metric

Default: 1

Default: 0

Mon=1, Tues=2, etc.

Day of week set

Enter mil itary format

Time of day set

Day of month set

Month of year set

Year of century set

0=no, 1=yes Default: 0

NOTE: If metric option is selected under , temperatures are expressed in degrees Celsius and pressures are expressed in kPa.

Page 32

CCN Enable/Disable

— Press to disable the CCN control of the chiller. This function will override CCN control commands. The CCN Enable value under must be ON to activate thi s funct ion. With CCN Ena ble se t to ON and Disable CCN Control set to “0,” the chiller will function normally under CCN control. With Disable CCN Control set to “1,” the chiller will operate in a local mode under its own control.

Reading and Changing Set Points

— Table 21 shows how to read and change the chilled fluid set point. Other set points can be changed by following the same procedure. Refer to Table 20 for the sequence of display of set points in each subfunction.

Table 21 — Reading and Changing

Chilled Fluid Set Point

KEYPAD DISPLAY COMMENTS

COOLING Change set point from Cool Setpoint 1

44.0 F default Cool Setpoint 1

ENTER

48.0 F

default to 48 F.

Set point change complete

SERVICE FUNCTION — This function allows the technician to view and input configuration data. Factory configuration data, field configuration data, and service configuration data may be viewed or entered through the keypad and display module. See Table 22 for a complete listing of configurable items. Whenever a processor module is replaced in the field, the complete list of configuration codes should be checked for correct settings. The current software version can be displayed. See Tabl e 23.

Scroll down in this function to display configuration information including number of compressors, tonnage, and compressor must-trip amps.

Password Protection of HSIO Configurable Service Points — To modify configurations and values and to use the

manual control subfunction, the password must be entered before the first change can be made. The default password is set to . See Table 24 for an example of how to enter the password to change the Lead/Lag configuration.

Options Configuration Tables 1 and 2

— These subfunctions can be accessed by pressing or and scrolling down to display the configuration options. See Table 22 for a complete list of these options.

Temperature Reset, Demand Limit and Head Pressure PID Configurations — Press and scroll down to view the configuration information. See T able 22 for a complete list.

Factory Configuration Codes

— Pressing allows entry into the factory and service configuration codes subfunction. Under this subfunction, there are 5 configuration codes that are downloaded at the factory. Each code is made up of 8 digits. If the processor module is replaced in the field, these 5 configuration codes should be checked using the keypad and HSIO display module. See Table 25 for a description of the factory configuration codes (codes 1 through 3) and service configuration codes (codes 4 and 5).

The factory and service configuration codes are found by pressing . These are preset from the factory. They can be verified by following the description in Table 23. These codes MUST be checked and corrected in the field if the PSIO-1 module is replaced.

NOTE: The LOCAL/OFF/REMOTE switch must be in the OFF position to change configuration codes.

A label is applied to a control box panel with a list of factory and service codes for particular units. Table 26 shows how to configure a new PSIO-1 module for use in a 30HXC106---530CA water cooled chiller.

Transducer Calibration

— Press and scroll down to view the transducer calibration information. See Table 22 for a complete list, and the Pressure Transducers section on page 61 for a description of this subfunction.

Manual Control Mode

— This control allows the user to have full control over the compressors, loaders, and the minimum load valve (if installed) of the machine. Normal safeties su ch as high pressure, oil level and pressure, and CPM related alarms are NOT bypassed in this control mode. The capacity control function and overrides ARE bypassed when using the manual control mode. To enter this mode, switch the LOR switch to OFF. Press at the HSIO . The display will read Manual Control Enable - Disable. Press and

ENTER

switch the LOR switch to Local. The display will change to Manual Control Enable - Enable. The Disable and Enable will appear on the second line of the display. See Table 22 for a complete list of this func tion.

Scroll down and press to start the desired com-

ENTER

pressor. The control will start the compressor if the pre-lube cycle is passed, just as in normal operation. Press to add loaders as desired and press to turn off loaders and

ENTER

compressors. The Minimum Load Valve can be energized using the same procedure.

Dual Chiller Configuration

— Press to enter the Dual Chiller control configuration. This method of control is for a stand-alone Master/Slave combination of chillers and wil l NOT work with the Flotronic™ System Manager (FSM) or Chillervisor™ System Manager (CSM). The Minus One Pass Cooler option is required for this configuration.

The chillers should be piped for series flow through the coolers. The Master chiller must be downstream from the Slave chiller leaving water. Both the Master and Slave chiller must be connected to the same CCN Level II communications bus with different addresses. To enable the dual chiller configuration the CCN Enable function must be set to Enable for each chiller, otherwise each chiller will operate independently. This value can be activated through the HSIO or through a CCN device. Both chillers should be configured for Close Control

and require flow switches to be installed. For cooler pump control, wire both Master and Slave chiller outputs to the cooler pump starter. All system inputs (temperature reset, demand limit, dual set point, etc.) should be connected to the Master chiller. If Lead/Lag Balance is disabled, the Master chiller will always be the lead chiller. If Lead/Lag Balance is enabled, the control will alternate between the Master and Slave chillers to keep their respective run hours balanced within the value configured for Lead/Lag Balance Delta. The desired leaving fluid set point for the Duplex chiller must be configured in the Master chiller. CCN Control of the chillers can be disabled locally through the HSIO by entering

and enabling the Disable CCN Control value. This value must be disabled before the chiller will return to Duplex control.

Page 33

Table 22 — Service Function and Subfunction Directory

SUBFUNCTION KEYPAD ENT RY DISPLAY COMMENT

1 Service Configuration

2 Options Configuration 1

3 Options Configuration 2

See Legend on page 36.

Software CESR_500100 Ver xxx

Unit Type x

Number of Cir A Comp x

Compressor A1 Tonnage xx

Compressor A2 Tonnage xx

Cap. High Temp Override x

Number of Cir B Comp x

Compressor B1 Tonnage xx

Compressor B2 Tonnage xx

Max. Cond. Temp Setpoint xxx.x dF

MOP Setpoint xx.x dF

Fan Staging Select x

CPM Board Used? Yes

Compr. A1 Must Trip Amps xxx.x

Compr. A2 Must Trip Amps xxx.x

Compr. B1 Must Trip Amps xxx.x

Compr. B2 Must Trip Amps xxx.x

Cooler Fluid Selec t x

Min. Load Valve Select x

Loading Sequence Select x

Lead/Lag Sequence Selectx1 = Automatic (Default), 2 = Circuit A leads,

Head Press. Control Type x

Motormaster Select x

Water Valve Type x

Ext. Reset Sensor Select x

Cooler Pump Interlock x

Cooler Pump Control x

Condenser Pump Control x

Condenser Flow Switch x

Condenser Water Sensorsx0 = Not used (Default)

Heat Reclaim Sensors x

Cooling Setpoint Select x

Heating Se tpoint Select x

1 = Air-cooled (30GX), 2 = Water-cooled (30HXC) 3 = Split system (30HXA)

30GX = 154 F (68 C) 30HXA = 152 F (67 C) 30HXC = 122 F (50 C)

Default = 52 F (11.1 C)

Displays “Not Used” or a number. See Table 7 (30GX only).

Value from CPM module. See Appendix A.

1 = Water (Default), 2 = Medium Temp Brine 3 = Low Temp Brine (HX only)

Displays Enable/Dsable Default: Dsable

1 = Equal circuit, 2 = Staged circuit Default: 2. See page 7.

3 = Circuit B leads 0 = None (Default, HX), 1 = Air cooled (Default, for GX and must be set to 1 for

HXA control of remote A/C condenser fans), 2 = Water cooled (HXC only) 0 = None (Default), 1 = Direct control

0 = None (Default), 1 = 4-20 mA, 2 = 2-10 V 3 = 20-4 mA, 4 = 10-2 V

0 = Space Temp Thermistor (Default) 1 = Outside Air Themistor

0 = No interlock 1 = Interlock enabled (Default)

0 = Not controlled (Default) 1 = On/Off control

0 = Not controlled (Default, and 30HXA control of remote A/C condenser fans) 1 = On/Off control 2 = Off when stages equal 0 (unit off)

Displays Enable/Dsable Default: Dsable

1 = Used CURRENTLY NOT SUPPORTED

0 = Single set point (Default), 1 = Dual set point (switch controlled), 2 = Dual set point (clock controlled)

0 = Single set point (Default), 1 = Dual set point (switch controlled), 2 = Dual set point (clock controlled) CURRENTLY NOT SUPPORTED

Page 34

Table 22 — Service Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMME NT

3 Options Configuration 2 (cont) Ramp Load Select

4 Reset Configuration Table

x Clock Control Select

Ice Configuration Select x

OAT Sensor Select x

Remote Alarm Select x

Alarm Reset Select x

Close Control Select x

Deadband Multiplier x.x

Current Unbalance Alarm x

COOLING RESET TYPE 1

Degrees Reset at 20 mA xx.x dF

COOLING RESET TYPE 2

Remote temp=No Reset xx.x dF

Remote temp=Full Reset xx.x dF

Degrees Reset xx.x dF

COOLING RESET TYPE 3

CHW Delta T=No Reset xx.x dF

CHW Delta T=Full Reset xx.x dF

Degrees Reset xx.x dF

COOLING RESET

0 = Disabled, 1 = Enabled (Default) See page 9.

0 = No clock control (Default) 1 = Local clock control 65 = CCN Clock Control

0 = Disabled (Default) 1 = Clock Control 2 = Demand Limit Control

0 = Disabled, 1 = Enabled Default: 0

0 = Not selected, 1 = Selected (Default, allows use of LOR switch to reset alarms)

0 = Disabled, 1 = Enabled Default: 0 See page 7.

Default: 1.0

Alarm at 10% imbalance; 0 = Disabled, 1 = Enabled Default: 1

See Temperature Reset section, page 41.

Default: 0

Default: 20

Default: 125

Default: 0

Default: 15

Default: 0

Select/Enable Reset Type x

HEATING RESET TYPE 1

Degrees Reset at 20 mA xx.x dF

HEATING RESET TYPE 2

Remote temp=No Reset xx.x dF

Remote temp=Full Reset xx.x dF

Degrees Reset xx.x dF

HEATING RESET TYPE 3

HTW Delta T=No Reset xx.x dF

HTW Delta T=Full Reset xx.x dF

Degrees Reset xx.x dF

HEATING RESET

Select/Enable Reset Type x

DEMAND LIMIT See Demand Limit Section, page 41.

Demand Limit at 20 mA xxx.x%

0 = No Reset (Default), 1 = 4-20 mA Reset 2 = External Reset, 3 = Return Fluid Reset

CURRENTLY NOT SUPPORTED

Default: 0

CURRENTLY NOT SUPPORTED

Default: 125

Default: 20

Default: 0

CURRENTLY NOT SUPPORTED

Default: 15

Default: 0

0 = No Reset (Default), 1 = 4-20 mA reset 2 = External reset, 3 = Return Fluid reset

Enter 0-100, Default: 0%

Page 35

Table 22 — Service Function and Subfunction Directory (cont)

SUBFUNCTION KEYPA D E N TRY DIS P L AY COMMENT

4 Reset Configuration Table (cont) Demand Limit Select

x Loadshed Group Number

x Loadshed Demand Delta

xxx% Maximum Loadshed Time

xx min WATER VALVE PID

0 = None (Default), 1 = Two-step switch, 2 = 4-20 mA, 3 = CCN Loadshed

0-99, Default: 0

0-60%, Default: 0

0-120 min, Default: 60 min

5 Factory Configuration Codes

6 NOT USED

7 Transducer Calibration

Proportional PID Gain x.x

Integral PID Gain x.x

Derivative PID Gain x.x

AIR MOTO R MASTER PID

Proportional PID Gain x.x

Integral PID Gain x.x

Derivative PID Gain x.x

FACTORY CODES

Configuration Code 1 xxxxxxxx

Configuration Code 2 xxxxxxxx

Configuration Code 3 xxxxxxxx

SERVICE CODES

Configuration Code 4 xxxxxxxx

Configuration Code 5 xxxxxxxx

CALIBRATION OFFSET See Pressure Transducer Calibration, page 61.

CIRCUIT A PRESSURE

Default = 1.0 Adjustable from -20.0 to 20.0

Default = 0.1 Adjustable from -20.0 to 20.0

Default = 0.0 Adjustable from -20.0 to 20.0

Default = 1.0 Adjustable from -20.0 to 20.0

Default = 0.1 Adjustable from -20.0 to 20.0

Default = 0.0 Adjustable from -20.0 to 20.0

Factory set. See Table 25.

See Legend on page 36.

Discharge Pressure xxx.x PSI

Suction Pressure xxx.x PSI

A1 Oil Pressure xxx.x PSI

A2 Oil Pressure xxx.x PSI

Economizer Pressure xxx.x PSI

CALIBRATION OFFSET

CIRCUIT B PRESSURE

Discharge Pressure xxx.x PSI

Suction Pressure xxx.x PSI

B1 Oil Pressure xxx.x PSI

B2 Oil Pressure xxx.x PSI

Economizer Pressure xxx.x PSI

Page 36

Table 22 — Service Function and Subfunction Directory (cont)

ENTER

SUBFUNCTION KEYPAD ENTRY DISPLAY COMME NT

7 Transducer Calibration (cont) Calibrate All at 0 PSIG

8 Manual Control Table

ENTER

9 Dual Chiller Configuration (Series Water Flow Only)

No Last Calibration Date

mmm-dd-yy Manual Control Enable

Dsable Password Protected

Enter: Manual Control Enable

ENTER

Dsable Manual Control Enable

Enable Circuit A Compressor 1

Off

LOR switch should be in OFF position

Will be displayed if not entered earlier in HSIO use

Manual control must be disabled to resume normal capacity control

Switch LOR switch to Local before proceeding

Circuit A Compressor 1OnProvided no alarms exist, control will attempt circuit start within 2 minutes.

Press to stop circuit.

Circuit A Compressor 2 Off to enable,

ENTER

to stop

Circuit A Loader 1 Off

to enable, to stop

Circuit A Loader 2 Off to enable,

to stop

Circuit A Min Load Valve Off

to enable, to stop

Circuit B Compressor 1 Off

to enable, to stop

Circuit B Compressor 2 Off to enable,

to stop

Circuit B Loader 1 Off

to enable, to stop

Circuit B Loader 2 Off

to enable, to stop

Circuit B Min Load Valve Off to enable,

to stop

MST_SLV

Master/Slave Select 0/1/2

Slave Address 0

Lead/Lag Balance 0/1

Lead/Lag Balance Delta xxx hours

0 = Disabled 1 = Master 2 = Slave

Default = 0 Adjustable from 0-236

0 = Disabled 1 = Enabled

Default = 168 Adjustable from 40-400

CCN — Carrier Control Network CHW — Chilled Water CPM — Compressor Protection Module dF — Degrees Fahrenheit HSIO — Standard Keypad HTW — Hot Water LOR — Local/Off/Remote MOP — Maximum Operating Pressure OAT — Outside Air Temperature PID — Proportional Integral Derivative

LEGEND

Page 37

Table 23 — Display Current Software Version

ENTER

FUNCTION

Software Version

KEYPAD

ENTRY

DISPLAY COMMENT

Software CESR_500100 Ver xxx

Carrier Software Part Number, where xxx is the revision number.

Table 24 — Compressor Lead/Lag Configuration

SUB-FUNCTION Options

Configurat ion 1

NOTE: Configurations may be mod i fied after entering the password. The password is only r equ ire d to be entered once. After a period of 10 minutes of no HSIO activity, the user is automatically logged out and the control requires that the password be entered on the next use.

KEYPAD

ENTRY

ENTER

DISPLAY

Cooler Fluid Select 1

Min. Load Valve Select Dsable

Loading Sequence Select 1

Lead/Lag Sequence Select 1

PASSWD PROTECT ED FUNC Enter password:

Lead/Lag Sequence Select 0

Lead/Lag Sequence Select 2

Page 38

Table 25 — Factory and Service Configuration Code Values

UNIT MODEL NUMBER CONF. CODE 1* CONF. CODE 2* CONF. CODE 3* CONF. CODE 4* CONF . CODE 5*

30GX080 11460010 13900000 00000170 15400521 12000093 30GX090, 105 11560010 13900000 00000180 15400521 12000093 30GX106 11560010 13900000 00000180 15400521 14000095 30GX115 11660010 13900000 00000190 15400521 14000095 30GX125 11660010 14600000 00000161 15400521 14000095 30GX136 11660010 15600000 00000162 15400521 16000097 30GX150 11560010 18000000 00000095 15400521 16000097 30GX151 11800010 15600000 00000176 15400521 07000088 30GX160 11660010 18000000 00000105 15400521 16000097 30GX161 11800010 16600000 00000177 15400521 07000088 30GX175 11800010 18000000 00000119 15400521 07000088 30GX176 11800010 18000000 00000119 15400521 03000084 30GX205 12663910 18000000 00000145 15400521 07000088 30GX206 12803910 16600000 00000217 15400521 09000090 30GX225 12804610 18000000 00000166 15400521 07000088 30GX226 12804610 18000000 00000166 15400521 09000090 30GX250 12806610 18000000 00000186 15400521 09000090 30GX251 12808010 16600000 00000258 15400521 05000086 30GX265 12808010 18000000 00000200 15400521 05000086 30GX281 12804610 28046000 00000240 15400521 05000086 30GX301 12805610 28056000 00000251 15400521 05000086 30GX325 12806610 28066000 00000262 15400521 05000086 30GX350 12808010 28080000 00000218 15400521 05000086 30HXA076 31390010 13900000 00000183 15200521 02000063 30HXA086 31460010 13900000 00000190 15200521 02000063 30HXA096 31560010 13900000 00000200 15200521 02000063 30HXA106 31660010 13900000 00000210 15200521 02000063 30HXA116 31660010 14600000 00000181 15200521 02000063 30HXA126 31660010 15600000 00000182 15200521 02000063 30HXA136 31800010 15600000 00000196 15200521 02000063 30HXA146 31800010 16600000 00000197 15200521 02000063 30HXA161 31800010 15600000 00000196 15200521 02000063 30HXA171 31660010 18000000 00000125 15200521 02000063 30HXA186 31800010 18000000 00000139 15200521 02000063 30HXA206 32663910 18000000 00000165 15200521 02000063 30HXA246 32805610 18000000 00000196 15200521 02000063 30HXA261 32806610 18000000 00000206 15200521 02000063 30HXA271 32808010 18000000 00000220 15200521 02000063 30HXC076 21390010 13900000 00000173 12200521 00000058 30HXC086 21460010 13900000 00000180 12200521 00000058 30HXC096 21560010 13900000 00000190 12200521 00000058 30HXC106 21660010 13900000 00000200 12200521 00000058 30HXC116 21660010 14600000 00000171 12200521 00000058 30HXC126 21660010 15600000 00000172 12200521 00000058 30HXC136 21800010 15600000 00000186 12200521 00000058 30HXC146 21800010 16600000 00000187 12200521 00000058 30HXC161 21800010 15600000 00000186 12200521 00000058 30HXC171 21660010 18000000 00000115 12200521 00000058 30HXC186 21800010 18000000 00000129 12200521 00000058 30HXC206 22663910 18000000 00000155 12200521 00000058 30HXC246 22805610 18000000 00000186 12200521 00000058 30HXC261 22806610 18000000 00000196 12200521 00000058 30HXC271 22808010 18000000 00000210 12200521 00000058

*Unit Type will be listed as air cooled, water cooled, or remote split system. Unit type is first digit in Configuration Code

1 and is 1 for 30GX units, 2 for 30HXC units, and 3 for 30HXA cooling only chillers. For other options, see Table 22 under the Service subfunction. A label listing configuration codes is located on the control box door or panel.

Page 39

Table 26 — Entering Configuration Codes

KEYPAD ENTRY DISPLAY RESPONSE

ENTER

FA C T ORY CODES

Configuration Code 1 00000000

Configuration Code 1 21660010

Configuration Code 2 00000000

Configuration Code 2 13900000

Configuration Code 3 00000000

Configuration Code 3 00000200

SERVICE CODES

Configuration Code 4 00000000

Configuration Code 4 12200521

Configuration Code 5 00000000

Configuration Code 5 00000058

SCHEDULE FUNCTION — This function provides a means to automatically switch the chille r from an occupied mod e to an unoccupied mode. Refer to Table 27 for a complete description of the function.

The schedules consist of 8 user-configurable occupied time periods. The control supports time schedules for local control, remote control and ice building. These time periods can be flagged to be in effect or not in effect on each day of the week. The day begins at 00.00 and ends at 24.00. The machine is in unoccupied mode unless a scheduled time period is in effect. If an occupied period is to extend past midnight, it must be programmed in the following manner: occupied period must end at 24:00 hours (midnight); a new occupied period must be programmed to begin at 00:00 hours.

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 24:00 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. Each time schedule can be overridden to

keep the chiller in an Occupied mode for 1, 2, 3 or 4 hours on a one-time basis.

Dual Set Point Control

— This feature can be enabled to allow the use of a second or unoccupied cooling set point. The function can be either switch controlled or clock controlled. To enable switch control, set the Cooling Setpoint Select under

to 1. See page 74 or 75 of Field Wiring section, depending on unit type, for switch input wiring to the PSIO-2 module. Configure Cool Setpoint 2 under to the desired value. The unit will then control leaving water temperature to Cool Setpoint 2 when the switch input is closed. To enable clock control, set the Cooling Setpoint Select under

to 2. Set Cool Setpoint 2 to the desired unoccupied value. Using , configure local operating schedules for the desired occupied and unoccupied time periods. The unit will then control leaving water temperature to Cool Setpoint 2 during unoccupied time periods.

Page 40

Table 27 — Schedule Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Ice Build Schedule*

2 Local Schedule†

3 Remote Schedule (Currently Not Used)

4 Holiday Configuration**

5-33 Holiday Configuration

ENTER

through

SCHEDULES: OCCPC01S Timed Override: 00

SCHEDULES: OCCPC01S Timed Override: 02

MTWTFSSH OCC UNOCC 01- 00000000 00:00 00:00

MTWTFSSH OCC UNOCC 01- 11111000 00:00 00:00

MTWTFSSH OCC UNOCC 01-11111000 21:00 00:00

MTWTFSSH OCC UNOCC 01-11111000 21:00 06:30

MTWTFSSH OCC UNOCC 02- 00000000 00:00 00:00

SCHEDULES: OCCPC02S Timed Override: 00

MTWTFSSH OCC UNOCC 01- 00000000 00:00 00:00

MTWTFSSH OCC UNOCC 01- 11111000 00:00 00:00

MTWTFSSH OCC UNOCC 01-11111000 06:30 00:00

MTWTFSSH OCC UNOCC 01-11111000 06:30 21:00

MTWTFSSH OCC UNOCC 02- 00000000 00:00 00:00

SCHEDULES: OCCPC65S Timed Override: 00

MTWTFSSH OCC UNOCC 01- 00000000 00:00 00:00

MTWTFSSH OCC UNOCC 01- 11111000 00:00 00:00

MTWTFSSH OCC UNOCC 01-11111000 06:30 00:00

MTWTFSSH OCC UNOCC 01-11111000 06:30 21:00

MTWTFSSH OCC UNOCC 02- 00000000 00:00 00:00

HOLIDAYS: HOLDY_01 Starts on 00/00 00 days

HOLIDAYS: HOLDY_01 Starts on 12/23 00 days

HOLIDAYS: HOLDY_01 Starts on 12/23 10 days

HOLIDAYS: HOLDY_02 Starts on 00/00 00 days

Extended Occupied Time

Two hour override entered

Displays current stored schedule (First two numbers are schedule, 01-08)

Monday-Friday now occupied

Occupied time now set

Unoccupied time now set Ice Build schedule completed

Can enter up to 7 additional ice build schedules

Extended Occupied Time

Displays current stored schedule (First two numbers are schedule, 01-08)

Monday-Friday now occupied

Occupied time now set

Unoccupied time now set Local schedule completed

Can enter up to 7 additional local schedules

Extended Occupied Time

Displays current stored schedule (First two numbers are schedule, 01-08)

Monday-Friday now occupied

Occupied time now set

Unoccupied time now set Remote schedule completed

Can enter up to 7 additional remote schedules

Can configure holiday start day and duration

Start of hol i day set

Holiday duration set

Allows configuration of 29 additional holiday periods

*Ice configuration select must be set to 1 for clock control. The ice configuration can be accessed by pressing and scrolling down.

†Clock control select must be set to 1 for clock control. The clock control can be accessed by pressing and scrolling down. **The BROADCAST function (BRODEFS table) must be activated (change to “YES” and download) when using the Remote Enhanced Display controller, Building

Supervisor or ComfortWorks® software for the control to recognize holidays.

Page 41

Temperature Reset —

The control system is capable of providing leaving fluid temperature reset based on return fluid temperature. Because the temperature difference between leaving and return temperature is a measure of the building load, return fluid temperature reset is essentially an average building load reset method.

Under normal operation, the chiller maintains a constant leaving fluid temperature approximately equal to the chilled fluid set point. As building load drops from 100% down to 0%, entering cooler fluid temperature drops in proportion to load. Thus, the temperature drop across the cooler drops from a typical 10° F (5.5° C) at full load to a theoretical 0° F (0° C) at no load. See Fig. 8.

At partial load, leaving chilled fluid temperature may be lower than required. If this is allowed to increase (reset), the efficiency of the chiller increases. Amount of reset can be defined as a function of cooler temperature drop. This is a simple linear function that requires 3 pieces of input data for the set function that will vary depending on measurement method used. See the following sections and Table 28.

NOTE: Reset set points are not accessible unless the reset function is enabled first. The Control Point will be recalculated taking into account the set point plus the amount of reset. This is done as a field configuration. Select one of the 3 choices for type of reset: Return Fluid Reset, External Temperature Reset, or 4 to 20 mA Signal Reset. See Table 28.

If dual set point control is enabled, the amount of reset is applied to whichever set point is in effect at the time.

T ables 29-31 demonstrate how to activate reset. EXTERNAL TEMPERATURE RESET — In this example,

the unit set point is reset from full load at 90 F (32 C ) to a maximum reset value of 10° F (5.5° C) at 25 F (–6.7 C) outdoor ambient. This me ans that if the chilled fluid set point is 4 4 F (6.7 C), there is no reset if the temperature is 90 F (32 C). At a temperature of 25 F (–6.7 C), the chilled fluid set point would be reset to 54 F (12.2 C). See Fig. 8 and Table 29. A field-supplied outdoor air thermistor must be connected to PSIO-2 as shown on page 74 or 75 of Field Wiring.

To activate this function for space te mperature reset leave both the External Reset Sensor Select and the OAT Sensor Select at 0, and change the Select/Enable Reset T ype to 2, following the procedure in T able 29.

EXTERNALLY POWERED RESET (4 to 20 mA) — In this example, the uni t set point is rese t from full lo ad at 4 mA to a maximum reset value of 10° F (5.5° C) at 20 mA. See Fig. 9 and Ta ble 30.

RETURN FLUID TEMPERATURE RESET — In this example, the unit set point i s reset from full load based on the chil led fluid return temperature. The example us es a reset val ue of 10 degrees at full reset. Full reset is at a 2-degree temperature difference across the cooler and no reset would be at a 10 ° F difference across the cooler. See Fig. 10 and Table 31.

Demand Limit —

Demand Limit is a feature that allo ws the unit capacity to be limited during periods of peak energy usage. There are 3 types of demand limiting which can be configured. The first type is through 2 switch inputs, which will reduce the maximum capacity to 2 user-configurable percentages. The second type is by a 4 to 20 mA signal input which will reduce the maximum capacity linearly between 100% at a 4 mA input signal (no reduction) down to the userconfigurable level at a 20 mA input signal. The third type uses the CCN Loadshed module and has the ability to limit the current operating capacity to maximum and further reduce the capacity if required.

T o use Demand Limit, sele ct the type of demand limit ing to use. Then configure the Demand Limit set points based on the type selected.

DEMAND LIMIT (Switch Controlled, 30GX only) — In this example, demand limit by switch control will be configured and the switch set points will be set at 75% and 40%. Capacity steps are controlled by 2 relay switch inputs field wired to PSIO-2, terminal 28 for switch 1 and terminal 25 for switch 2. See Tabl e 32.

For Demand Limit by switch control, closing the first stage demand limit contact will put the unit on t he first demand limi t level. The unit will not exceed the percentage of capacity entered as Demand Switch 1 set point. Closing contacts on the second demand limit switch prevents the unit from exceeding the capacity entered as Demand Switch 2 set point. The demand limit stage that is set to the lowest demand takes priority if both demand limit inputs are closed. If the demand limit p ercentage does not match unit staging, the unit will limi t capacity to the closest capacity stage.

T o Disable Demand Limit: Enter as shown in Table 32. Scroll down to Demand Limit Select and press

ENTER

to select no Demand Limit control.

Table 28 — Temperature Reset Set Point Limits

INPUT DAT A DESCRIPT ION

Maximum Reset Amount — Allowable range for maxi mu m amount when LWT set point is reset.

Maximum Reset Amount — Temperature at which maximum res et o ccur s.

Minimum Reset Reference — Temperature at which no reset occurs.

CHW — Chilled Water OAT — Outdoor Air Temperature LWT — Leaving Fluid Temperature

LEGEND

(With 500-Ohm resistor) Variable Limits Variable Limits Variable Limits

Degrees Reset at 20 mA

Type 1 — 4-20 mA

(–30 to 30 F) –34 to –1 C

— — Remote temp =

Type 2 — OAT/Occupied Space

(External Sensor)

Degrees Reset (–30 to 30 F)

Full reset

No reset

MEASUREMENT METHOD

–34 to –1 C

(20 to 125 F) –7 to 52 C

Type 3 — Return Fluid

Degrees Reset (–30 to 30 F)

CHW Delta T = Full Reset

CHW Delta T = No Reset

–34 to –1 C

(0 to 15 degrees F) 0 to 8° C cooler temperature rise

Page 42

6.7 (12)

5.5 (10)

4.4 (8)

3.3 (6)

2.2 (4)

RESET AMOUNT C (F)

1.1 (2)

0.0 (0)

-18 (0) -12 (10) -7 (20) -1 (30) 4 (40) 10 (50) 16 (60) RESET REFERENCE TEMPERATURE-OUTDOOR AIR OR SPACE TEMPERATURE THERMISTOR C (F)

BUILDING LOAD

RESET AMOUNT

Fig. 8 — Cooling External Temperature Reset

6.7 (12)

5.5 (10)

4.4 (8)

21 (70) 27 (80)

32 (90)

38(100)

100

PERCENT BUILDING LOAD

3.3 (6)

2.2 (4)

RESET AMOUNT C (F)

1.1 (2)

6.7 (12)

5.5 (10)

4.4 (8)

3.3 (6)

RESET AMOUNT C (F)

2.2 (4)

0 (0)

2 (1)

4 (2)

6 (3)

RESET REFERENCE = 4-20 mA SIGNAL INPUT (VOLTS DC)

8 (4)

10 (5)

12 (6)

14 (7)

Fig. 9 — 4 to 20 mA Cooling Temperature Reset

RESET AMOUNT

16 (8)

18 (9)

20 (10)

100

1.1 (2)

0.0 (0)

0.0 (0) 0.5 (1) 1.1 (2) 1.6 (3) 2.2 (4) 2.7 (5) 3.3 (6) 3.8 (7) 4.4 (8) RESET REFERENCE TEMPERATURE = COOLER DELTA T (COOLER EWT - LWT) C (F)

Fig. 10 — Cooling Return Water Reset

BUILDING LOAD

5.0 (9)

5.5 (10)

PERCENT OF BUILDING LOAD

Page 43

Table 29 — Setting External Temperature Reset Table 30 — Setting External Powered Reset

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

Cooler Fluid Select 1

Min. Load Valve Select Disable

Loading Sequence Select 1

Lead/Lag Sequence Select 1

Head Press. Control Type 0

Motormaster Select 0

Water Valve Type 0

Ext. Reset Sensor Select 0

Ext. Reset Sensor Select1Outdoor Ambient sensor

Cooling Setpoint Select 0

Heating Setpoint Select 0

Ramp Load Select 0

Clock Control Select 1

Ice Configuration Select 0

OAT Sensor Select 0

OAT Sensor Select 1

COOLING RESET TYPE 1

Degrees Reset at 20 mA

0.0 dF COOLING RESET TYPE

2 Remote temp = Full Reset

20.0 dF Remote temp = Full Reset

ENTER

25.0 dF Remote temp = No Reset

125.0 dF Remote temp = No Reset

ENTER

90.0 dF Degrees Reset

0.0 dF Degrees Reset

ENTER

10.0 dF

COMMENT

selected for reset

OAT sensor enabled

COOLING RESET Scroll down to this point

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

COOLING RESET TYPE 1

Degrees Reset at 20 mA

0.0 dF Degrees Reset at 20 mA

10.0 dF COOLING RESET Scroll down to this point

Select/Enable Reset T ype 0

ENTER

Select/Enable Reset T ype14-20 mA reset selected

Table 31 — Setting Return Fluid

Temperature Reset

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

COOLING RESET TYPE 1

COOLING RESET TYPE3Scroll down to this point

CHW Delta T = No Reset

15.0 dF CHW Delta T = No Reset

10.0 dF CHW Delta T = Full Reset

0.0 dF CHW Delta T = Full Reset

2.0 dF Degrees Reset

0.0 dF Degrees Reset

10.0 dF COOLING RESET

Select/Enable Reset Type 0

Select/Enable Reset Type3Return Fluid reset selected

COMMENT

Select/Enable Reset Type 0

ENTER

Select/Enable Reset Type2External reset selected

Page 44

EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) — In this example, the 4 to 20 mA Demand Limit will be configured and the 20 mA demand limit percentage will be set to 50%. See T able 33 and Fig. 1 1.

DEMAND LIMIT (CCN Loadshed Controlled) — In this example, the CCN Loadshed Demand Limit will be configured. The loadshed group will be set to 1, demand delta will be set to 40% and the maximum loadshed time will be set to 90 minutes. See T able 34.

The Loadshed Group number is established by the CCN system designer. The PIC (product integrated control) will respond to a Redline command from the Loadshed control. When the Redline command is received, the current stage of capacity is set to the maximum stages available. Should the loadshed control send a Loadshed command, the PIC will reduce the current stages by the value entered for Loadshed Demand delta. For the above example the Loadshed Demand delta is 40%. If the chiller is operating at 80% of total capacity when a Redline command is rece ived, the maximum ava ilabl e capacity is set to 8 0%. When a Loadshe d comma nd is rece ived, the chiller capacity will be reduced by 40%. The chiller can now operate at a total capacity of no more than 48% [80% – (80% x 40%)] until a Cancel Redline or Cancel Loadshed command is received. The control will disable the Redline/Loadshed command if no Cancel command has been received within the configured maximum loadshed time limit.

Table 32 — Setting Switch-Controlled

Demand Limit

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

COOLING RESET TYPE 1

DEMAND LIMIT Scroll down to this point

Demand Limit at 20 mA

0.0% Demand Limit Select

0 Demand Limit Select

1 COOLING

DEMAND LIMIT Scroll down to this point

Demand Switch 1 Setpoint

80.0% Demand Switch 1 Setpoint

75.0% Demand Switch 2 Setpoint

50.0% Demand Switch 2 Setpoint

40.0%

COMMENT

T w o step s witch configured

Configuration complete

Table 33 — Setting Demand Limit

(4 to 20 mA Controlled;

2 to 10 vdc With 500-Ohm Resistor)

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

COOLING RESET TYPE 1

DEMAND LIMIT Scroll down to this point

Demand Limit at 20 mA

0.0% Demand Limit at 20 mA

50.0% Demand Limit Select

0 Demand Limit Select24-20 mA control configured

Table 34 — Setting Demand Limit

(CCN Loadshed Controlled)

KEYPAD

ENTRY

ENTER

DISPLAY

RESPONSE

COOLING RESET TYPE 1

DEMAND LIMIT Scroll down to this point

Demand Limit at 20 mA

0.0% Demand Limit Select

0 Demand Limit Select

3 Loadshed Group Number

0 Loadshed Group Number

1 Loadshed Demand Delta

0 Loadshed Demand Delta

40% Maximum Loadshed Time

60 min Maximum Loadshed Time

90 min

CCN Loadshed control configured

Configuration complete

COMMENT

100

100% CAPACITY AT 4 mA

MAX. ALLOWABLE LOAD (%)

Fig. 11 — 4 to 20 mA Demand Limiting

75% CAPACITY AT 12 mA

DEMAND LIMIT SIGNAL (4-20 mA INPUT)

50% CAPACITY AT 20 mA

16 18

Page 45

TROUBLESHOOTING

The 30GX,HX screw chiller control has many features to aid in troubleshooting. By using the keypad and display module and the Status function, operating conditions of the chiller are displayed while the unit is running. The Test function allows for operational checkout of compressor loaders, fans, EXVs, solenoids, and other components while the chiller is stopped. The Service function displays how configurable items are configured and provides a manual control mode where the compressors can be started and loaded. If an operating fault is detected, an alarm is generated and an alarm code is displayed under the subfunction along with an explanation of the fault. Up to 10 current alarm codes are stored under this subfunction. For checking specific items, see T abl e 14.

Checking Display Codes —

machine has been programmed to operate, check the diagnostic information displayed in the Status function and the configuration information displayed in the Service function.

Unit Shutoff —

To shut the unit off, move the LOCAL/ OFF/REMOTE switch to OF F position. All compres sors and solenoids stop immediately.

Complete Unit Stoppage —

can be caused by any of the following conditions:

• cooling load satisfied

• remote on/off contacts open

• programm ed schedule

• emergency stop command from CCN

• general power failure

• blown fuse in control power feed disconnect

• open control circuit fuse(s)

• LOCAL/OFF/REMOTE switch moved to OFF position

• freeze protection trip

• low flow protection trip

• open contacts in chilled water flow switch (optional)

• Open contacts in any auxiliary interlock. Terminals that

are jumpered from factory are in series with control switch. Opening the circuit between these terminals places unit in Stop mode, similar to moving the control switch to OFF position. Unit cannot start if these contacts are open. If they open while unit is running, the unit stops

• cooler entering or leaving fluid thermistor failure

• low/high transducer supply voltag e

• loss of communications between processor module and

other control modules

• low refrigerant pressure

• off-to-on delay is in effect

If a stoppage occurs more than once as a result of any of the above safety devices, determine and correct the cause before attempting another restart.

Single Circuit Stoppage —

can be caused by the following:

• low oil pressure

• open contacts in high pressure switch

• low refrigerant pressure

• thermistor failure

• transducer failure

• alarm condition from CPM module

Stoppage of one circuit by a safety device action does not affect other circuit. When a safety device trips, the circuit is shut down immediately and EXV closes.

To determine how the

Complete unit stoppage

Single circuit stoppage

If a stoppage occurs more than once as a result of any of the preceding safety devices, determine and correct the cause before attempting another restart.

Restart Procedure —

After the cause for stoppage has been corrected, restart is either automatic or manual, depending on the fault. Manual reset requires that the alarm(s) be reset via the HSIO. Press and then to clear manual

ENTER

reset alarms. If the Alarm Reset Select feature is selected ( ), a manual reset alarm can also be reset by switching the LOR switch from LOCAL/REMOTE to OFF and back to LOCAL/REMOTE again. If an alarm was from the CPM module, depress the reset button located on the control/fuse panel for 5 seconds before clearing the alarm through the HSIO. Some typical fault conditions are described in Table 35. For a complete list of fault conditions, codes, and reset type, see Table 36.

POWER FAILURE EXTERNAL TO THE UNIT — Unit restarts automatically when power is restored.

Table 35 — Typical Stoppage Faults

and Reset Types

STOPPAGE FAULT RESET TYPE

Loss of Co nd en se r F l o w ( 3 0HX C ) Manual reset Cooler Freeze Protection (Chilled Fluid, Low Temperature) Cooler Fluid Pump Interlock Automatic reset (Manual for closed

Control Circuit Fuse Blown Unit restarts automatically when power High-Pressure Switch Open Manual reset

Low Sat. Suction Temperature Manual reset Low Oil Pressure Manual reset Loss of Communications with

WSM or FSM Controller

FSM — Flotronic™ System Manager WSM — Water System Manager

LEGEND

Alarms and Alerts —

Auto reset first time, manual if repeated in same day

contacts when pump is off) is restored

Automatic reset

These are warnings of abnormal or fault conditions, and may cause either one circuit (alert) or the whole unit (alarm) to shut down. They are assigned code numbers as described in Table 36. The alarm descriptions are displayed on the HSIO when the subfunction is entered. When a communication loss occurs to a hardware point, an alert or alarm may be generated. Refer to Table 37. The PSIO also recognizes illegal configurations. Illegal configurations are shown in Table 38.

When an alarm or alert is activated, the relay K3 (for 30GX units) or K6 (for 30HX units) will close. See Field Wiring section on page 70 for wiring details.

Table 36 contains a detailed description of each alarm and alert code error and possible cause.

ALARM/ALERT RESET — Automatic alarms will reset without operator intervention if the condition corrects itself. One or more of the following methods must be used to reset manual alarms:

To reset PSIO alarms, first find and correct the cause of the alarm. Then from the HSIO press and to

ENTER

clear the alarm. If the Alarm R eset Select in is s et to “1,” the default value, the LOCAL-OFF-REMOTE switch can be switched from “Local” or “REMOTE” to “OFF” for 5 seconds and back to its original position to reset the alarm.

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Compressor Protection Module (CPM) alarms, 1.xx, 2.xx,

5.xx, or 6.xx require additional steps to reset these alarms. To clear these alarms, first find and correct the cause of the alarm. Then press and hold the Reset Button located on the CPM board for 5 seconds. This action will reset only the alarmed circuit, and clear the CPM. Next, reset the alarm in the PS IO as described above. For CPM alarms, 1.95, 2.95, 5.95 and 6.95, first correct the configuration header problem, turn LOCAL-

hold the reset button on the unit’s control/fuse panel for 5 seconds. This action removes power to the CPM, and should not be used while another compressor is in operation. Next, reset the alarm in the PSIO as described above.

Compressor Alarm/Alert Circuit —

sor is controlled by a CPM processor, which controls the compressor operation. Power is supplied to the CPM logic circuit.

OFF-REMOTE switch to the “OFF ” position, then press and

Table 36 — Alarm and Alert Codes

ALARM/ALERT

CODE

0 —

1.xx

2.xx

5.xx

6.xx

CPM SUBCODES

(xx)

x.0 —No Error — — — — x.1 Alarm High Pressure Switch

x.2 Alarm No Motor Current CPM reads less than

x.25* Alarm Current Imbalance

x.27* Alert Current Imbalance

x.3 Alarm Current Imbalance

x.35 Alarm Single Phase Current

x.4 Alarm High Motor Current CPM detects high cur-

x.5 Alarm Ground Fault CPM detects ground

x.75 Alarm Contactor Failure CPM detects min. 10%

x.8 Alarm Current Phase

x.85 Alarm Motor Over

x.9 Alarm Open Thermistor CPM detects open cir-

x.95 Alarm Config. Header Fault CPM finds error with

x.10 Alarm Shorted Thermistor CPM detects short

ALARM OR

ALERT

See CPM subcodes below

DESCRIPTION

No Alarms or Alerts

Exist

Compressor A1 Failure

Compressor A2 Failure

Compressor B1 Failure

Compressor A2 Failure

Trip

>10% (Alarm)

>10% (Warning)

>25%

Loss

Reversal

Temperature

WHY WAS THIS

ALARM GENERATED?

——— —

See CPM subcodes below

HPS input to CPM module open

10% of MTA on all legs for >3 seconds

CPM measures current imbalance between phases greater than 10% for 25 minutes

CPM measures current imbalance between phases greater than 25% for 25 minutes

CPM measures current imbalance between phases greater than 50% (running current < 50% of MTA) or 30% (running current > of MTA) for 1 second

rent compared to MTA setting

current (4.5 ± 2.0 amps)

of MTA for 10 seconds after shutting off compressor contactor. Oil solenoid is energized.

CPM detects phase reversal from toroid reading or from incoming power supply

CPM detects high motor temperature

cuit in motor temp themistor

MTA value punched out in header

circuit in motor temp thermistor

50%

ACTION TAKEN

BY CONTROL

See CPM subcodes below

Comp. shut down Manual/Button Loss of condenser air/ water

Comp. shut down Manual/Button Power supply disconnected,

Circuit shut down Manual/Button Loose terminals on power

None — Loose terminals on power

Circuit shut down Manual/Button Loose terminals on power

Circuit shut down Manual/Button Blown fuse, wiring error, loose

Comp. shut down Manual/Button Operation beyond chiller

Comp. shut down Manual/Button Motor winding(s) gone to

All remaining compressors shut down. All loaders deenergized. Min. load valve of affected circuit energized (if equipped)

Circuit shut down Manual/Button Terminal block power supply

Comp. shut down Manual/Button Motor cooling (all) or Econo-

Comp. shut down Manual/Button Wiring error or faulty ther-

Comp. shut down Manual/Button Header pins on CPM board

Comp. shut down Manual/Button Wiring error or faulty

RESET METHOD

Manual See CPM subcodes Manual See CPM subcodes Manual See CPM subcodes Manual See CPM subcodes

Manual/Button Faulty contactor, contactor

below below below below

flow. Operation beyond chiller capability. Liquid valve not open.

blown fuse(s), wiring error, contactor not energized, faulty current toroid, check toroid wiring

wires. Poor power supply. Displayed only if current unbalance alarm feature is enabled

wires. Poor power supply. Displayed only if current unbalance alarm feature is disabled

wires. Poor power supply.

terminals

capability, improperly punched configuration header, blown fuse

ground, wiring error, loose plug connector.

welded, wiring error.

leads not in correct phase. Toroid wire harness crossed. Check compressor contactor.

mizer (2 comp. circuits) solenoid failure, low refrigerant charge.

mistor†

either all or none punched out, header not fully sealed in CPM board.

thermistor†

Each compres-

PROBABLE

CAUSE

Page 47

ALARM/ALERT

CODE

7 Alert Cir. A Discharge Gas

8 Alert Cir. B Discharge Gas

9 Alarm Cooler Leaving Fluid

10 Alarm Cooler Entering Fluid

11 Alert Condenser Leaving

12 Alert Condenser Entering

15 Aler t Compressor A1 High

16 Aler t Compressor A2 High

17 Aler t Compressor B1 High

18 Aler t Compressor B2 High

21 Alert External Reset Temper-

22 Alert Circuit A Discharge

23 Alert Circuit B Discharge

24 Alert Circuit A Suction

25 Alert Circuit B Suction

26 Alert Comp A1 Oil Pressure

27 Alert Comp A2 Oil Pressure

28 Alert Comp B1 Oil Pressure

29 Alert Comp B2 Oil Pressure

30 Alert Circuit A Economizer

ALARM OR

ALERT

DESCRIPTION

Thermistor Failure

Fluid Thermistor Failu re

Motor Temperature

ature Thermistor Failure

Pressure Transducer Failure

Transducer Failure

Table 36 — Alarm and Alert Codes (cont)

WHY WAS THIS

ALARM GENERATED?

Thermistor outside range of –40 to 245 F (–40 to 118 C) or DGT > 210 F (98.9 C)

Thermistor outside range of –40 to 245 F (–40 to 118 C)

Thermistor outside range of –39.9 to 245 F (–39.9 to 118 C) for 5 consecutive readings

Thermistor outside range of –40 to 245 F (–40 to 118 C)

Calibration offset more than 6 PSIG (41 kPa) or Voltage ratio (volts read/ ref. voltage) more than

99.9% or less than 0.5% Calibration offset more