Carrier 30GX090, 30HXA086, 30GX105, 30GX106, 30GX115 Controls, Start-up, Operation, Service, And Troubleshooting

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Controls, Start-Up, Operation,

Service, and Troubleshooting

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.). Only trained, qualiﬁed installers and servicemechanicsshould 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. Wear safety glasses and work gloves. Use care in handling, rigging, and setting this equipment, and in handling all electrical components.

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

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

To prevent potential damage to heat exchanger tubes always run ﬂuid through heat exchangers when adding or removing refrigerant charge.

DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of 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.

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

Page

SAFETY CONSIDERATIONS ...................1

GENERAL ...................................2

MAJOR SYSTEM COMPONENTS ..............3

Processor Module (PSIO-1) ...................3

DSIO-HV Relay Module .......................3

Electronic Expansion Device Module .........3

Compressor Protection Module (CPM) .........3

PSIO-2 (8052) Module ........................3

Keypad and Display Module

(Also Called HSIO-II) .......................3

Control (LOR) Switch .........................3

OPERATION DATA ..........................3-42

Electronic Expansion Device (EXD) ...........3

• EXV OPERATION

• ECONOMIZER OPERATION

Oil Pumps ...................................4

Motor Cooling ...............................4

Back Pressure Valve (30GX and 30HXA only) ..4

Sensors .....................................4

Compressor Protection Module (CPM) .........4

• OUTPUTS

• INPUTS

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

Starting Option ............................5

Capacity Control .............................6

• 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 .......................8

• GENERAL

• AIR COOLED UNITS (30GX)

• WATER COOLED UNITS (30HX)

• ADJUSTING PID ROUTINES

Cooler and Condenser (30HXC)

Pump Control .............................10

30GX080-265

30HXA,HXC076-271

ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers

50/60Hz

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

Book 2 Tab 5c

PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg 1 1-98 Replaces: 30G,H-2T

Series 0,1,2

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CONTENTS (cont)

Page

• COOLER PUMP CONTROL

• CONDENSER PUMP CONTROL

Cooler Heater Control .......................13

Keypad and Display Module

(Also Called HSIO-II) ......................13

• ACCESSING FUNCTIONS

AND SUBFUNCTIONS.......................13

• AUTOMATIC DEFAULT DISPLAY.............13

• STATUS FUNCTION .........................16

• TEST FUNCTION ...........................25

• HISTORY FUNCTION........................25

• SET POINT FUNCTION ......................25

• SERVICE FUNCTION ........................30

• SCHEDULE FUNCTION......................37

Temperature Reset ..........................39

• EXTERNAL TEMPERATURE RESET

• EXTERNALLY POWERED RESET

• RETURN FLUID TEMPERATURE RESET

Demand Limit ...............................39

• DEMAND LIMIT

• EXTERNALLY POWERED DEMAND LIMIT

• DEMAND LIMIT (CCN Loadshed Controlled)

TROUBLESHOOTING ......................43-52

Checking Display Codes ....................43

Unit Shutoff ................................43

Complete Unit Stoppage .....................43

Single Circuit Stoppage .....................43

Restart Procedure ...........................43

• POWER FAILURE EXTERNAL TO THE UNIT

Alarms and Alerts ...........................43

Compressor Alarm/Alert Circuit ..............43

EXD Troubleshooting Procedure .............50

• INSPECTING/OPENING ELECTRONIC EXPANSION VALVES

• INSPECTING/OPENING ECONOMIZERS

SERVICE ..................................52-66

Servicing Coolers and Condensers ..........52

• TUBE PLUGGING

• RETUBING

• TIGHTENING COOLER/CONDENSER HEAD BOLTS

Inspecting/Cleaning Heat Exchangers ........53

• COOLERS

• CONDENSERS (30HX Only)

Water Treatment ............................53

Condenser Coils (30GX Only) ................53

• COIL CLEANING

Condenser Fans (30GX Only) ................54

Refrigerant Charging/Adding Charge .........54

Oil Charging/Low Oil Recharging ............55

Oil Filter Maintenance .......................56

• REPLACING THE EXTERNAL OIL FILTER

• REPLACING THE INTERNAL OIL FILTER

Compressor Changeout Sequence ...........56

• BURNOUT CLEAN-UP PROCEDURE

Moisture-Liquid Indicator ....................58

Filter Drier ..................................58

Liquid Line Service Valve ....................58

Thermistors ................................58

• LOCATION

• THERMISTOR REPLACEMENT

Pressure Transducers .......................59

• PRESSURE TRANSDUCER CALIBRATION

• TROUBLESHOOTING

Safety Devices ..............................62

• COMPRESSOR PROTECTION

• OIL SEPARATOR HEATERS (30GX)

• COOLER PROTECTION

Relief Devices ..............................62

• PRESSURE RELIEF VALVES

Control Modules ............................64

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

• RED LED

• GREEN LED

Carrier Comfort Network (CCN) Interface .....64

• PROCESSOR MODULE (PSIO-1)

• HIGH VOLTAGE RELAY MODULE (DSIO-HV)

Replacing Defective Processor Module .......66

Winter Shutdown Preparation ................66

PRE-START-UP PROCEDURE ................67

START-UP AND OPERATION .................67

FIELD WIRING ............................68-73

APPENDIX A

(Compressor Must Trip Amps) ...........74-76

APPENDIX B

(Capacity Loading Sequence) ............77-79

APPENDIX C (Available Accessories) .........80

APPENDIX D (CPM Conﬁgurations) .........81-85

APPENDIX E (Cooler and

Condenser Pressure Drop) ...............86-88

APPENDIX F

(Typical System Components) ............89,90

INDEX ......................................91

START-UP CHECKLIST ..............CL-1 to CL-8

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 30GX080-265 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 in circuit B.

The 30GX/HX Series chillers feature microprocessorbased electronic controls and electronic expansion devices (EXD) in each refrigeration circuit.

The control system cycles compressor loaders and/or compressors to maintain the selected leaving ﬂuid temperature set point. The system automatically positions the EXD to maintain the speciﬁed refrigerant level in the cooler.Thesystem also has capabilities to control a condenser water valve to maintain suitable leaving-water temperature for the30HXC 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 HSIOII), 2 electronic expansion devices (EXDs), 1 compressor protection module (CPM) per compressor, a PSIO-2 module, 6 thermistors, and 8 transducers. Aremoteenhanceddisplay is available as an accessory.

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MAJOR SYSTEM COMPONENTS

Processor Module (PSIO-1) —

This module is an 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 (as required), 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 standarddisplaymodulethrougha3-wire communications bus called COMM3. The remote enhanced display (accessory) is connectedtothePSIO-1modulethrough 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 — The DSIO-HV module has

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 — The elec-

tronic 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.

CompressorProtectionModule(CPM)— The com-

pressor protection module monitors several of the compressor safeties and controls 4 of the outputs used to control each compressor. The CPM monitors compressor current, compressor voltage, high pressure switch status, and compressor motor temperature. The CPM controls the compressor contactors, oil solenoid, and motor cooling solenoid. Each CPM sends the PSIO-1 its circuit’s motor temperature, alarm status of the module, and the compressor relay status.

PSIO-2 (8052) Module — This module is used as an

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

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

This device consists of a keypad with 8 function 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 13.

Control (LOR) Switch — Control of the chiller is de-

ﬁned by the position of the LOCAL/OFF/REMOTE (LOR) switch. This is a 3-position manual switch that allows the 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 is different than the switch that is used in the Flotronic™ II controls conﬁguration. The CCN control is enabled through the HSIO-II. The switch allows unit operation as shown in Table 1.

In the LOCAL position, the chiller is allowed to operate 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

REMOTE

CONTACTS

CCN

CONFIGURATION

CCN

STATE

UNIT

MODE

OFF NR NR NR LOCAL OFF

LOCAL NR

DISABLE NR LOCAL ON

ENABLE

RUN CCN ON

STOP CCN OFF

REMOTE

OPEN NR NR LOCAL OFF

CLOSED

DISABLE NR LOCAL ON

ENABLE

RUN CCN ON

STOP CCN OFF

LEGEND

CCN — Carrier Comfort Network NR — Input Not Read by Processor

NOTE: Iftheunit is conﬁgured for aclock,then the unit isunderclock control if it is in an ON mode.

OPERATION DATA

Electronic Expansion Device (EXD) —

The microprocessor 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. Aseriesof calibrated slots are located inside the 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 thermistors wired in series, 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.Astherefrigerantlevel rises (falls) in the cooler, the resistance of the closest 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 accurately maintain a speciﬁed level.

The level sensor monitors the refrigerant liquid level in the cooler and sends this information to the PSIO-1. At initial start-up, 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.

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ECONOMIZER OPERATION — Economizers are factory installed on 30GX105-265 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.Abubbler tube supplies a small amount of discharge gas to ensure that the ﬂoat will be able to workproperly. As the refrigerantpassesthrough the EXD, its pressure is reduced to an intermediate 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 machine 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 in the compression cycle.

Oil Pumps — The 30GX/HX screw chillers use one ex-

ternally 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 and is not used again until the next start-up. 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 additional attempt to build oil pressure. The control generates an alarm if the second attempt fails.

Motor Cooling — Compressor motor winding tempera-

tures are controlled to a set point of 200 F (93.3 C). The control accomplishes this by cycling the motor cooling olenoid 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.

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

This valve is located on the oil separator outlet on 30GX units and mounted on the oil separator shell of 30HXAunits. 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 — The 30GX,HX control system (based on the

Flotronic™ II chiller control system)gathersinformationfrom sensors to control the operation of the chiller. The units use up to 9 standard pressure transducers, 7 standard thermistors (including 3 motor temperature thermistors), and 2liquidlevel thermistors to monitor and control system operation. The sensors are listed in Table 2.

Compressor Protection Module (CPM) — Each

compressor has its own CPM. 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

• voltage imbalance protection

• current imbalance protection

• compressor oil solenoid control

• motor cooling solenoid control

• sensor bus communications

• starting and running overcurrent protection

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

OUTPUTS:

• compressor contactor

• compressor oil solenoid

• compressor motor cooling solenoid

• Wye-Delta transition relay INPUTS:

• motor temperature

• three-phase voltage

• three-phase current

• high-pressure switch

Adiagram of the CPM board is shown in Fig. 1. There are line voltage inputs at L1, L2, and L3. Below these inputs are the current toroid inputs at Plug 1. Below Plug 1 are the 3 COMM3 communication terminals. In the lower left corner of the board are the inputs for motor winding temperature. The address DIP (dual-in-line package) switch and compressor must-trip amps header are factory set. For compressor A1, switches 2 and 4 should be set. For compressor A2 (30HXA,C206-271AND 30GX205-265), switches 2, 3, and 4 should be set. For compressor B1, switches 1 and 4 should be set.

T overifypropermusttripampsheaderconﬁguration,press

and use the up arrow key on the HSIO to locate the

must trip amp values. Press the reset button on the HSIO/ fuse panel to update these values. See Appendix A. If the values do not match those in Appendix A, verify with Appendix D that the conﬁguration headers have been properly punched out.

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Table 2 — Thermistor and Transducer Locations

THERMISTORS

Sensor Description Location Connection Terminals

T1 Cooler Leaving Fluid Temp Cooler Head Leaving Fluid Side PSIO-2, J7 pins 2,3 T2 Cooler Entering Fluid Temp Cooler Head Entering Fluid Side PSIO-2, J7 pins 5,6 Motor Temp A1 Motor Temperature A1 Compressor A1 Junction Box CPM-A1, T terminals Motor Temp A2* Motor Temperature A2 Compressor A2 Junction Box CPM-A2, T terminals Motor Temp B1 Motor Temperature B1 Compressor B1 Junction Box CPM-B1, T terminals T5 Discharge Gas TempA Top of Condenser Circuit A (30HXC Only) PSIO-2, J7 pins 8,9

Top of Oil Separator Circuit A (All Other Units)

T6 Discharge Gas Temp B Top of Condenser Circuit B (30HXC Only) PSIO-2, J7 pins 11,12

Top of Oil Separator Circuit B (All Other Units)

LL-A (T3) Liquid Level Circuit A Top of Cooler Circuit A PSIO-1, J7 pins 5,6 LL-B (T4) Liquid Level Circuit B Top of Cooler Circuit B PSIO-1, J7 pins 8,9 T7 (optional)† Outdoor Air Thermistor Outside Air Stream PSIO-2, J7 pins 20,21 STP (optional)† Space Temperature Conditioned Space PSIO-2, J7 pins 23,24 T8 (optional)† Condenser Entering Water Temp Condenser Entering Fluid Line PSIO-2, J7 pins 14,15 T9 (optional)† Condenser Leaving Water Temp Condenser Leaving Fluid Line PSIO-2, J7 pins 17,18

PRESSURE TRANSDUCERS

Sensor Description Location Connection Terminals DPT-A Discharge Pressure Circuit A Top of Condenser Circuit A (30HXC Only) PSIO-1, J7 pin 22

Top of Oil Separator Circuit A (All Other Units)

SPT-A Suction Pressure Circuit A Top of Cooler Circuit A PSIO-1, J7 pin 19 EPT-A Economizer Pressure Circuit A Economizer Line Entering Comp A PSIO-1, J7 pin 10 OPT-A1 Oil Pressure Compressor A1 Compressor A1 Oil Connection PSIO-1, J7 pin 25 OPT-A2* Oil Pressure Compressor A2 Compressor A2 Oil Connection PSIO-1, J7 Pin 1

DPT-B Discharge Pressure Circuit B Top of Condenser Circuit B (30HXC Only) PSIO-1, J7 pin 16

Top of Oil Separator Circuit B (All Other Units)

SPT-B Suction Pressure Circuit B Top of Cooler Circuit B PSIO-1, J7 pin 31 EPT-B Economizer Pressure Circuit B Economizer Line Entering Comp B PSIO-1, J7 pin 13 OPT-B Oil Pressure Compressor B Compressor B1 Oil Connection PSIO-1, J7 pin 28

*30HX206-271 only.

†Sensors are available as accessories for ﬁeld installation.

The CPM communicates on the COMM3 communication bus to the PSIO-1 module. Proper operation of theCPMboard can be veriﬁed by observing the 3 LEDs (light-emitting diodes) located on the board. The top LED is red and blinks at a rate of once every 1 to 2 seconds. This indicates that the module is powered and operating correctly.ThemiddleLED is yellow and blinks when there is an automatic reset alarm condition. The yellow LED remains on and does not blink for manual reset alarm conditions. The bottom LED is green and blinks when the module is satisfactorily communicating with the PSIO-1 module. The CPM communicates the status of its inputs and outputs, and reports 18 different alarm conditions to the PSIO-1. The alarms are listed in Table 3.

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 compressor and ‘‘xx’’ to the alarm value in Table 3 (decimal point removed). For example, the HSIO might displayAlarm 1.70 for a voltage phase reversal occurring on compressor A1. Similarly, the display would read 5.85 for a motor overtemperature condition on compressor B1.AlertsforcompressorsA2 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 4 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.

Table 3 — Compressor Protection Module

Feedback Codes

ALARM CONDITION VALUE

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 18% 3.0 Single Phase Current Loss 3.5 High Motor Current 4.0 Ground Fault 5.0 Voltage Imbalance Alarm 3% 5.5 Voltage Imbalance Warning 3% 5.7 Voltage Imbalance 7% 6.0 Voltage Phase Reversal 7.0 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

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

All 30GX,HX chillers operating at voltages of 208/230-3-60 or 230-3-50 (5 or 8 at Position 12 in model number) are supplied with factory installed Wye-Deltastarters. 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.

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Where current limitations exist, the Wye-Deltaoptionmay 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 Wye connected. The compressor will attain about 100% of its normal operating speed (approximately 3 to 6 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 mechanically 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 to the compressor and will require that the compressor be replaced.

Capacity Control — The control system cycles com-

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 external 4 to 20 mA signal (requires ﬁeldsupplied 500-ohm,1⁄2watt resistor), or from a network signal.

The capacity routine runs every 30 seconds. The routine attempts to maintain the Control Point at the desired set point. Each time it runs, the control reads the entering and leaving ﬂuid temperatures. The control determines the rate at which conditions are changing and calculates 2 variables based on these conditions. Next, a capacity ratio (Load/Unload Fac-

tor 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 starts (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 compressors, to minimize the number of starts and stops on each compressor.Adelay 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 to prevent all the units from restarting at once after a power failure. A value of zero for this variable does not mean that the unit should be running.

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

1. Thenextcompressor 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 in a circuit, the 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.

L1 L2

CURRENT TOROID INPUT PLUG

2 3

T T

TEMPERATURE

ADDRESS DIP SWITCH

COMM3

24/115/230 VAC

INPUTS/OUTPUTS

COMPRESSOR PROTECTION MODULE (CPM)

COMPRESSOR MUST TRIP AMPS HEADER

1 2

RED LED

YELLOW LED

GREEN LED

MOTOR INPUT

PUSH THIS SIDE OF SWITCH DOWN TO SET ADDRESS

1234

ROCKER DOWN

Fig. 1 — Compressor Protection Module

LED — Light-Emitting Diode

NOTES:

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

2. The yellowLEDblinks during automaticreset alarm, and is continuously lit when the manual reset alarm is active.

3. The green LID blinks continuously when communicating properly with PSIO-1.

Page 7

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.Allstagesofunloadingareavailable.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 (Version 3.0 and later) 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 30GX205-265 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.

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 initiated by energizing the Minimum Load valve relay.The control energizes loaders as needed thereafter. Similarly, the Minimum Load valve relay will be energized forthelaststage of capacity to be used before the circuit is shut down.

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

Deadband Multiplier — The user conﬁgurableDeadbandMultiplier ( ) 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.

COMPRESSOR JUNCTION BOX

JUMPER BARS

COMPRESSOR CONTACTOR

TERMINAL BLOCK

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

TERMINAL BLOCK

COMPRESSOR STARTER ASSEMBLY

COMPRESSOR JUNCTION BOX

Fig.3—Wye-Delta Compressor Wiring

Page 8

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 ( ) —Limitstherate of change of leaving ﬂuid temperature. If the unit is in a cooling mode and

conﬁgured for Ramp Loading, the control makes 2 comparisons before deciding to change stages of capacity. The control calculates a temperature difference between the control point and leaving ﬂuid temperature. If the differenceisgreater than 4° F (2.2° C) and the rate of change (°F or °Cperminute) is less 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 and the EXD is not opened any further. If the discharge superheat is less than 10° F (5.6° C) and decreasing, the EXD is closed 50 steps every 10 seconds. If the discharge superheat is less 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,thecontrol will compare the circuit Saturated Suction temperature with a predetermined freeze point. For water circuits, the freeze point is 28 F (−2.2 C). For brine circuits, the freeze point 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 cir-

cuits, the freeze point can be entered by pressing and scrolling 12 items down. The control will use the Brine

Freeze Point value less 6°F (3.3°C) as the freeze point to compare with the Saturated Suction temperature. The default for the Brine Freeze Point is 34 F (1.1 C) which means the control will use 28 F (−2.2 C) as the freeze point. This value is adjustable from −15 F to 34 F (−26.1 to 1.1 C). For

water (brine) circuits, if the Saturated Suction temperature falls below 34 F (1.1 C) (the Brine Freeze Point), 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 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) for30GX, 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 —Thecontrol 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 analog water valve (30HXC) to maintain the saturated condensing temperature to a conﬁgurable set point. The fans are staged or speed varied (30GX) or water valve controlled (30HX) based on each circuit’s saturated condensing temperature and compressorstatus.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 Table 4. Fan stage settings are shown in Table 5. AIR COOLED UNITS (30GX) — See Fig. 5 for condenser

fan locations.

47 46 45 44

43 42 41

0 200 400 600 800 1000

TIME (SECONDS)

2 STARTS

3 STARTS

DEADBAND EXAMPLE

LWT (F)

MODIFIED DEADBAND

STANDARD DEADBAND

LWT (C)

LEGEND

LWT — Leaving Water

Temperature

Fig. 4 — Deadband Multiplier

Page 9

No Motormastert Control — The fans are controlled based on Saturated Condensing Temperature. The ﬁrst fan stage for each circuit is turnedonwheneverthecompressoristurned on.Afan stage is added when the Saturated Condensing Temperature (SCT) exceeds the Head Pressure Set Point. The Head Pressure Set 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.Thecontrolusesthehigher of the 2 Saturated Condensing Temperature values for 30GX080-150 and 160 units. For the 30GX151 and 161-265 units, each circuit’s fan stages are independently controlled based on the circuit Saturated Condensing Temperature. Refer to Table 6 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. This controller can be used in one of 2 ways. 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. To obtain this accessory for ﬁeld installation, order by part number 30GX-900---012forasinglecontroller package (30GX080150 and 160). Order part number 30GX-900---014 for a dual controller package (30GX151 and 161-265). 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 161-265 units, each circuit’s fan stages are independently controlled based on the circuit Saturated Condensing Temperature. Refer to Table6 for condenser fan staging information.

WATER-COOLED UNITS (30HX) — The 30HX chillers can be conﬁgured to control direct or reverse-acting water valves that are controlled bya4to20mAsignal. A 2 to 10 VDC signal can be used by installing a 500-ohm resistor across the 2 output terminals of the 4 to 20 mA signal. This 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 both the water and 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.

Table 4 — Field Conﬁgured Chiller Options

CONFIGURATION OPTION DESCRIPTION HSIO LOCATION FACTORY CONFIGURED?

Fan Staging Select Air cooled staging method

Yes. See Table 5

Motormaster Control Select Applies to air cooled units only

Yes. 0 = None

Set to 1 to enable (Motormaster only)

Water Valve Type Applies to water cooled unit only

Yes. 0 = None

Setto1=4−20mA,2=0−10V,

3=20−4mA,4=10−0V

Table 5 — Fan Staging Settings for Air Cooled (30GX) Units

UNIT 30GX DESCRIPTION OPTION NUMBER

080-105

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

106-125

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

136, 150, 160

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

151, 161, 175,

205, 225

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

176

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

206, 226, 250

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

251, 265

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

LEGEND

SCT — Saturated Condensing Temperature

Page 10

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 default values are located in the Service function. See page 30. 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. The default for the derivative term is zero. This valve is used to control ‘‘droop,’’which is common in master/ submaster control schemes. The value should not need to be changed.

Cooler and Condenser (30HXC) Pump Control —

The 30GX and 30HX chillers can be conﬁgured forcooler and condenser (30HXC) pump control. Inputs for a cooler ﬂow switch or interlock and condenser ﬂow switch are also provided.

COOLER PUMP CONTROL ( ) — The factory default setting for cooler pump control is ‘‘Not Controlled.’’

All chillers are enabled at the factory for cooler pump interlock. See page 71 of Field Wiring section for wiring of cooler ﬂow switch and/or cooler pump interlock contacts. Whether cooler pump control is enabled or not, the control generates an alarm if this input does not close within one minute after the unit switches to an occupied mode or the cooler pump is turned on. See Alarms and Alerts section, page 43 for a description of Alarms 53-55. If cooler pump control is enabled, the control waits one minute and checks the interlock or switch input before starting to determine if cooling is needed. The cooler pump is turned on when the chiller is in the occupied mode and turned offotherwise.The cooler pump is turned on in either of two override conditions: If the cooler freeze protection alarm has been generated, the cooler pump is turned on if not already running. If a cooler heater is being used and has been on for more than 15 minutes during saturated suction freeze protection, the cooler pump is turned on.

CONTROL BOX END

13 5 7

24 6 8

CONTROL BOX END

7911

6810

CONTROL BOX END

Fig. 5 — 30GX Condenser Fan Locations

30GX080-105 30GX106-125

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

30GX206, 226, 250

30GX136, 150, 160

30GX251, 265

Page 11

Table 6 — 30GX080-265 Condenser Fan Staging (PSIO-1 Controlled)

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

080-105

Standard

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

High Static

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

106-125

Standard

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

High Static

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

136, 150,

160

Standard

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

High Static

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

151, 161, 175

205, 225

Standard

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

High Static

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

176

Standard

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

High Static

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

206, 226, 250

Standard

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

High Static

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

251, 265

Standard

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

High Static

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

LEGEND

Comp. — Compressor FC — Fan Contactor

*Fan Relay number displayed when using to test fans.

†Proper rotationof these fans tobe checked whencompressor(s) is running.SeeFig. 5 forcondenser fan locationswhen viewing

from the control box end.

Page 12

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 Type 1 using

the Service function). The second method of control is to turn the pump on when the ﬁrst compressor is started and off when the last compressor is turned off (set to Type 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 is generated if the ﬂow switch input is not closed.

READ CIRCUIT SATURATED CONDENSING TEMPERATURE AND CURRENT FAN STAGE

IS SCT GREATER THAN HEAD PRESSURE SET POINT?

INCREASE CURRENT FAN STAGE BY ONE

ADD 15° F TO HEAD PRESSURE SET POINT FOR NEXT 35 SECONDS

DECREASE CURRENT FAN STAGE BY ONE

HAS SCT BEEN 35° F LESS THAN HEAD PRESSURE SET POINT 2 MINUTES?

YES

LEGEND

SCT — Saturated Condensing Temperature

Fig. 6A — 30GX Head Pressure Control Without MotormasterT III Control

30GX UNITS — MOTORMASTER III CONTROL NOT INSTALLED

30GX UNITS — MOTORMASTER III CONTROL INSTALLED

DECREASE CURRENT FAN STAGE BY ONE

YES

IS SCT GREATER THAN HEAD PRESSURE SET POINT PLUS 15F?

INCREASE CURRENT FAN STAGE BY ONE

YES

READ CIRCUIT SATURATED CONDENSING TEMPERATURE AND CURRENT FAN STAGE

INCREASE CURRENT FAN STAGE BY ONE

YES

CALCULATE NEW PID VALUE. DOSE OUTPUT REQUIRE MORE FANS?

OUTPUT NEW mA SIGNAL TO CONTROLLER

DOES PID OUTPUT REQUIRE LESS FANS?

LEGEND

PID — Proportional Integral Derivative SCT — Saturated Condensing Temperature

Fig. 6B — 30GX Head Pressure Control With Motormaster III Control

Page 13

Cooler Heater Control — Accessory cooler heaters

can be ordered for the 30GX chillers. If installed and enabled, 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.

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

This module allows the operator to communicate 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 7 shows a brief description of the keypad buttons. Table 8A shows the 6 functions (identiﬁed by name) and the subfunctions (identiﬁed by number). Table 8B shows the 6 functions (identiﬁed by name) and the subfunctions (identiﬁed by number) when using the optional LID-2B controller. Table 9 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 press to go directly to A1 Oil Pressure. Use a simi-

lar procedure to view an item near the bottom of a subfunction. To view the Circuit A Oil Switch status, press and . Use a similar procedure to view an item near

the bottom of a subfunction. Toview Condenser Pump Flow Switch status, press , , and . This proce-

dure is available in all functions except the TEST function. AUTOMATIC DEFAULT DISPLAY — When the keypad

has not been used for 10 minutes, the display automatically switches to the rotating automatic default display. This display contains the 5 parts shown below.

Entering Fluid Temp

xx.x° F

Leaving Fluid Temp

xx.x° F

Percent Total Capacity

xxx.x%

Total Number of Alarms

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.

Table 7 — Keypad and Display Module Usage

FUNCTION

KEYS

USE

STATUS — For displaying diagnostic codes and current operating information about the machine.

HISTORY — For displaying run time, cycles, and previous alarms.

SERVICE — For entering speciﬁc unit conﬁguration information 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 day/time information. TEST — For testing operating of the analog and

discrete outputs.

OPERATIVE

KEYS

USE

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.

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

Page 14

Table 8A — HSIO Functions and Subfunctions

SUBFUNCTION

NO.

FUNCTIONS

Status

Test Schedule Service History Set Point

Alarm Display

Circuit A Discrete Outputs

Ice Build Occupancy Schedule

Factory Conﬁguration

Operating Hours Set Points

General Parameters Display

Circuit B Discrete Outputs

Local/Normal Occupancy Schedule

Options Conﬁguration 1

Alarm History English/Metric

Circuit A Analog Values

Unit Discrete Outputs

Remote CCN Occupancy Schedule

Options Conﬁguration 2

— Bus Address

Circuit A Discrete Inputs/ Outputs Table

Valves and MotormasterT Control

Holiday 01 Conﬁguration

Reset/Demand Limit Conﬁguration

— Time/Date

Conﬁguration

Circuit B Analog Values

— Holiday 02

Conﬁguration

Machine Conﬁguration Codes

— CCN

Enable/Disable

Circuit B Discrete Inputs/ Outputs Table

— Holiday 03

Conﬁguration

———

Unit Analog Parameters

— Holiday 04

Conﬁguration

Transducer Calibration

——

Miscellaneous Inputs/Outputs

— Holiday 05

Conﬁguration

Manual Control — —

Operating Modes — Holiday 06

Conﬁguration

Master/Slave Conﬁguration

——

Capacity Control — Holiday 07

Conﬁguration

———

Dual Chiller — Holiday 08

Conﬁguration*

———

*Subfunctions through are for conﬁguring Holidays 09 through 30.

Page 15

Table 8B — Functions and Subfunctions Cross-Reference for the Optional LID-2B Controller

The optional LID-2B 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 8A). For example, in Table 8A, the alarm history is accessed through the HSIO by pressing 2 and the History button on the keypad (see Table 7). The LID-2B cross

reference table lists the menu item from the LID-2B which contains the alarm history information. In another example, from Table 8A, 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 LID-2B menu.

HSIO

SUBFUNCTION

NO.

HSIO FUNCTION KEY

Status

Test Schedule Service History Set Point

STATUS A_UNIT_1

SERVICE CONTROL TEST

SCHEDULE OCCPC012

SERVICE EQUIPMENT CONFIGURATION

SERVICE EQUIPMENT CONFIGURATION STRTHOUR

SETPOINT

STATUS A_UNIT_1

SERVICE CONTROL TEST

SCHEDULE OCCPC02S

SERVICE EQUIPMENT CONFIGURATION OPTIONS1

SERVICE ALARM HISTORY

SERVICE LID CONFIGURATION

STATUS CIRCA_AN

SERVICE CONTROL TEST

SCHEDULE OCCPC65S

SERVICE EQUIPMENT CONFIGURATION OPTIONS2

—

SERVICE CONTROLLER IDENTIFICATION

STATUS CIRA_DIO

SERVICE CONTROL TEST

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_01

SERVICE EQUIPMENT CONFIGURATION RESETCON

—

SERVICE TIME AND DATE

STATUS CIRCB_AN

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_02

SERVICE EQUIPMENT CONFIGURATION CONCODES

—

STATUS A_UNIT_1

STATUS CIRB_DIO

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_03

———

STATUS UNIT_2

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_04

SERVICE EQUIPMENT SERVICE CALIBRTE

——

STATUS UNIT_3

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_05

SERVICE EQUIPMENT SERVICE MAN_CTRL

——

STATUS MODE_TBL

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_06

SERVICE EQUIPMENT CONFIGURATION MSTR_SLV

——

SERVICE CONTROL ALGORITHM STATUS LOADFACT

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_07

———

SERVICE CONTROL ALGORITHM STATUS LEADLAG

—

SERVICE EQUIPMENT CONFIGURATION HOLIDAY,HOLDY_08*

——

—

*Subfunctions through are for conﬁguring Holidays 09 through 30, and are also found under Service, Equipment

Conﬁguration.

NOTE: The optional LID-2B controller uses the same password (1111) as the HSIO.

Page 16

Table 9 — Accessing Functions and Subfunctions

OPERATION KEYPAD ENTRY DISPLAY RESPONSE

To access a function, press subfunction no. and function name key. Display shows subfunction group.

Circuit A Discrete Outputs Loader A1

Relay is OFF

To move to other elements, scroll up or down using arrow keys.

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

When the last element in a subfunction has been displayed, the ﬁrst element is repeated.

Loader A1 Relay is OFF

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 B Discrete Outputs

Loader B1 Relay is OFF

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

STATUS FUNCTION — This function shows the rotating display, current status of alarm and alert (diagnostic) codes, capacity stages, operating modes, chilled water set point, all measured system temperatures and pressures, analog inputs, and switch inputs. Refer to Table 10 for a complete description of the function.

Alarms/Alerts — Alarms and alerts are messages that one or more faults have been detected. The alarms and alerts indicate 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. Toviewthem,

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. See Table 11.

IMPORTANT: Do not clear the alarms without ﬁrst reviewing the full list and investigating and correcting the cause of the alarms.

When an alarm or alert is stored in the display and the

machine automatically resets, the alarm/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 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 Table 10. CircuitAand B Analog and Discrete Information —Circuit

A Analog Values can be viewed bypressing 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 dis-

played. Press and to view the identical analog values and discrete inputs and outputs for Circuit B. See

Table 10 for a complete display.

Page 17

Unit Analog Parameters and Temperature Reset — Press

and scroll down to display the unit entering and leav-

ing 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 con-

denser 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 10 for a complete list.

Modes —Theoperatingmodesaredisplayed to indicate the operating status of the unit at a given time. See Table 12 for a complete list of all modes.

To enter the MODES subfunction, press and use

the key to view all current modes of operation. See Table 13.

Capacity Control — Pressing , this subfunction displays the load/unload factor, control point, and leav-

ing 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 18

Table 10 — Status Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Alarms

Alarm : xx Reset Alarms: 1 <ENTER>

All current alarms are displayed Use as needed

2 General Parameters GENERAL PARAMETERS

Displays LOCAL ON/OFF or CCN ON/OFF

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

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

3 Circuit A Analog Values

CIRCUIT A ANALOG VALUES

Percentage of total circuit capacity currently in use.

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

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

See Legend on page 23.

Page 19

Table 10 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

3 Circuit A Analog Valves (cont)

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 A1 Feedback x.x Volts

See Table 3.

CPM A2 Feedback x.x Volts

See Table 3.

Circuit A Econ Pressure xxx.x PSI

4 Circuit A Discrete Inputs/Outputs

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

5 Circuit B Analog Values

CIRCUIT B ANALOG VALUES

Percentage of total circuit capacity currently in use.

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

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

Page 20

Table 10 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

5 Circut B Analog Valves (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

See Table 3.

CPM B2 Feedback x.x Volts

See Table 3.

Circuit B Econ Pressure xxx.x PSI

6 Circuit B Discrete Inputs/Outputs

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

7 Unit Analog Parameters

UNIT ANALOG PARAMETERS Cooler Entering Fluid

xx.x dF Cooler 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 Legend on page 23.

Page 21

Table 10 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

7 Unit Analog Parameters (cont)

TEMPERATURE RESET 4-20 mA Reset Signal

xx.x mA Return Reset Signal

xx.x dF External Reset Signal

xx.x dF Outdoor Air Temp

xx.x dF Calculated Reset

xx.x dF

8 Misc. Inputs/Outputs

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 xx.x 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/No

Heat/Cool Switch Heat/Cool

Dual Set point Switch Off/On

Cooler Heater Off/On

Options Temperature 1 xx.x dF

Not Used

Options Temperature 2 xx.x dF

Not Used

9 Operating Modes

MODES :MODE_TBL mode name ON/OFF

Only active modes displayed LOCAL OFF Scroll with down arrow key to display CCN OFF

Page 22

Table 10 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

9 Operating Modes (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 DELAYACTIVE 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

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 23

Table 10 — Status Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 11 Dual Chiller

DUAL CHILLER Unit Master / Slave

0/1/2

0 = Neither 1 = Slave 2 = Slave

Master / Slave Ctrl Active Yes/No

Lead Chiller 1/2

1 = Master 2 = Slave

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

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

Slave Chiller Total Cap xxx.x%

Lead / Lag Changeover Yes if Lead / Lag Balance Enabled Master / Slave Error

1/2/3/4/5/6

1 = Master / Slave 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

LEGEND

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

Table 11 — Reading and Clearing Alarms

KEYPAD ENTRY DISPLAY COMMENT

Alarm: 02 Reset Alarms: 1 <ENTER>

Comp A1 Fail - 1.70 Volt Alarm : 15:12 04/15/96

Comp A1 Fail - 1.70 Volts 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>

Press Reset button ﬁrst

Alarm: 00 Reset Alarms: 1 <ENTER>

Alarms reset and cleared

Entering Fluid Temp xx.x dF

Returns to rotating default display

Leaving Fluid Temp xx.x dF

Percent Total Capacity xxx.x%

Total Number of Alarms xx

MODES: MODE

TBL

List of All Current Modes

Page 24

Table 12 — Operational and Mode Display Codes

CODE DESCRIPTION

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

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

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

in 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.

CLOCK OFF Unit is off due to internal clock schedule.

LOR switch is in LOCAL position.

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

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

CCN ON Unit is on due to CCN command. LOR

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

CLOCK ON Unit is on due to internal clock schedule or

occupied override function. LOR switch is in LOCAL position.

DUAL SP ACTIVE (1st SP)

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 SP ACTIVE (2nd SP)

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 ACTIVE

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 return ﬂuid, outdoor-air temperature, space temperature, or 4 to 20 mA signal.*

DEMAND LIMIT ACTIVE

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.*

FSM CONTROLLING

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

RAMP LOADING ACTIVE

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 function in (page 25). 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 ACTIVE

Timed override is in effect. This isa1to 4 hour temporary override of the programmed schedule, forcing unit to occupied mode. Override can be implemented with unit under LOCAL/REMOTE or CCN control. Override expires after each use.

WSM CONTROLLING

Water System Manager is controlling the chiller.

SLOW CHANGE OVERRIDE

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

CODE DESCRIPTION

OFF TO ON DELAY ACTIVE

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.

LOAD LIMIT ACTIVE

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.

2 CHILLR LEAD LAG ACTIVE

Future Use.

2 CHILLR LL COMM FAILURE

Future Use.

CIRCUIT A LOW DISCHARGE SUPERHT

If the circuit discharge superheat is less than 15° F (8.3° C), the capacity control routine will not add any stages (to either circuit).

If the compressor has been running for at least 3 minutes, the EXV will not be opened any further. If the circuit discharge superheat is less than 10° F (5.6° C) and falling, the circuit EXV will be closed 50 steps every 10 seconds.

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.

CIRCUIT B LOW DISCHARGE SUPERHT

See description for Circuit A above.

CIRCUIT A HIGH SCT

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 operating 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.

CIRCUIT B HIGH SCT

See description for Circuit A above.

LEGEND

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

*Aﬁeld-supplied500Ohm

⁄2W resistor must be installed across the

input terminals when usinga4to20mAsignal.

Table 13 — Reading Current Operating Modes

KEYPAD ENTRY DISPLAY

MODES :MODE_TBL CCN ON

DEMAND LIMIT ACTIVE

Page 25

TEST FUNCTION — The test function operates the diagnostic 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 Table 14 for a com-

plete description of the test function.

To start a test of discrete outputs, press . To end the test, simply press the key or press . Pressing 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 solenoids. Similarly, Circuit B discrete outputs can be tested in

.Additionaldiscrete outputs, including condenser fans,

cooler heater, water pumps, and remote alarms can be tested in .

Press to access Valves and Motormastert device 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 EXV to 50%, 75%, and 100%. The EXV may be closed in 25% steps by pressing for each desired step. Wait

30 seconds 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 page 72 of Field Wiring 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. 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 automatically leaves the test function

and resumes the normal rotating display. See Table 15. 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 16 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 Table 17 for a complete description of the function.

Cooling Set Point 1,2

Water:

Medium

Temperature Brine:

Low

Temperature Brine:

38 to 70 F

(3.3 to 21.1 C)

14 to 70 F

(−10 to 21.1 C)

−13 to 70 F

(−25 to 21.1 C)

Reset Set Points

Maximum

Reset Range:

−30 to 30 F

(−17 to 17 C)

External Temperature

Reset:

−40 to 240 F

(−40 to 118 C)

Chiller Fluid D:

0° to 15 F

(0° to 8 C)

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

500 Ohm resistor) Demand Limit Set Points Switch Input: Step1—0to100% Capacity Reduction

Step2—0to100% Capacity Reduction

External Signal: Maximum Demand Limit 4 to 20 mA

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

(2-10 vdc with 500 Ohm 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) Water cooled chillers (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 measure being used. Type 0 is for English and type 1 is for

Metric. Address — For CCN conﬁgurations, press and

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

Time — Press and scroll down to read and change the unit day of week, time, day of month, month of year and

year of century. See the examples in Table 17 for making changes to these values.

CCN Enable/Disable — Press to disable the CCN control of the chiller. This function will override CCN con-

trol commands. The CCN Enable value under must be ON to activate this function. With CCN Enable set 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 18 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 17 for the sequence of display of set points in each subfunction.

Page 26

Table 14 —Test Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Circuit A Discrete Output

Circuit A Discrete Output Loader A1 Relay is OFF

Loader A1 Relay is ON

Loader A2 Similarly, use to test remaining outputs. Press the

down arrow key or to turn an output off.

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

NOTE: Output will display Relay is ABSENT when not conﬁgured

2 Circuit B Discrete Outputs

Circuit B Discrete Outputs Loader B1 Relay is OFF

Loader B1 Relay is ON

Loader B2 Similarly, use to test remaining outputs. Press the

down arrow key or to turn the output off.

Minimum Load Valve B 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 Relay is ABSENT when not conﬁgured

3 Unit Discrete Output

Unit Discrete Output Fan 1 Relay is OFF

Fan 1 Relay is ON

Fan 2 Similarly use to test remaining outputs. Press the

down arrow key or to turn output off.

Fan 3 Fan 4 Fan 5 Energizes Circuit A fans for 30HXA units. Fan 6 Energizes Circuit B fans for 30HXA units. Cooler Pump Condenser Pump Cooler Heater Alarm Remote Alarm 1 Currently not supported.

Page 27

Table 14 —Test Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

3 Unit Discrete Output (cont)

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.

4 Valves and Motormaster

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

Circuit A EXV Valve Target Percent = 25%

Step in 25% increments.

Circuit A EXV Valve Target Percent = 50%

Wait 30 seconds between each step for valve to stop moving.

Circuit A EXV Valve Target Percent = 75%

Valve may be closed in 25% increments by keying in . Wait 30 seconds between each step for valve to stop moving.

Circuit A EXV Valve Target Percent = 100%

Circuit B EXV Valve Target Percent = 0%

Test same method as for Circuit A

Circuit A Water Valve Target Percent = 0%

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

LEGEND

EXV — Electronic Expansion Valve

Table 15 — Using Test Function

KEYPAD ENTRY DISPLAY RESPONSE COMMENTS

Circuit A Discrete Output Loader A1 Relay is OFF

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

Loader A1 Relay is ON

Compressor Loader A1 solenoid energized

Loader A1 Relay is OFF

Compressor Loader A1 solenoid deenergized

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

Circuit A EXV Valve Target Percent = 25%

Continue pressing to step to 50%, 75%, and 100%.

Circuit A EXV Valve Target Percent = 0

Continue pressing to step closed.

LEGEND

EXV — Electronic Expansion Valve

Page 28

Table 16 — History Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Operating Hours

Machine Operating Hours xxx.x hours

Number of hours unit has at least 1 compressor running

Number of unit starts from zero capacity

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

Machine Starts xxx

Circuit A 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 Operating Hours

xxx.x hours Compressor B1 Hours

xxx.x hours Compressor B2 Hours

xxx.x hours Starts

Compressor B1 Starts xxx

Compressor B2 Starts xxx

2 Alarm History

Previous Alarm 1 - description Alarm description, time/day of occurrence

Lists 10 most recent alarms. Use key when necessary

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

Page 29

Table 17 — Set Point Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Set Point Table

COOLING Cool Setpoint 1

xx.x dF

Default: 44.0

Cool Setpoint 2 xx.x dF

Default: 44.0

Cooling Ramp Loading xx.x dF

Default: 0.5 HEATING NOT SUPPORTED Heat Setpoint 1

xx.x dF

NOT SUPPORTED

Default: 98.0 Heat Setpoint 2

xx.x dF

NOT SUPPORTED

Default: 98.0 Heating Ramp Loading

xx.x dF

NOT SUPPORTED

Default: 0.5 HEAD PRESSURE

Head Pressure Setpoint A xxx.x dF

Default: 113.0 (GX)

100.0 (HXA) 85.0 (HXC)

Head Pressure Setpoint B xxx.x dF

Default: 113.0 (GX)

100.0 (HXA) 85.0 (HXC)

DEMAND LIMIT Demand Switch 1 Setpoint

xxx.x%

Default: 80.0% Demand Switch 2 Setpoint

xxx.x%

Default: 50.0% LCW Delta Alarm Limit

xxx.x dF

Default: 50.0 dF Minutes Off Time

xxx min

Default: 0 min Motor Temp Set Point

xxx.x dF

Default: 200.0 dF

2 Units

US IMPERIAL/METRIC 0

0 = English (Default)

1 = Metric

3 Address

TARGETADDRESS x

Default: 1 TARGET BUS NUMBER

Default: 0

4 Time

Day of Week Monday

Mon=1, Tues=2, etc. Day of Week

Wednsday

Day of week set TIME (HOUR:MIN)

00:00

Enter military format TIME (HOUR:MIN)

10:30

Time of day set DAY OF MONTH

xx DAY OF MONTH

Day of month set MONTH OF YEAR

xx MONTH OF YEAR

Month of year set YEAR OF CENTURY

xx YEAR OF CENTURY

Year of century set

5 CCN Disable

Disable CCN Control x

0=no, 1=yes

Default: 0

LEGEND

CCN — Carrier Comfort Network LCW — Leaving Chilled Water

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

Page 30

Table 18 — Reading and Changing

Chilled Fluid Set Point

KEYPAD ENTRY DISPLAY RESPONSE COMMENTS

COOLING Change set point from

default to 48 F.

Cool Set point 1

44.0 F default Cool Set point 1

48.0 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 19 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 Table 20.

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 21 for an example of how to

enter the password to change the Lead/Lag conﬁguration. Options Conﬁguration Tables 1 and 2 — These subfunc-

tions can be accessed by pressing or and scrolling down to display the conﬁguration options. See Table 19

for a complete list of these options. Temperature Reset, Demand Limit and Head Pressure PID

Conﬁgurations —Press andscrolldowntoview the conﬁguration information. See Table 19 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 22 for a descriptionofthefactory 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 22. 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. Table23shows how to conﬁgure a new PSIO-1 module for use in a 30HXC106---501CA water cooled chiller.

Transducer Calibration — Press and scroll down to view the transducer calibration information. See Table 19

for a complete list, and the Pressure Transducers section on page 59 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 such 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 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 19 for a complete list of this function.

Scroll down and press to start the desired com-

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 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 will NOT work with the Flotronic™ System Manager (FSM). 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.BoththeMasterand 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 oper-

ate independently. This value can be activated through the HSIO or through a CCN device. Both chillers should be con-

ﬁgured 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 dis-

abled 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 31

Table 19 — Service Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Service Conﬁguration

Software CESR_500100 Ver xxx

Unit Type x

1 = Air-cooled,2=Water-cooled 3 = Split system

Number of Cir A Comp x

Compressor A1 Tonnage xx

Compressor A2 Tonnage xx

Oil Switch Conﬁguration x

Number of Cir B Comp x

Compressor B1 Tonnage xx

Compressor B2 Tonnage xx

Max. Cond. Temp Setpoint xxx.x dF

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

MOP Set point xx.x dF

Default = 52 F (11.1 C)

Fan Staging Select x

Displays ‘‘Not Used’’ or a number. See Table 5

CPM Board Used? Yes

Compr. A1 Must Trip Amps xxx.x

Value from CPM module. See Appendix A.

Compr. A2 Must Trip Amps xxx.x

Value from CPM module. See Appendix A.

Compr. B1 Must Trip Amps xxx.x

Value from CPM module. See Appendix A.

Compr. B2 Must Trip Amps xxx.x

CURRENTLY NOT USED

2 Options Conﬁguration 1

Cooler Fluid Select x

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

Min. Load Valve Select x

Displays Enable/Dsable Default: Dsable

Loading Sequence Select x

1 = Equal circuit, 2 = Staged circuit Default: 2. See page 6

Lead/Lag Sequence Select x

1 = Automatic (Default), 2 = Circuit A leads, 3 = Circuit B leads

Head Press. Control Type x

0 = None (Default, HX), 1 = Air cooled (Default, GX),2=Water cooled

Motormaster Select x

0 = None (Default), 1 = Direct control

Water Valve Type x

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

Ext. Reset Sensor Select x

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

Cooler Pump Interlock x

0 = No interlock 1 = Interlock enabled (Default)

Cooler Pump Control x

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

Condenser Pump Control x

0 = Not controlled (Default) 1 = On/Off Control 2 = Off when stages equal 0 (unit off)

Condenser Flow Switch x

Displays Enable/Dsable Default: Dsable

Condenser Water Sensors x

0 = Not used (Default), 1 = Used

Heat Reclaim Sensors x

CURRENTLY NOT SUPPORTED

3 Options Conﬁguration 2

Cooling Setpoint Select x

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

Heating Setpoint Select x

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

See Legend on page 34.

Page 32

Table 19 — Service Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

3 Options Conﬁguration 2 (cont)

Ramp Load Select x

0 = Disabled, 1 = Enabled (Default) See page 8

Clock Control Select x

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

Ice Conﬁguration Selectx0 = Disabled (Default)

1 = Clock Control 2 = Demand Limit Control

OAT Sensor Select x

0 = Disabled, 1 = Enabled Default: 0

Remote Alarm Select x

0 = Disabled, 1 = Enabled Default: 0

Alarm Reset Select x

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

Close Control Select x

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

Deadband Multiplier x.x

Default: 1.0

Current Unbalance AlarmxAlarm at 10% imbalance; 0 = Disabled, 1 = Enabled

Default: 1

Voltage Unbalance AlarmxAlarm at 3% imbalance; 0 = Disabled, 1 = Enabled

Default: 1

4 Reset Conﬁguration Table

COOLING RESET TYPE1See Demand Limit section, page 39 Degrees Reset at 20 mA

xx.x dF

Default: 0

COOLING RESET TYPE 2

Remote temp=No Reset xx.x dF

Default: 20

Remote temp=Full Reset xx.x dF

Default: 125

Degrees Reset xx.x dF

Default: 0

COOLING RESET TYPE 3

CHW Delta T=No Reset xx.x dF

Default: 15

CHW Delta T=Full Reset xx.x dF

Default: 0

Degrees Reset xx.x dF

Default: 0 COOLING RESET Select/Enable Reset Typex0 = No Reset (Default),1=4-20 mA Reset,

2 = External Reset, 3 = Return Fluid Reset HEATING RESET TYPE1CURRENTLY NOT SUPPORTED

Degrees Reset at 20 mA xx.x dF

Default: 0 HEATING RESET TYPE2CURRENTLY NOT SUPPORTED Remote temp=No Reset

xx.x dF

Default: 125 Remote temp=Full Reset

xx.x dF

Default: 20 Degrees Reset

xx.x dF

Default: 0 HEATING RESET TYPE3CURRENTLY NOT SUPPORTED HTW Delta T=No Reset

xx.x dF

Default: 15 HTW Delta T=Full Reset

xx.x dF

Default: 0 Degrees Reset

xx.x dF

Default: 0 HEATING RESET Select/Enable Reset Typex0 = No Reset (Default), 1 = 4-20 mA reset,

2 = External reset, 3 = Return Fluid reset DEMAND LIMIT See Demand Limit section, page 39

Demand Limit at 20 mA xxx.x%

Enter 0-100, Default: 0%

Page 33

Table 19 — Service Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

4 Reset Conﬁguration Table (cont)

Demand Limit Select x

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

Loadshed Group Numberx0-99, Default: 0 Loadshed Demand Delta

xxx%

0-60%,Default: 0

Maximum Loadshed Time xx min

0-120 min, Default: 60 min WATER VALVE PID Proportional PID Gain

x.x

Default = 1.0

Adjustable from -20.0 to 20.0 Integral PID Gain

x.x

Default = 0.1

Adjustable from -20.0 to 20.0 Derivative PID Gain

x.x

Default = 0.0

Adjustable from -20.0 to 20.0 AIR MOTOR MASTER

PID Proportional PID Gain

x.x

Default = 1.0

Adjustable from -20.0 to 20.0 Integral PID Gain

x.x

Default = 0.1

Adjustable from -20.0 to 20.0 Derivative PID Gain

x.x

Default = 0.0

Adjustable from -20.0 to 20.0

5 Factory Conﬁguration Codes

FACTORY CODES Conﬁguration Code 1

xxxxxxxx

Factory set. See Table 22. Conﬁguration Code 2

xxxxxxxx

Factory set. See Table 22. Conﬁguration Code 3

xxxxxxxx

Factory set. See Table 22. SERVICE CODES Conﬁguration Code 4

xxxxxxxx

Factory set. See Table 22. Conﬁguration Code 5

xxxxxxxx

Factory set. See Table 22.

6 NOT USED 7 Transducer Calibration

CALIBRATION OFFSET See Pressure Transducer Calibration, page 59 CIRCUIT A PRESSURE 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 Calibrate All at 0 PSIG

No Last Calibration Date

mmm dd - yy

See Legend on page 34.

Page 34

Table 19 — Service Function and Subfunction Directory (cont)

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

8 Manual Control Table

Manual Control Enable Dsable

LOR switch should be in OFF position

Password Protected Enter:

Will be displayed if not entered earlier in current HSIO use

Manual Control Enable Dsable

Manual Control Enable Enable

Switch LOR switch to Local before proceeding

Circuit A Compressor 1 Off

Circuit A Compressor 1 On

Provided no alarms exist, control will attempt circuit start within 2 minutes.

Press to stop circuit.

Circuit A Compressor 2 Off

to enable, 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

9 Dual Chiller Conﬁguration

MST SLV Master/Slave Select

0/1/2

0 = Disabled 1 = Master 2 = Slave

Slave Address 0

Default = 0 Adjustable from 0-236

Lead/Lag Balance 0/1

0 = Disabled 1 = Enabled

Lead/Lag Balance Delta xxx hours

Default = 168 Adjustable from 40-400

LEGEND

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

Page 35

Table 20 — Displaying Current Software Version

FUNCTION

KEYPAD

ENTRY

DISPLAY COMMENT

Software Version

Software CESR_500100 Ver XXX

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

Table 21 — Compressor Lead/Lag Conﬁguration

SUB-FUNCTION KEYPAD

ENTRY

DISPLAY

Options Conﬁguration 1

Cooler Fluid Select 1

Min. Load Valve Select Dsable

Loading Sequence Select 1

Lead/Lag Sequence Select 1

PASSWD PROTECTED FUNC Enter Password:

Lead/Lag Sequence Select 0

Lead/Lag Sequence Select 2

NOTE: Conﬁgurationsmay be modiﬁed afterentering the password.Thepassword is only required 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.

Page 36

Table 22 — 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 14000095 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

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 Code1andis 1 for 30GX units,2for 30HXC units, and 3for30HXA cooling onlychillers. For other options, see Table 19 under the Service subfunction. A label listing conﬁguration codes is located on the control box door or panel.

Page 37

Table 23 — Entering Conﬁguration Codes

KEYPAD ENTRY DISPLAY RESPONSE

FACTORY 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 chiller from an occupied mode to an unoccupied mode. Refer to Table 24 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

selection under to 1. See page 72 or 73 of Field Wiringsection, depending on unit type, for switch input wir-

ing to the PSIO-2 module. Conﬁgure Cool Setpoint 2 under

to the desired value. The unit will then control leav-

ing water temperature to Cool Setpoint 2 when the switch input is closed. To enable clock control, set the Cooling

Setpoint selection under to 2. Set Cool Setpoint 2 to the desired unoccupied value. Using , conﬁgure lo-

cal 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 38

Table 24 — Schedule Function and Subfunction Directory

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Ice Build Schedule*

SCHEDULES: OCCPC01S Timed Override: 00

Extended Occupied Time

SCHEDULES: OCCPC01S Timed Override: 02

Two hour override entered

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

Displays current stored schedule (First 2 numbers are schedule, 01-08)

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

Monday-Friday now occupied

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

Occupied time now set

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

Unoccupied time now set Ice Build schedule completed

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

Can enter up to 7 additional ice build schedules

2 Local Schedule†

SCHEDULES: OCCPC02S Timed Override: 00

Extended Occupied Time

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

Displays current stored schedule (First 2 numbers are schedule, 01-08)

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

Monday-Friday now occupied

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

Occupied time now set

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

Unoccupied time now set Local schedule completed

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

Can enter up to 7 additional local schedules

3 Remote Schedule (Currently Not Used)

SCHEDULES: OCCPC65S Timed Override: 00

Extended Occupied Time

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

Displays current stored schedule (First 2 numbers are schedule, 01-08)

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

Monday-Friday now occupied

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

Occupied time now set

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

Unoccupied time now set Remote schedule completed

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

Can enter up to 7 additional remote schedules

4 Holiday Conﬁguration**

HOLIDAYS : HOLDY_01 Starts on 00/00 00 days

Can conﬁgure holiday start day and duration

HOLIDAYS : HOLDY_01 Starts on 12/23 00 days

Start of holiday set

HOLIDAYS : HOLDY_01 Starts on 12/23 10 days

Holiday duration set

5-33 Holiday Conﬁguration

through

HOLIDAYS : HOLDY_02 Starts on 00/00 00 days

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 9YES9 and download) when using the LID-2B controller, Building

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

Page 39

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 25.

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 25.

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

Tables 26-28 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 means that if the chilled ﬂuid set point is 44 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 T able26.Aﬁeld-suppliedoutdoorairthermistormustbeconnected to PSIO-2 as shown in Fig. 37.

To activate this function for space temperature reset leave both the External Reset Sensor Select and the OAT Sensor Select at 0, and change the Select/Enable Reset Type to 2, following the procedure in Table 26.

EXTERNALLY POWERED RESET (4 to 20 mA) — In this example, the unit set point is reset from full load at 4 mA to a maximum reset value of 10° F (5.5° C) at 20 mA. See Fig. 9 and Table 27.

RETURN FLUID TEMPERATURE RESET — In this example, the unit set point is reset from full load based on the chilled ﬂuid return temperature. The example uses a reset value 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 28.

Demand Limit — Demand Limit is a feature that allows

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 bya4to20mAsignal input which will reduce the maximum capacity linearly between 100% ata4mAinput 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.

To use Demand Limit, select the type of demand limiting 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 Table 29.

For Demand Limit by switch control, closing the ﬁrst stage demand limit contact will put the unit on the ﬁrst demand limit 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 percentage does not match unit staging, the unit will limit capacity to the closest capacity stage.

To Disable Demand Limit: Enter as shown in Table 29. Scroll down to Demand Limit Select and press

to select no Demand Limit control.

Table 25 — Temperature Reset Set Point Limits

INPUT DATA DESCRIPTION

MEASUREMENT METHOD

Type 1 — 4-20 mA

(With 500-Ohm Resistor)

Type2—OAT/Occupied Space

(External Sensor)

Type 3 — Return Fluid

Variable Limits Variable Limits Variable Limits

Maximum Reset Amount — Allowable range for maximum amount which LWT set point is reset.

Degrees Reset at 20 mA

(−30 to 30 F)

−34 to −1 C

Degrees Reset (−30 to 30 F)

−34 to −1 C

Degrees Reset (−30 to 30 F)

−34 to −1 C

Maximum Reset Reference — Temperature at which maximum reset occurs.

— — Remote temp =

Full Reset

(20 to 125 F)

−7 to 52 C

CHW Delta T = Full Reset

(0 to 15 degrees F) 0to8°C cooler temperature rise

Minimum Reset Reference — Temperature at which no reset occurs.

— — Remote temp =

No Reset

(20 to 125 F)

−7 to 52 C

CHW Delta T = No Reset

(0 to 15 degrees F) 0to8°C cooler temperature rise

LEGEND

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

Page 40

-18 (0) -12 (10) -7 (20) -1 (30) 4 (40) 10 (50) 16 (60)

21 (70) 27 (80)

32 (90)

38(100)

RESET REFERENCE TEMPERATURE-OUTDOOR AIR OR SPACE TEMPERATURE THERMISTOR C (F)

100

0.0 (0)

1.1 (2)

2.2 (4)

3.3 (6)

4.4 (8)

5.5 (10)

6.7 (12)

RESET AMOUNT C (F)

RESET AMOUNT

BUILDING LOAD

PERCENT BUILDING LOAD

Fig. 8 — Cooling External Temperature Reset

0 (0)

2 (1)

4 (2)

6 (3)

8 (4)

10 (5)

12 (6)

14 (7)

16 (8)

18 (9)

20 (10)

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

0 (0)

1.1 (2)

2.2 (4)

3.3 (6)

4.4 (8)

5.5 (10)

6.7 (12)

RESET AMOUNT C (F)

Fig.9—4to20mACooling Temperature Reset

Fig. 10 — Cooling Return Water Reset

Page 41

Table 26 — Setting External Temperature Reset

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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 selected for reset

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

OAT sensor enabled

COOLING RESET TYPE 1

Degrees Reset at 20 mA

0.0 dF COOLING RESET TYPE

2 Remote temp = No Reset

20.0 dF Remote temp = No Reset

25.0 dF Remote temp = Full Reset

125.0 dF Remote temp = Full Reset

90.0 dF Degrees Reset

0.0 dF Degrees Reset

10.0 dF COOLING RESET Scroll down

to this point.

Select/Enable Reset Type 0

Select/Enable Reset Type2External reset

selected

Table 27 — Setting Externally Powered Reset

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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 Type 0

Select/Enable Reset Type14-20 mA reset

selected

Table 28 — Setting Return Fluid

Temperature Reset

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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

Page 42

EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) — In this example, the 4 to 20 mADemandLimit will be conﬁgured and the 20 mA demand limit percentage will be set to 50%. See Table 30 and Fig. 11.

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 Table 31.

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 received, the maximum available capacity is set to 80%. WhenaLoadshedcommand is received, 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 29 — Setting Switch-Controlled Demand Limit

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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

Two step switch conﬁgured

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%

Conﬁguration complete

Table 30 — Setting Demand Limit

(4 to 20 mA Controlled;

2 to 10 vdc With 500-Ohm Resistor)

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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 Select

4-20 mA control conﬁgured

Table 31 — Setting Demand Limit

(CCN Loadshed Controlled)

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

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

CCN Loadshed control conﬁgured

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

Conﬁguration complete

50% CAPACITY AT 20 mA

75% CAPACITY AT 12 mA

100% CAPACITY AT 4 mA

0 (0)

2 (1)

4 (2)

6 (3)

8 (4)

10 (5)

12 (6)

14 (7)

16 (8) 18 (9)

20 (10)

DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT (VOLTS DC)

100

MAX. ALLOWABLE LOAD (%)

Fig. 11—4to20mADemand Limiting

Page 43

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. TheServicefunctiondisplayshowconﬁgurable 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 Table 10.

Checking Display Codes — To determine how the

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 OFF position. All compressors and solenoids stop immediately.

Complete Unit Stoppage — Complete unit stoppage

can be caused by any of the following conditions:

• cooling load satisﬁed

• remote on/off contacts open

• programmed 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 voltage

• 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 — 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

• Overload relay trip. 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

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 reset alarms. If the Alarm Reset Select feature

is selected ( ), a manual reset alarm can also be reset by switching the LOR switchfromLOCAL/REMOTEtoOFF

and back to LOCAL/REMOTE again. If an alarm was from the CPM module, depress theresetbuttonlocatedontheHSIO or fuse bracket before clearing the alarm through the HSIO. Some typical fault conditions are described in Table 32. For a complete list of fault conditions, codes, and reset type, see Table 33.

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

Table 32 — Typical Stoppage Faults

and Reset Types

STOPPAGE FAULT RESET TYPE

Loss of Condenser Flow (30HXC) Manual reset Cooler Freeze Protection

(Chilled Fluid, Low Temperature)

Auto reset ﬁrst time, manual if repeated in same day

Chilled Fluid Pump Interlock Automatic reset (Manual for

closed contacts when pump is off)

Control Circuit Fuse Blown Unit restarts automatically when

power is restored

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

Automatic reset

LEGEND

FSM — Flotronic™ System Manager WSM — Water System Manager

Alarms and Alerts — These are warnings of abnormal

or fault conditions, and may cause either one circuit or the whole unit to shut down. They are assigned code numbers as described in Table 33. 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 34. The PSIO also recognizes illegal conﬁgurations. Illegal conﬁgurations are shown in Table 35.

Table 33 contains a detailed description of each alarm and

alert code error and possible cause. Manual reset is accomplished by entering from the HSIO and press-

ing or moving the LOCAL/OFF/REMOTE Switch to the OFF position, then back to LOCAL or REMOTE po-

sition (If Alarm Reset Select is enabled).

CompressorAlarm/AlertCircuit — Each compres-

sor is controlled by its own CPM processor, which closes contacts between plug terminals PL2-3 and PL2-6 to start the compressor. Power is supplied to the CPM logic circuit through each compressor high-pressure switch and into plug terminal PL2-2. If the high-pressure switch opens, the CPM generates an alarm.

NOTE: Similar connections for each compressor can be followed on the unit wiring diagrams located on the unit.

Page 44

Table 33 — Alarm and Alert Codes

ALARM/ALERT

CODE

ALARM OR

ALERT

DESCRIPTION

WHY WAS THIS

ALARM GENERATED?

ACTION TAKEN

BY CONTROL

RESET

METHOD

PROBABLE

CAUSE

0 — No Alarms or Alerts

Exist

— ———

1.xx See CPM subcodes below

Compressor A1 Failure See CPM subcodes

below

See CPM subcodes below

Manual See CPM subcodes

below

2.xx See CPM subcodes below

Compressor A2 Failure See CPM subcodes

below

See CPM subcodes below

Manual See CPM subcodes

below

5.xx See CPM subcodes below

Compressor B1 Failure See CPM subcodes

below

See CPM subcodes below

Manual See CPM subcodes

below

6.xx See CPM subcodes below

Compressor B2 Failure See CPM subcodes

below

See CPM subcodes below

Manual See CPM subcodes

below

CPM SUBCODES

(xx)

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

Trip

HPS input to CPM module open

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

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

x.2 Alarm No Motor Current CPM reads less than

10% of MTA on all legs for >3 seconds

Comp. shut down Manual/Button Power supply discon-

nected, blown fuse(s), wiring error, contactor not energized, faulty current toroid, motor overload tripped

x.25* Alarm Current Imbalance

>10% (Alarm)

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

Circuit shut down Manual/Button Loose terminals on

power wires. Poor power supply. Disabled only if alarm feature is

enabled in

x.27* Alert Current Imbalance

>10% (Warning)

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

None — Loose terminals on

power wires. Poor power supply. Displayed only if alarm feature is

disabled in

x.3 Alarm Current Imbalance

>18%

CPM measures current balance between phases greater than 18% for 25 minutes

Circuit shut down Manual/Button Loose terminals on

power wires. Poor power supply.

x.35 Alarm Single Phase Current

Loss

CPM measures current imbalance between phases greater than 20%

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

loose terminals.

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

rent compared to MTA setting

Comp. shut down Manual/Button Operation beyond chiller

capability, improperly punched conﬁguration header, blown fuse

x.5 Alarm Ground Fault CPM detects ground

current (2.5 ± 2.0 amps)

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

to ground, wiring error, loose plug connector, current toroid plugs not facing same direction.

x.55* Alarm Voltage Imbalance >3%

(Alarm)

CPM measures voltage imbalance between phases greater than 3% for 25 minutes

Circuit shut down Manual/Button Compressor fault, local

utility supply imbalance, Poor power supply. Displayed only if alarm feature is enabled in

x.57* Alert Voltage Imbalance >3%

(Warning)

CPM measures voltage imbalance between phases greater than 3% for 25 minutes

None — Compressor fault, local

utility supply imbalance. Displayed only if alarm feature is disabled in

x.6 Alarm Voltage Imbalance >7% CPM measures voltage

imbalance between phases greater than 7% for 25 minutes

Circuit shut down Manual/Button Compressor fault, local

utility supply imbalance

x.7 Alarm Volt Phase Reversal CPM detects incoming

power supply out of phase

Chiller shut down and not allowed to start

Manual/Button Leads at CPM board

not connected. Supply power not in phase; interchange any 2 incoming leads.

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

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

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

Manual/Button Faulty contactor, con-

tactor welded, wiring error.

x.8 Alarm Current Phase Reversal CPM detects phase re-

versal from toroid reading

Circuit shut down Manual/Button Multiple terminal block

power supply leads not in phase. Toroid wire harness crossed, toroid not all facing same direction

Page 45

Table 33 — Alarm and Alert Codes (cont)

ALARM/ALERT

CODE

ALARM OR

ALERT

DESCRIPTION

WHY WAS THIS

ALARM GENERATED?

ACTION TAKEN

BY CONTROL

RESET

METHOD

PROBABLE

CAUSE

CPM SUBCODES

(xx)

x.85 Alarm Motor Over Temperature CPM detects high motor

temperature

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

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

x.9 Alarm Open Thermistor CPM detects open

circuit in motor temp thermistor

Comp. shut down Manual/Button Wiring error or faulty

thermistor.†

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

MTAvalue punched out in header

Comp. shut down Manual/Button Header pins on CPM

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

x.10 Alarm Shorted Thermistor CPM detects short

circuit in motor tempt thermistor

Comp. shut down Manual/Button Wiring error or faulty

thermistor.†

ALARM/ALERT

CODE

7 Alert Cir. A Discharge Gas

Thermistor Failure

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

Circuit A shut down Manual Thermistor failure, motor

cooling solenoid failure or wiring error.

8 Alert Cir. B Discharge Gas

Thermistor Failure

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

Circuit B shut down Manual Thermistor failure, motor

cooling solenoid failure or wiring error.

9 Alarm Cooler Leaving Fluid

Thermistor Failure

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

Chiller shut down. Automatic Thermistor failure, dam-

aged cable/wire or wiring error.

10 Alarm Cooler Entering Fluid

Thermistor Failure

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

Uses 0.1° F/% Total Capacity as rise/ton.

Automatic Thermistor failure, dam-

aged cable/wire or wiring error.

11 Alert Condenser Leaving

Fluid Thermistor Failure

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

None. Chiller continues to run.

Automatic Thermistor failure, dam-

aged cable/wire or wiring error.

12 Alert Condenser Entering

Fluid Thermistor Failure

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

None. Chiller continues to run.

Automatic Thermistor failure, dam-

aged cable/wire or wiring error.

15 Alert Compressor A1 High

Motor Temperature

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

Compressor A1 shut down

Manual Thermistor failure, motor

cooling (all) or Economizer (2 comp. circuits) solenoid failure.

16 Alert Compressor A2 High

Motor Temperature

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

Compressor A2 shut down

Manual Thermistor failure, motor

cooling (all) or Economizer (2 comp. circuits) solenoid failure.

17 Alert Compressor B1 High

Motor Temperature

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

Compressor B1 shut down

Manual Thermistor failure, motor

cooling (all) or Economizer (2 comp. circuits) solenoid failure.

18 Alert Compressor B2 High

Motor Temperature

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

Compressor B2 shut down

Manual Thermistor failure, motor

cooling (all) or Economizer (2 comp. circuits) solenoid failure.

21 Alert External Reset Tem-

perature Thermistor Failure

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

Reset disabled. Runs under normal control/ set points.

Automatic Thermistor failure or

wiring error.

22 Alert Circuit ADischarge

Pressure Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit A shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

23 Alert Circuit B Discharge

Pressure Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit B shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

24 Alert Circuit ASuction Pres-

sure Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit A shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

25 Alert Circuit B Suction Pres-

sure Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit B shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

26 Alert Comp A1 Oil Pressure

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Comp A1 shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

27 Alert Comp A2 Oil Pressure

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Comp A2 shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

Page 46

Table 33 — Alarm and Alert Codes (cont)

ALARM/ALERT

CODE

ALARM OR

ALERT

DESCRIPTION

WHY WAS THIS

ALARM GENERATED?

ACTION TAKEN

BY CONTROL

RESET

METHOD

PROBABLE

CAUSE

28 Alert Comp B1 Oil Pressure

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Comp B1 shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

29 Alert Comp B2 Oil Pressure

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Comp B2 shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

30 Alert Circuit A Economizer

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit A shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

31 Alert Circuit B Economizer

Transducer Failure

Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.

Circuit B shut down Automatic Transducer failure,

power supply failure or wiring damage/error.

32 Alarm Transducer Supply Out-

side 4.5 to 5.5 Volts

Reference voltage measured at PSIO-1, J7-34,35 less than 4.5 V or greater than 5.5 V.

Chiller shut down Automatic Power supply failure or

wiring error. Low transformer voltage.

34 Alert 4-20 mA Reset Input

Out of Range

If conﬁgured and input signal to PSIO-2, J7-19,20(HX), J7-22,23(GX) less than 2 mA or greater than 20 mA

Reset function disabled. Normal set point used

Automatic Faulty signal generator,

wiring error, 500 ohm resistor missing or not properly installed.

35 Alert 4-20 mA Demand Limit

Input Out of Range

If conﬁgured and input signal to PSIO-2, J7-22,23(HX), J7-13,14(GX) less than 2 mA or greater than 20 mA

Demand limit ignored. Runs under normal control based on 100% demand limit.

Automatic Faulty signal generator,

wiring error, 500 ohm resistor missing or not properly installed.

36 Alarm Loss of Communication

with ‘‘Hardware Point’’

PSIO-1 has lost communication with one of the points in Table 34.

See Table 34. Automatic Failed module, wiring

error, failed transformer, loose connection plug, wrong address

37 Alert Circuit A Low Saturated

Suction Temperature

SST reads 6 F (3.3 C) or more below the freeze point for 3 minutes. Point is 28 F (−2.2 C) for water, set point minus 8 F (4.4 C) for brines.

Circuit A shut down Manual Low refrigerant charge,

plugged strainer, faulty expansion valve. Low water ﬂow.

38 Alert Circuit B Low Saturated

Suction Temperature

SST reads 6 F (3.3 C) or more below the freeze point for 3 minutes. Point is 30 F (−1.1 C) for water, cooling set point minus 8 F (4.4 C) for brines.

Circuit B shut down Manual Low refrigerant charge,

plugged strainer, faulty expansion valve. Low water ﬂow.

40 Alert Compressor A1 Low Oil

Pressure

See Note 1. Comp A1 shut down Manual Low Water Temperature,

low refrigerant charge, plugged oil ﬁlter, closed oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer.

41 Alert Compressor A2 Low Oil

Pressure

See Note 1. Comp A2 shut down Manual Low Water Temperature,

low refrigerant charge, plugged oil ﬁlter, closed oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

42 Alert Compressor B1 Low Oil

Pressure

See Note 1. Comp B1 shut down Manual Low Water Temperature,

low refrigerant charge, plugged oil ﬁlter, closed oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

43 Alert Compressor B2 Low Oil

Pressure

See Note 1. Comp B2 shut down Manual Low Water Temperature,

low refrigerant charge, plugged oil ﬁlter, closed oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

44 Alarm Circuit A Condenser

Freeze Protection (alarm ignored for brine chillers)

For W/C chillers only, if SCT <34 F (1.1 C)

Chiller shut down. Turn Cond pump On if Chiller is Off

Automatic Failed/bad discharge

pressure transducer, refrigerant leak, conﬁgured for watercooled condenser

Page 47

Table 33 — Alarm and Alert Codes (cont)

ALARM/ALERT

CODE

ALARM OR

ALERT

DESCRIPTION

WHY WAS THIS

ALARM GENERATED?

ACTION TAKEN

BY CONTROL

RESET

METHOD

PROBABLE

CAUSE

45 Alarm Circuit B Condenser

Freeze Protection (alarm ignored for brine chillers)

For W/C chillers only , if SCT <34 F (1.1 C)

Chiller shut down. Turn Cond pump On if Chiller is Off

Automatic Failed/bad discharge

pressure transducer, refrigerant leak, conﬁgured for watercooled condenser

46 Alarm Cooler Freeze Protec-

tion

Cooler EWT or LWT less than freeze point. Freeze point is 34 F (1.1 C) for water, cooling set point minus 8 F (4.4 C) for brines.

Chiller shut down. Leave Cooler pump on. Turn Cooler pump On if Chiller is Off.

Automatic** Faulty thermistor, low

water ﬂow

47 Alert Circuit A High Saturated

Suction Temperature

After ﬁrst 90 seconds, SST > 55 F (12.8 C) and EXV < 1% for 5 minutes

Circuit A shut down Manual Faulty expansion valve,

liquid level sensor or transducer.

48 Alert Circuit B High Saturated

Suction Temperature

After ﬁrst 90 seconds, SST > 55 F (12.8 C) and EXV < 1% for 5 minutes

Circuit B shut down Manual Faulty expansion valve,

liquid level sensor or transducer.

49 Alarm Loss of Condenser Flow Flow switch not closed

within 1 minute after pump is started or if ﬂow switch opens during normal operation for >10 seconds

Chiller shut down Manual Low condenser water

ﬂow, failed condenser pump

50 Alarm Illegal Conﬁguration x Illegal Conﬁguration has

been entered. Correction needed.

Chiller cannot start. See Table 35.

Manual Conﬁguration error.

51 Alarm Initial Conﬁguration

Required

No conﬁguration has been entered.

Chiller cannot start Manual Conﬁguration omitted.

52 Alarm Unit is in Emergency

Stop

CCN command received to shut unit down.

Chiller shut down CCN/

Automatic

Network command.

53 Alarm Cooler Pump Interlock

Failed at Start-Up

Interlock did not close within 1 minute after transition

Chiller shut down. Pump turned off.

Automatic Failure of cooler pump

or controls

54 Alarm Cooler Pump Interlock

Opened Unexpectedly

Interlock opened for at least 5 seconds during operation

Chiller shut down. Pump turned off.

Automatic Failure of cooler pump

or controls

55 Alarm Cooler Pump Interlock

Closed When Pump OFF

Interlock closed when pump relay is off

Cooler pump remains off. Unit prevented from starting.

Manual Failure of cooler pump

relay or interlock, welded contacts

56 Alert Loss of Communication

with WSM

No communications have been received by PSIO-1 within 5 minutes of last transmission.

WSM forces removed. Runs under own control

Automatic Failed module, wiring

error, failed transformer, loose connection plug, wrong address

57 Alert Circuit A Liquid Level

Sensor Failure

Sensor reads 245 F (118 C) or −40 F (−40 C) with SST > 9 F (−12.8 C)

Runs, but controls EXV based on Disch. Superheat

Automatic Thermistor circuit open,

faulty liquid level sensor, wiring error

58 Alert Circuit B Liquid Level

Sensor Failure

Sensor reads 245 F (118 C) or −40 F (−40 C) with SST > 9 F (−12.8 C)

Runs, but controls EXV based on Disch. Superheat

Automatic Thermistor circuit open,

faulty liquid level sensor, wiring error

59 Alarm Compressor A1

Pre-Start Oil Pressure

Oil Pump did not build sufficient pressure during pre-lube cycle.

Circuit cannot start Manual Low oil, oil pump failure,

oil solenoid failure, oil transducer failure, check valve failed open, oil shutoff valve closed

60 Alarm Compressor A2

Pre-Start Oil Pressure

Oil Pump did not build sufficient pressure during pre-lube cycle.

Circuit cannot start Manual Low oil, oil pump failure,

oil solenoid failure, oil transducer failure, check valve failed open, oil shutoff valve closed

61 Alarm Compressor B1

Pre-Start Oil Pressure

Oil Pump did not build sufficient pressure during pre-lube cycle.

Circuit cannot start Manual Low oil, oil pump failure,

oil solenoid failure, oil transducer failure, check valve failed open, oil shutoff valve closed

62 Alarm Compressor B2

Pre-Start Oil Pressure

Oil Pump did not build sufficient pressure during pre-lube cycle.

Circuit cannot start Manual Low oil, oil pump failure,

oil solenoid failure, oil transducer failure, check valve failed open, oil shutoff valve closed

63 Alarm Circuit A&B OFF for

Alerts. Unit down

Control has shut down both circuits due to alerts.

None Automatic Check individual alarms

64 Alert Circuit A Loss of Charge Discharge pressure

reading <10 PSIG for 30 seconds

Circuit A shut down Manual Refrigerant leak or

transducer failure

65 Alert Circuit B Loss of Charge Discharge pressure

reading <10 PSIG for 30 seconds

Circuit B shut down Manual

66 Alarm Loss of Communication

with FSM

No communications have been received by PSIO-1 within 5 minutes of last transmission.

FSM forces removed Runs under own control

Automatic Wiring faulty or module

failure

67 Alert Circuit A High Discharge

Pressure

SCT > MCT_SP + 5 F (2.8 C)

Circuit shut down Automatic** Faulty transducer/high

pressure switch, low/ restricted condenser air/water ﬂow.††

Page 48

Table 33 — Alarm and Alert Codes (cont)

ALARM/ALERT

CODE

ALARM OR

ALERT

DESCRIPTION

WHY WAS THIS

ALARM GENERATED?

ACTION TAKEN

BY CONTROL

RESET

METHOD

PROBABLE

CAUSE

68 Alert Circuit B High Dis-

charge Pressure

SCT > MCT_SP + 5 F (2.8 C)

Circuit shut down Automatic** Faulty transducer/high

pressure switch, low/ restricted condenser air/water ﬂow.††

70 Alert High Leaving Chilled

Water Temperature

LCW read > LCW Delta Alarm limit and total capacity is 100% and current LCW > LCW reading 1 minute ago

Alert only. None Automatic Building load greater

than unit capacity, low water/brine ﬂow, or compressor fault. Check for other alarms or alerts.

71 Alert Circuit A Low Oil Level Level switch input open

for 4th time in same day.

Circuit A shut down Manual Low oil level, failed

switch, wiring error, failed DSIO module

72 Alert Circuit B Low Oil Level Level switch input open

for 4th in same day.

Circuit B shut down Manual Low oil level, failed

switch, wiring error, failed DSIO module

73 Alert Circuit A Low Discharge

Superheat

Superheat <5 F (2.8 C) for 10 minutes

Circuit A shut down Manual Faulty thermistor,

transducer or EXV or Economizer. Motor cooling solenoid stuck open.

74 Alert Circuit B Low Discharge

Superheat

Superheat <5 F (2.8 C) for 10 minutes

Circuit B shut down Manual Faulty thermistor,

transducer or EXV or Economizer. Motor cooling solenoid stuck open.

75 Alarm Comp. A1 Max. Oil

Delta P, check oil line

(Discharge press − Oil press) >100 PSI for more than 5 seconds

Comp. A1 shut down Manual Plugged oil ﬁlter, closed

oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

76 Alarm Comp. A2 Max. Oil

Delta P, check oil line

(Discharge press − Oil press) >100 PSI for more than 5 seconds

Comp. A2 shut down Manual Plugged oil ﬁlter, closed

oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

77 Alarm Comp. B1 Max. Oil

Delta P, check oil line

(Discharge press − Oil press) >100 PSI for more than 5 seconds

Comp. B1 shut down Manual Plugged oil ﬁlter, closed

oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

78 Alarm Comp. B2 Max. Oil

Delta P, check oil line

(Discharge press − Oil press) >100 PSI for more than 5 seconds

Comp. B2 shut down Manual Plugged oil ﬁlter, closed

oil valve, bad oil solenoid, compressor oil check valve stuck, oil line check valve stuck, plugged oil strainer

79 Alarm Comp. A1 Failed Oil

Solenoid

Diff. Oil pressure >2.5 PSI during period after oil pump starts and before oil solenoid opens

Comp. A1 not allowed to start

Manual Faulty oil solenoid valve

80 Alarm Comp. A2 Failed Oil

Solenoid

Diff. Oil pressure >2.5 PSI during period after oil pump starts and before oil solenoid opens

Comp. A2 not allowed to start

Manual Faulty oil solenoid valve

81 Alarm Comp. B1 Failed Oil

Solenoid

Diff. Oil pressure >2.5 PSI during period after oil pump starts and before oil solenoid opens

Comp. B1 not allowed to start

Manual Faulty oil solenoid valve

82 Alarm Comp. B2 Failed Oil

Solenoid

Diff. Oil pressure >2.5 PSI during period after oil pump starts and before oil solenoid opens

Comp. B2 not allowed to start

Manual Faulty oil solenoid valve

LEGEND

CCN — Carrier Comfort Network CPM — Compressor Protection Module DGT — Discharge Gas Temperature EWT — Entering Water Temperature EXV — Electronic Expansion Valve FSM — Flotronic™ System Manager HPS — High-Pressure Switch LCW — Leaving Chilled Water LWT — Leaving Water Temperature MCT

SP — Maximum Condensing Temperature Set Point MTA — Compressor Must Trip Amps SCT — Saturated Condensing Temperature SST — Saturated Suction Temperature W/C — Water-Cooled WSM — Water System Manager

*Current and voltage imbalance alarms x.25 and x.55 may be changed to

warnings x.27 and x.57 after successful start-up of the chiller.

†Compressors are equipped with 2 motor winding temperature ther-

mistors. Verify ﬁrst thatthe problem isnot a wiringerror before usingbackup thermistor.

**Reset automatic ﬁrst time, manual if repeated on the same date.

††Note that the high-pressureswitch should trip before this alertis generated.

Check HPS operation if this alert is generated.

NOTES:

1. Low Oil Pressure Alert Criteria and Set Points Where: Pd= Discharge pressure, Ps= Suction pressure, Po= Oil pressure and Pe= Economizer pressure Two oil pressure set points are used. Oil Set point 1 is always 15 psig.

a. If (Pd−Ps) <125, then Oil Set point 2 = 0.235 x (Pd−Ps) + 0.588 b. If (Pd−Ps) > = 125 and <165, then Oil Set point2=2.0x(Pd−Ps)

− 220.0

c. If (Pd−Ps) > = 165, then Oil Set point 2 = 0.6364 x (Pd−Ps) + 5.0 The 2 set points are used by the control for the Low Oil Pressure alert trip

criteria below: a. Oil Pressure is ignored during the ﬁrst 5 seconds after a compressor is

started.

b. In period between 5 and 30 seconds after starting, the alert will begen-

erated if (Po−Pe) < [(Oil Set point 1)/30] x (Compressor Run time in seconds) for 3 consecutive readings

c. After 30 seconds run time, the alert will be generated if:

1) (Po−Pe) < Oil Set point 1 for 15 seconds OR

2) (Po−Ps) < Oil Set point 2 for 25 seconds

2. (Po−Pe) is theOilpressure differential displayed in for Circuit A and for Circuit B.

Page 49

Table 34 — Hardware Point Communications Loss/Action Taken

HARDWARE POINT CONTROL POINT NAME

ACTION TAKEN UNTIL

COMMUNICATION RESTORED

ALARM Alarm Relay No Action CFLOW_SW Cooler Flow Switch Chiller shut down COND_ENT Condenser Entering Water Thermistor Same as Alert 12 COND_LWT Condenser Leaving Water Thermistor Same as Alert 11 COND_PMP Condenser Pump Relay Chiller shut down COOL_EWT Cooler Entering Water Thermistor Same as Alarm 10 COOL_LWT Cooler Leaving Water Thermistor Chiller shut down COOL_HTR Cooler Heater Turn ON Cooler Pump relay COOL_PMP Cooler Pump Relay No Action DFLOW_SW Condenser Flow Switch Chiller shut down DISTMP_A Discharge Gas Temp Circuit A (Oil Temp) Circuit shut down DISTMP_B Discharge Gas Temp Circuit A (Oil Temp) Circuit shut down DISTMP_B Discharge Gas Temp Circuit B (Oil Temp) Circuit shut down DMD_SW1 Demand Limit Switch 1 No Action DMD_SW2 Demand Limit Switch 2 No Action DPA Discharge Pressure Circuit A Circuit shut down DPB Discharge Pressure Circuit B Circuit shut down DUAL Dual Setpoint Switch Control to Setpoint 1 ECN_PR_A Circuit A Economizer Pressure Circuit shut down ECN_PR_B Circuit B Economizer Pressure Circuit shut down EXVA Expansion Valve, Circuit A Circuit shut down EXVB Expansion Valve, Circuit B Circuit shut down FAN_1 Fan Relay 1 No Action FAN_2 Fan Relay 2 No Action FAN_3 Fan Relay 3 No Action FAN_4 Fan Relay 4 No Action FAN_5 Fan Relay 5 No Action FAN_6 Fan Relay 6 No Action HC_SW Heat/Cool Switch Chiller shut down HR_EWT Heat Reclaim Entering Water Thermistor No Action HR_LWT Heat Reclaim Leaving Water Thermistor No Action ICE_DONE Ice Complete Indicator Disable function ICE_VALV Ice Valve Disable function K_A1_FBK Compressor A1 Feedback Compressor shut down K_A1_RLY Compressor A1 Relay Compressor shut down K_A2_FBK Compressor A2 Feedback Compressor shut down K_A2_RLY Compressor A2 Relay Compressor shut down K_B1_FBK Compressor B1 Feedback Compressor shut down K_B1_RLY Compressor B1 Relay Compressor shut down K_B2_FBK Compressor B2 Feedback Compressor shut down K_B2_RLY Compressor B2 Relay Compressor shut down LOADR_A1 Compressor A1 Loader No Action LOADR_A2 Compressor A2 Loader No Action LOADR_B1 Compressor B1 Loader No Action LOADR_B2 Compressor B2 Loader No Action LMT_MA Demand Limit 4-20 mA Input Disable function LOR_SW Local/Off/Remote Switch Chiller shut down MLV_A Min. Load Valve Relay Circuit A Disable function MLV_B Min. Load Valve Relay Circuit B Disable function MOTOR_A Circuit A MotormasterT Output Disable function MOTOR_B Circuit B Motormaster Output Disable function MTRCL_A1 Compressor A1 Motor Cooling Compressor shut down MTRCL_A2 Compressor A2 Motor Cooling Compressor shut down MTRCL_B1 Compressor B1 Motor Cooling Compressor shut down MTRCL_B2 Compressor B2 Motor Cooling Compressor shut down OAT Outside Air Temperature Disable function OIL_A1 Compressor A1 Oil Pressure Transducer Compressor shut down OIL_A2 Compressor A2 Oil Pressure Transducer Compressor shut down OIL_B1 Compressor B1 Oil Pressure Transducer Compressor shut down OIL_B2 Compressor B2 Oil Pressure Transducer Compressor shut down OILA_HTR Circuit A Oil Heater Disable function OILA_SW Circuit A Oil Level Circuit shut down OILB_HTR Circuit B Oil Heater Disable function OILB_SW Circuit B Oil Level Circuit shut down OILPMP_A CircuitA Oil Pump NoAction OILPMP_B Circuit B Oil Pump No Action OILSOL_A Circuit A Oil Solenoid Circuit shut down OILSOL_B Circuit B Oil Solenoid Circuit shut down P_REF 5 Volt Transducer Reference Chiller shut down RALARMx Remote Alarm Relay x (1-16) Disable function RST_MA Temp. Reset 4-20 mA signal Disable function SPA Circuit A Suction Transducer Circuit shut down SPB Circuit B Suction Transducer Circuit shut down TLEV_A Circuit A Cooler Level Sensor Control EXV-A by discharge superheat TLEV_B Circuit B Cooler Level Sensor Control EXV-B by discharge superheat TMTR_A1 Compressor A1 Motor Thermistor Compressor shut down TMTR_A2 Compressor A2 Motor Thermistor Compressor shut down TMTR_B1 Compressor B1 Motor Thermistor Compressor shut down TMTR_B2 Compressor B2 Motor Thermistor Compressor shut down T_SPACE External Space Temp Thermistor Disable function VALVE_A Circuit A Water Valve Control Circuit shut down VALVE_B Circuit B Water Valve Control Circuit shut down

Page 50

Table 35 — Illegal Conﬁgurations Recognized

by PSIO-1

CODE

NUMBER

ILLEGAL CONFIGURATION

DESCRIPTION

Incorrect Check Sum in conﬁguration code (factory or service code)

2 Unit type outside range of (1-3) 3

Number of compressors in a circuit outside the range of 0-2

Air cooled chiller with a fan type outside the range of 1-16

Air cooled chiller with Low Temperature Brine ﬂuid

Water cooled chiller conﬁgured for air cooled head pressure

Selecting both OAT and Space Temp sensors for External Reset operation

8 Air cooled chiller with condenser water pump 9 Air cooled chiller with condenser thermistors

MOP Set point is outside the range of 40 - 55 F (4.4 - 12.8 C)

Maximum Condensing Temperature Set point (MCT_SP) is outside the range of 0 - 158 F (-17.8 - 70 C)

LEGEND

MOP — Minimum Operating Temperature OAT — Outdoor-Air Temperature

EXD Troubleshooting Procedure — Follow steps

below to diagnose and correct EXV/Economizer problems.

On 30HX units with economizers, verify that the valve

for the bubbler tube (bottom of economizer) is open. Check EXV motor operation ﬁrst. Press on the HSIO II

keypad and select the appropriate EXV. Press to move the valve to 25%. You should be able to feel the ac-

tuator moving by placing your hand on the EXV or economizer body (the actuator is located about one-half to twothirds of the way up from the bottom of the economizer shell).

Press three more times until the display reads 100% for a Target Percent (waiting until actuator stops each time).

A hard knocking should be felt from the actuator when

it reaches the top of its stroke (can be heard if surroundings are relatively quiet). Press again if

necessary to conﬁrm this. Press four times to step the actuator closed in 25% increments, waiting again in be-

tween each move. The actuator should knock when it reaches the bottom of its stroke. If it is believed that the valve is not working properly, continue with the checkout procedure below:

Check the EXV output signals at appropriate terminals

on EXV driver module (see Fig. 12). Connect positive test lead to terminal 1 on the EXV driver for Circuit A and to terminal 7 for Circuit B. Set meter for approximately 20 vdc. Enter Valves and Motor Master test subfunction by pressing

on the HSIO. The EXV for Circuit A will be dis-

played; if desired, press the down arrow key for Circuit B. When at the desired valve, press . The display should change to show a Target Percent of 25%. The driver should

drive the circuit EXV under test. During the next several seconds, connect negative test lead to pins 2, 3, 4, and 5 in succession (pins 8, 9, 10 and 11 for Circuit B). Voltage should rise and fall at each pin. If it remains constant at a voltage or shows 0 volts, remove the connector to the valve and recheck.

Press to close the circuit EXV. Check the DSIO

address setting (the address should be 50). If a problem still exists, replace the EXV driver module. If the voltage reading is correct, the expansion valve and EXV wiring should be checked. Check the EXV terminal strip and interconnecting wiring.

1. Checkcolorcodingand wire connections. Make sure they

are connected to the correct terminals at the EXV driver and EXV plug and that the cables are not crossed.

2. Check for continuity and tight connection at all pin

terminals.

Check the resistance of the EXV motor windings.

Remove the DSIO-EXV plug J4 terminal strip and check the resistance between the common lead (red wire, terminal D) and remaining leads, A, B, C, and E (see Fig. 12). The resistance should be 25 ohms ± 2 ohms.

RED

GRN

WHT

BLK

BRN

RED

GRN

WHT

BLK

BRN

EXV-A

EXV-B

EXV DRIVER BOARD, J4

EXV — Electronic Expansion

Valve

Fig. 12 — EXV Cable Connections to EXV Driver Module, DSIO-EXV

Page 51

INSPECTING/OPENING ELECTRONIC EXPANSION VALVES

IMPORTANT:ObtainreplacementO-ringbeforeopening EXV. Do not reuse O-rings.

To check the physical operation of an EXV, the following

steps must be performed:

1. Close the liquid lineservicevalveof the circuit to bechecked. Put the LOR switch in the OFF position. Using the HSIO, enter the manual service mode by pressing

. Enable the mode by pressing . Switch

the LOR switch to the Local position. Scroll down to the desired compressor and press to turn it on. Let

compressor run until gage on suction pressure port reads between 5 and 10 psig. Press to turn the com-

pressor off. Immediately after the compressor shuts off, close the discharge valve.

2. Remove any remaining refrigerant from the system low side using proper reclaiming techniques. Drain oil from cooler using Schrader port in cooler inlet line. Turn off the line voltage power supply to the compressors and control circuit power.

3. Remove screws holding top cover of EXV. Carefully remove the top cover from the EXV making sure EXV plug is still connected.

IMPORTANT: When removing top cover from EXVs, be careful to avoid damage to motor leads.

4. Entertheappropriate EXVtest step for EXV-A or EXV-B by pressing on the HSIO. Scroll down to display

the desired EXV. Press and to initiate the test. Observe the operation of the valve motor and lead screw.

The motor shouldturncounterclockwise,andthe lead screw should move up out of the motor hub until the valve is fully open. Lead screw movement should be smooth and uniform from fully closed to fully open position. Press

as needed to reach 100% open. Wait 30 seconds

in between each step for motor to stop moving. Press

to check open to closed operation. If the valve is

properly connected to the processor and receiving correct signals, yet does not operate as described above, the valve should be replaced.

INSPECTING/OPENING ECONOMIZERS — To check the physical operation of an economizer (see Fig. 13), the following steps must be performed:

1. Close the liquid lineservicevalveof the circuit to bechecked. Put the LOR switch in the OFF position. Using the HSIO, enter the manual service mode by pressing

. Enable the mode by pressing . Switch

the LOR switch to the Local position. Scroll down to the desired compressor and press to turn it on. Let

compressor run until gage on suction pressure port reads between 5 and 10 psig. Press to turn the com-

pressor off. Immediately after the compressor shuts off, close the discharge valve and the bubbler valve on 30HX units (located in elbow ﬁtting on condenser shell).

2. Remove any remaining refrigerant from the system low side and discharge piping using proper reclaiming techniques. For 30GX units, there is no shutoff valve in the bubbler tube line. Drain oil from cooler using Schrader port in cooler inlet line. Turn off the line voltage power supply to the compressors and control circuit power.

3. Remove the shell retaining bolts on the bottomoftheeconomizer and the bolts that secure the shell to the unit frame or mounting bracket. Cut the motor cooling line leaving the top of the economizer.Carefullyremovetheshellfrom the economizer. Make sure EXV plug is still connected.

IMPORTANT: When removing shell from economizer, it must be lifted off as close to vertical as possible to prevent damage to any of the internal parts. Use a catch pan beneath the economizer as oil will come out when the shell is removed. Be careful to avoid damage to motor leads.

4. Entertheappropriate EXVtest step for EXV-A or EXV-B by pressing on the HSIO. Scroll down to display

the desired EXV. Press and to initiate the test. Observe the operation of the valve motor and lead screw.

as needed to reach 100% open. Wait 30 seconds

in between each step for motor to stop moving. Press

to check open to closed operation. If the valve is

properly connected to the processor and receiving correct signals, yet does not operate as describedabove,theeconomizer should be replaced.

5. Additional items to check for: a. Verify that ﬂoat assembly (see cross section view in

Fig. 13) moves up and down freely. It should take only a minimal force (less than one pound) to move the float and there should be no binding.

b. Check the bubbler tube (found by carefully lifting the

ﬂoat) for crimps, etc. and verify that the end of the tube is open.

6. Reassemble economizer; retorque shell retaining bolts to 35 ft-lb (48 N-m).

If operating problems persist after reassembly, they may be due to a bad liquid level sensor, suction pressure transducer or intermittent connections between the processor board terminals and EXV plug. Recheck all wiring connections and voltage signals.

Other possible causes of improper refrigerant ﬂow control could be restrictions in the liquid line. Check for plugged strainer(s) or restricted metering slots in the EXV or economizer. Formation of ice or frost on lower body of electronic expansion valve is one symptom of restricted metering slots. However, frost or ice formation is normally expected when leaving ﬂuid temperature from the cooler is below 40 F. Clean or replace valve if necessary.

NOTE (non-economizer units only): Frosting of valve is normal during compressor test steps and at initial start-up. Frost should dissipate after 5 to 10 minutes operation in a system that is operating properly. If valve is to be replaced, wrap valve with a wet cloth to prevent excessive heat from damaging internal components.

Page 52

SERVICE

ServicingCoolersandCondensers—

When cooler heads and partition plates are removed, tube sheets are exposed showing the ends of tubes. The 30GX,HX units use a ﬂooded cooler design. Water ﬂows inside the tubes.

TUBE PLUGGING — A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon the cooler must be retubed. All tubes in the 30GX and 30HX coolers and 30HX condensers can be removed. Loss of unit capacity and efficiency as well as increased pump power will result from plugging tubes. Failed tubes should be replaced as soon as possible. Up to 10% of the total number of tubes can be plugged before retubing is necessary. Figure 14 shows an Elliot tube plug and a crosssectional view of a plug in place. The same components for plugging and rolling tubes can be used for all coolers and 30HXC condensers. See Table 36.

Use extreme care when installing plugs to prevent damage to the tube sheet section between the holes.

RETUBING (See Table 37) — When retubing is to be done, obtain service of qualiﬁed personnel experienced in boiler maintenance and repair.Moststandardprocedurescanbefollowed when retubing the 30GX and 30HX heat exchangers. A7%crushisrecommended when rolling replacement tubes into the tubesheet. A 7% crush can be achieved by setting the torque on the gun at 48 to 50 in.-lb (5.4 to 5.6 N-m).

The following Elliot Co. tube rolling tools are required:

B3400 Expander Assembly B3401 Cage

B3405 Mandrel B3408 Rolls

Place one drop of Loctite No. 675 or equivalent on top of tube prior to rolling. This material is intended to ‘‘wick’’ into the area of the tube that is not rolled into the tube sheet, and prevent ﬂuid from accumulating between the tube and the tube sheet. New tubes must also be rolled into the center tube sheet to prevent circuit-to-circuit refrigerant leakage.

Table 36 — Plugging Components

COMPONENTS FOR PLUGGING PART NUMBER For Tubes

Brass Pin 853103-1A* Brass Ring 853002-640*

For Holes without Tubes

Brass Pin 853103-1A* Brass Ring 853002-738*

Roller Extension S82-112/11 Loctite No. 675† Locquic ‘‘N’’†

*Order directly from: Elliot Tube Company, Dayton, Ohio.

†Can be obtained locally.

Table 37 — Tube Diameters

ITEM INCHES MILLIMETERS

Tube sheet hole diameter: 0.756 19.20 Tube OD 0.750 19.05 Tube ID after rolling:

(includes expansion due to clearance)

0.704 to

0.710

17.88 to

18.03

NOTE: Tubes replaced along heat exchanger head partitions must be ﬂush with tube sheet.

TIGHTENING COOLER/CONDENSER HEAD BOLTS O-Ring Preparation — When reassembling cooler and con-

denser heads, always check the condition of the O-ring(s) ﬁrst. The O-ring should be replaced if there are any visible signs of deterioration, cuts or damage. Apply a thin ﬁlm of grease to the O-ring before installation. This will aid in holding the O-ring into the groove while the head is installed. Torque all bolts to the following speciﬁcation and in the sequence shown in Fig. 15.

⁄4-in. Diameter Perimeter and

Plate Bolts ........................200to225ft-lb.

(271 to 305 N-m)

SHELL BOLTS

OUTLET FOR MOTOR COOLING LINE CONNECTION

STEPPER MOTOR HARNESS

MOUNTING BRACKET BOLTS

STEPPER MOTOR

FLOAT ASSEMBLY

DISCHARGE GAS BUBBLER TUBE

OUTLET TO BOTTOM OF COOLER

LIQUID INLET TUBE FROM CONDENSER

Fig. 13 — 30GX,HX Cutaway View of

Economizer Assembly

PIN AND RING INSTALLED

TUBE SHEET

TUBE

RING

Fig. 14 — Tube Plugging

Page 53

1. Install all bolts ﬁnger tight.

2. Follow numbered sequence shown for head type being installed. This will apply even pressure to the O-ring.

3. Apply torque in one-third steps until required torque is reached. Load all bolts to each one-third step before proceeding to the next one-third step.

4. No less than one hour later, retighten all bolts to required torque values.

5. Restore water/brine ﬂow and check for leaks. Fix leaks as necessary. Replace insulation (on cooler heads only).

Inspecting/Cleaning Heat Exchangers

COOLERS — Inspect and clean the cooler tubes at the end of the ﬁrst operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Tube condition in the cooler will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/brine circuit. Inspect the entering and leaving thermistors for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found.

CONDENSERS (30HX Only) — Since this water circuit is usually an open-type system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at regular intervals, and more often if the water is contaminated. Inspect the entering and leaving condenser water thermistors (if installed) for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found.

Higher than normal condenser pressures, together with inability to reach full refrigeration load, usually indicate dirty tubes or air in the machine. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes

may be dirty, or water ﬂow may be incorrect. Due to the pressure in the R-134a system, air usually will not enter the machine; the refrigerant will leak out.

During the tube cleaning process, use brushes specially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes.

Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment procedures.

Water Treatment — Untreated or improperly treated

water may result in corrosion, scaling, erosion, or algae. The services of a qualiﬁed water treatment specialist should be obtained to develop and monitor a treatment program.

Water must be within designﬂowlimits,cleanandtreated to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller or condenser damage resulting from untreated or improperly treated water.

Condenser Coils (30GX Only)

COIL CLEANING — Clean coils with a vacuum cleaner, fresh water,compressedair, or a bristle brush (not wire). Units installed in corrosive environments should have coil cleaning as part of a planned maintenance schedule. In this type of application, all accumulations of dirt should be cleaned off the coil.

BLANK PLATE

BLANK PLATES

Fig. 15 — Cooler and Condenser Head Recommended Bolt Torque Sequence

Page 54

Do not use high-pressure water or air to clean coils as ﬁn damage may result.

Condenser Fans (30GX Only) — Each fan is sup-

ported by a formed wire mount bolted to a fan deck and covered with a wire guard. The exposed end of the fan motor shaft is protected from weather by grease. If the fan motor must be removed for service or replacement, be sure to regrease fan shaft and reinstall fan cover, retaining clips, and fan guard. For proper performance, the fans should be positioned as shown in Fig. 16 or 17. Tighten setscrews to 14 ± 1 ft-lb (18 ± 1.3 N-m).

Check for proper rotation of the fan(s) once reinstalled (clockwise for high static and counterclockwise for standard viewed from above). If necessary to reverse, switch leads at contactor(s) in control box.

Refrigerant Charging/Adding Charge

IMPORTANT: These units are designed for use with R-134a only. DO NOT USE ANY OTHER REFRIGERANT in these units without ﬁrst consulting your Carrier representative.

When adding or removing charge,circulatewaterthrough the condenser (30HXC) and cooler at all times to prevent freezing. Freezing damage is considered abuse and may void the Carrier warranty.

DO NOT OVERCHARGE system. Overcharging results in higher discharge pressure with higher cooling ﬂuid consumption,possiblecompressordamageand higher power consumption.

Indication of low charge on a 30HXC system: NOTE: To check for low refrigerant charge on a 30HXC,

several factors must be considered.A ﬂashing liquid-line sight glass is not necessarily an indication of inadequate charge. There are many system conditions where a ﬂashing sightglass occurs under normal operation. The 30HXC metering device is designed to work properly under these conditions.

1. Make sure that the circuit is running at a full-load con-

dition. To check whether circuit A is fully loaded, enter

on the HSIO keypad. The display will read

‘‘CIRCUIT AANALOG VALUES.’’Using the down arrow key on the keypad, scroll down once to ‘‘Total Capacity.’’Ifthisvalue is 100%, the circuit is at full load. To check circuit B, follow the same procedure, but enter

on the keypad.

2. It may be necessary to use the Manual Control feature to

force the circuit into a full-load condition. If this is the case, see the instructions for using the Manual Control feature in Table 19 of this manual.

3. With the circuit running at full load, verify that the cooler

leaving ﬂuid temperature is in the range of 38 to 46 F (3.3 to7.8C).Checkpressure drop across liquid line strainer and replace strainer if necessary.

4. Atthis condition, observe the refrigerant in the liquid line

sight glass. If there is a clear sight glass, and no signs of ﬂashing, then the circuit is adequately charged. Skip the remaining steps.

5. Iftherefrigerantappearstobe ﬂashing, the circuit is probably low on charge. Verify this by checking the EXV Percent Open. This information can be accessed by

entering on the HSIO keypad for Circuit A, or

for Circuit B. Scroll down using the down arrow

key on the keypad, until EXV Percent Open is displayed.

6. If the EXV Percent Open is greater than 60%, and the liquid-line sight glass is ﬂashing, then the circuit is low on charge. Follow the procedure for adding charge for 30HXC units.

To add charge to the 30HXC systems:

1. Make sure that the unit is running at full load, and that the cooler leaving ﬂuid temperature is in the range of 42 to 46 F (5.6 to 7.8 C).

2. At these operating conditions, check the liquid line sight glass. If there is a clear sight glass, then the unit has sufﬁcient charge. If the sight glass is ﬂashing, then check the EXV Percent Open. If this is greater than 60%, then begin adding charge.

NOTE:Aﬂashing liquid line sight glass at operating conditions other than those mentioned above is not necessarily an indication of low refrigerant charge.

3. Add 5 lb of liquid charge into the cooler using the

⁄4-in. Schrader-type ﬁtting located on the tube entering the bottom of the cooler.Thisﬁttingislocated between the Electronic Expansion Valve (EXV) (size 076-146 units), or the economizer (size 161-271 units) and the cooler.

4. Observe the EXV Percent Open value. The EXV should begin closing as charge is being added. Allow the unit to stabilize. If the EXV Percent Open remains above 60%, and the sight glass continues ﬂashing, add an additional 5 lb of liquid charge.

5. Allow the unit to stabilize, and again check the EXV Percent Open. Continue adding 5 lb at a time of liquid refrigerant charge, and allow the unit to stabilize before checking the EXV position.

PLASTIC FAN PROPELLER

CLEARANCE OF 0.25 INCHES (6.4 MM) FOR STANDARD CONDENSER FANS

FAN DECK SURFACE

FAN ORIFICE

Fig. 16 — Condenser Fan Position (Standard Fan)

POSITION TOP OF HIGH STATIC FAN PROPELLER HUB

2.15 INCHES (54.6 mm) ABOVE FAN DECK SURFACE

FAN DECK SURFACE

STATIC FAN PROPELLER

FAN HUB

2.15 IN.

MOTOR SHAFT

Fig. 17 — Condenser Fan Position (High Static Fan)

Page 55

6. WhentheEXVPercentOpenisintherangeof 40 to 60%, check the liquid line sight glass. Slowly add enough additional liquid charge to ensure a clear sight glass. This should be done slowly to avoid over-charging the unit.

7. Verify adequate charge by continuing to run at full load with 42 to 46 F (5.6 to 7.8 C) cooler leaving ﬂuid temperature. Check that the refrigerant is not ﬂashing in the liquid-line sight glass. The EXV Percent Open should be between 40 and 60%. The cooler level indicator should be in the range of 1.5 to 2.2.

Indication of low charge on a 30HXA, GX systems:

1. Make sure that the circuit is running at a full load condition and all condenser fans are energized and running at full speed. To check whether circuit A is fully loaded,

enter on the HSIO keypad. The display will read ‘‘CIRCUIT AANALOG VALUES.’’Using the down ar-

row key on the keypad, scroll down once to ‘‘Total Capacity.’’Ifthisvalue is 100%, the circuit is at full load. To check circuit B, follow the same procedure, but enter

on the keypad.

2. It may be necessary to use the Manual Control feature to force the circuit into a full-load condition. If this is the case, see the instructions for using the Manual Control feature in Table 19 on page 31 of this manual.

3. With the circuit running at full-load, verify that the cooler leaving ﬂuid temperature is in the range of 38 to 48 F (5.6 to 7.8 C).

4. For 30HXA chillers, raise the compressor discharge to approximately 125 F (51.7 C) saturated discharge temperature (185 psig [1276 kPa]). For 30GX chillers, raise the compressor discharge to approximately 130 F (54.4 C) saturated discharge temperature (198 psig [1366 kPa]). Measure the liquid temperature entering the expansion device for 30HXAunits. For 30GX units, measure the liquid temperature after the tee where all liquid lines have joined. The liquid temperature should be approximately 107 F (41.7 C) for optimum charge. If the temperature is greater than 107 F (41.7 C) and the sight glass is ﬂashing, the circuit is undercharged.

5. Add 5 lb of liquid charge into the cooler using the

⁄4-in. Schrader-type ﬁtting located on the tube entering the bottom of the cooler.Thisﬁttingislocated between the Electronic Expansion Valve (EXV) (30HXA076-146 units, 30GX080-090 units), or the economizer (30HXA161271 units, 30GX105-176 units) and the cooler.

6. Allow the system to stabilize and then recheck the liquid temperature. Repeat Step 5 as needed allowing the system to stabilize between each charge addition. Slowly add charge as the sight glass begins to clear to avoid overcharging.

Oil Charging/Low Oil Recharging

Addition of oil charge to 30HX,GX systems:

1. If the 30HX,GX unit shuts off repeatedly on Low Oil Level (Alert number 71 or 72), this may be an indication of inadequate oil charge. It could also mean simply that oil is in the process of being reclaimed from the low-side of the system.

2. Begin by running the unit at full load for 1

⁄2hours. Use the Manual Control feature of the software if the unit does not normally run at full load.

3. After running the unit for 1

⁄2hours, allow the unit to restart and run normally. If the Low Oil Level alarms persist, continue following this procedure.

4. Close the liquid line service valve, and place a pressure gage on top of the cooler. Enable the manual control feature using the HSIO keypad, and turn the LOR switch to local. Start the desired compressor by pressing

on the keypad, at the appropriate line on the

display.

5. Before starting the compressor, the unit will go through its normal pre-lube pump routine. If there is an insufﬁcient level of oil in the oil separator, the compressor will not start, and a pre-start oil pressure alarm will be posted. Skip to Step 8.

6. If the compressor starts successfully, observe the cooler pressure gage. When this gage reads approximately

10 psig, press on the HSIO keypad, and move the LOR switch to the off position.

7. Open the liquid line service valve and allow the unit to restart and run normally. If the Low Oil Level alarms persist, continue following this procedure.

8. If none of the previous steps were successful, the unit is low on oil charge. Add oil to the oil separator using the

⁄4-in. Schrader-type ﬁtting on the discharge line entering the top of the oil separator (30HX units) or through the Schrader ﬁtting on the top of the oil separator (30GX units).

Do not add oil at any other location as improper unit operation may result.

9. Make sure that the unit is not running when adding oil, as this will make the oil charging process easier. Because the system is under pressure even when the unit is not running, it will be necessary to use a suitable pump (hand pump or electric pump) to add oil to the system.

10. Using a suitable pump, add

⁄2gal. (1.89 L) of Castrol Icematict SW-220 Polyolester oil (Carrier Speciﬁcation number is PP47-32; absolutely no substitutes are approved) to the system. Make sure that the oil level safety switch is NOT jumpered, and allow the unit to restart and run normally. Do not exceed maximum oil change. See Table 38.

11. If low oil level problems persist, add another 1.89 L (

⁄2gal.) of oil. Continue adding oil in 1.89 L (1⁄2gal.) increments until the problem is resolved. If it is necessary to add more than 5.75 L (1.5 gallons) of oil to the system, contact your Carrier distributor service department.

Table 38 — Maximum Oil Charges

UNIT SIZE

CIRCUIT A

(gal)

CIRCUIT A

(L)

CIRCUIT B

(gal)

CIRCUIT B

(L)

30GX080-176 5.0 18.9 5.0 18.9

30GX205-265 7.0 26.5 5.0 18.9 30HXA076-186 5.0 18.9 5.0 18.9 30HXC076-186 4.5 17.0 4.5 17.0 30HXC206-271 7.5 28.4 5.0 18.9

Page 56

OilFilter Maintenance — Each compressor has its own

internal oil ﬁlter and each circuit also has an in-line external ﬁlter. The internal oil ﬁlter pressure drop should be checked and ﬁlter changed (if necessary) after the initial 200-300hours of compressor operation. It is recommended that oil line pressure loss checks be made on an annual basis thereafter to determine the need for ﬁlter changes.Theneedforﬁltermaintenance can be monitored through system pressure drop. Discharge pressure is read at the oil separator and oil pressure is read at the compressor. This pressure differential is typically 15 to 20 psi (103 to 138 kPa) for a system with clean internal and external ﬁlters. See Pressure Transducers section, page 59 for information on removing discharge pressure transducers to measure discharge pressure. Figure 18 shows the location of the oil pressure bleed port on the compressor.A gage can be attached to this point so that two pressure drops can be measured.Thedifference between discharge pressure and the gage pressure will be the pressure loss due mainly to the external oil ﬁlter. If this value exceeds 10 psi (69 kPa), replace the external ﬁlter. The difference between the gage pressure and compressor oil pressure is the pressure drop through the internal oil ﬁlter. Replace the internal oil ﬁlter if the pressure drop is greater than 30 psi (207 kPa).

REPLACING THE EXTERNAL OIL FILTER

Compressor oil is pressurized. Use proper safety precautions when relieving pressure.

Fully front seat (close) the angle valve on the ﬁlter. Connect a charging hose to the oil pressure bleed port and drain the oil trapped between the ﬁlter and the internal check valve.

Use the function to cycle the oil solenoid a few times to properly seat the internal check valve as the pressure is

being relieved. If the oil pressure does not bleed off using this method it will be necessary to remove the entire circuit charge.Apint of oil is typically what is removed during this process. Remove the charging hose.

Unscrew the nut from the other side of the ﬁlter and remove the old ﬁlter. Remove protective plastic caps from new ﬁlter and install. Draw a vacuum at the bleed port. Remove charging hose. Open angle valve enough to let oil ﬂow. Check both ﬁttings for leaks and repair if necessary.Backseat angle valve.

REPLACING THE INTERNALOILFILTER — Follow the procedure above to the point that the oil has been drained from the bleed port. Using a

⁄4-in. allen wrench, remove the internal ﬁlter access cover (see Fig. 18). Remove the old ﬁlter. Replacement ﬁlters (one for each compressor) are factory supplied to cover the ﬁrst changeout. After that, ﬁlters are ﬁeld supplied. Remove the old O-ring from internal check valve. Lightly oil O-ring and install into groove. Install new ﬁlter open end ﬁrst into the housing. Replace access cover and retorque to 150 ft-lb (203 N-m). Follow procedure in previous section for opening angle valve and purging lines. Check for leaks and repair if necessary.

Compressor Changeout Sequence

NOTE: Replacement compressors can be ordered by calling 800-CARLYLE (800-227-5953). In most cases, replacement compressors can be shipped in 1 to 2 business days.

Compressor service requires metric tools and hardware.

Change compressors according to the following procedure:

1. Turn off all main and control circuit power supplying the machine.

2. Close the discharge and liquid valve(s), suction valve, and cooler inlet line service valve (if equipped), oil line shutoff valve, economizer bubble tube valve (30HXA,C161-271 only) andminimumloadshutoff valve (if equipped) for circuit to be changed. Disconnect the oil inlet line from the compressor. Disconnect oil ﬁlter with ﬁtting at shutoff valve side and set ﬁlter and compressor inlet line assembly aside.

3. Removeanyremainingrefrigerantinthecompressorand refrigerant lines using proper reclaiming techniques.All of the refrigerant that is in the cooler must be removed if there is no suction service valve installed on the cooler.

IMPORTANT: Cooler and condenser pumps must be energized. Fluid must be ﬂowing through heat exchangers whenever adding or removing charge.

4. Removejunctionboxcoverofcompressortobechanged. Check main power leads for marked numbers. If no numbers are visible on leads, mark leads with appropriate numbers to match those printed on the ends of the terminal lugs. This is extremely important as powerleads

MUST be installed on the exact terminals fromwhich they were removed.

5. Disconnectmain power leads from compressor terminal lugs. Mark remaining control circuit wires (connected together with wire nuts) for ease of reconnecting later. The following color scheme applies (verify with label diagram on panel):

Loader 1 2 Violet wires Loader 2 2 Pink wires Motor Cooling Solenoid 1 Blue wire, 1 Brown wire * Oil Solenoid 1 Orange wire, 1 Brownwire* High-Pressure Switch 2 Red wires

*One lead from the motor cooling and oil solenoids are con-

nected together with a single brown wire.

6. Remove loader (mark solenoids no. 1 and 2 for replacement) and oil solenoids and high-pressure switch from compressor. Using 2 wrenches, carefully remove the oil pressure transducer from the compressor. These will all be reconnected to the replacement compressor.

NOTE: Some oil will leak out of the transducer ﬁtting when the transducer is removed. See Fig. 18.

7. Mark motor temperature leads (2 blue wires) and remove from quick connect terminals in the junction box.

The next steps involve compressor unbolting and removal. Compressor seals are made using O-rings. Use care when removing bolts and disconnecting ﬂanges. The O-rings must NOT be re-used. New O-rings are provided with the replacement compressor. The 06N screw compressors weigh ap- proximately 900 pounds. Be sure that an appropriate lifting cart or hoist is used to avoid injury. See Fig. 19 for lifting locations and center of gravity dimensions. Make sure compressor is properly rigged before unbolting.

8. Remove the 2 bolts securing the motorcooling/economizer line ﬂange to the compressor.

Page 57

9. Remove the four M14 bolts securing the discharge line ﬂange to the compressor. Two of the bolts also secure the mounting bracket for the external oil ﬁlter. Support the oil line to prevent damage to the line while the compressor is being changed. For 30GX units, place temporary protectionovercoilstoprevent ﬁn and tube damage.

10. Movelifting apparatus into place and attach to the 2 lifting rings on the compressor. Apply minimal tension to hold the compressor while the remaining bolts are removed.

11. Remove the

⁄8-in. holddown bolt securing the foot at the dischargeendof the compressor to themountingbracket on the cooler.A foot bracket will be mounted to the replacement compressor.

12. Remove the 4 lockwashers and nuts securing the compressor to the suction ﬂange of the cooler. The compressor is held in place using four M14 x 2 studs through the suction nozzle of the cooler. The studs have an E-12 external Torx drive head. If possible, remove studs; if studs hit the cooler insulation, leave them in place — they will not interfere with compressor removal or installation. Save all the hardware as it will be needed to install the replacement compressor.

13. After checking to ensure all lines, wires, conduits, etc. are free and out of the way, remove compressor from cooler.Apply a light ﬁlm of O-ring grease to new O-ring and place back into groove in mounting ﬂange of compressor. If the new compressor is the A1 or A2 (30HX units) compressor, remove the compressor junction box and rotate it 180 degrees. Tighten screws to 6.8 to

9.5 N-m (5 to 7 ft-lb). The A1 and A2 compressors are on the right side of the unit when facing the unit control box.

14. Remove suction cover plate and bolts from new compressor and set compressor on unit ﬂange. Thread the studs all the way back into the compressor. Install the 4 lockwashers and nuts ﬁnger-tight. Tighten bolts in a crossing pattern to a range of 81.4 to 135.6 N-m (60 to 100 ft-lb). Do NOT overtighten as damage may result to O-ring. Install and tighten hold down bolt in mounting foot.

15. Remove motor cooling/economizer and discharge line cover plates from new compressor.

16. Apply a light ﬁlm of O-ring grease to motor cooling/ economizer and discharge line O-rings, place back into grooves and install ﬂange bolts. Tighten discharge line bolts in a crossing pattern to a range of 81.4 to

135.6 N-m (60 to 100 ft-lb). Tighten motor cooling/ economizer bolts to a range of 81.4 to 108.5 N-m (60 to 80 ft-lb). Do NOT overtighten as damage may result to O-rings.

17. Reconnect the oil ﬁlter to the shutoff valve and oil line to the compressor. Install oil line straight into ﬁtting until ferrule seats against ﬁtting. Thread packing nut onto ﬁtting and tighten ﬁnger tight. Use a backup wrench to ﬁnish tightening the nut. Do not overtighten.

18. Reinstall the loader and oil solenoids, high-pressureswitch, and oil pressure transducer. Make sure the loader solenoids are installed on the correct number loader.

19. Reconnect conduits back into compressor junction box. Reconnect all wiring that was removed in Steps 4, 5, and 7. The replacement compressor comes with a reverse rotation switch. This switch must be wired in series with the high-pressure switch for compressor protection. Reconnect these wires as shown in Fig. 20.

20. Leak check compressor and refrigerant lines with nitrogen. Repair any leaks found. Remove nitrogen from system. Evacuate compressor and refrigerant lines. Refer to the Refrigerant and Oil Charging sections on pages 54 and 55 for recharging procedures.

21. Open all shutoff valves and leak check the circuit and all ﬁttings and joints. Repair any leaks found.

JUNCTION BOX OIL BLEED PORT

HIGH PRESSURE SWITCH

LOADER SOLENOID NO. 1

INTERNAL OIL FILTER ACCESS (3/4 in.)

OIL PRESSURE TRANSDUCER

OIL SOLENOID

LOADER SOLENOID NO. 2

LOADER COVER PLATE

Fig. 18 — Transducer Removal

DISCHARGE END

GEAR COVER END

CENTER OF GRAVITY OF COMPRESSOR

508 mm (20.0 in.)

178 mm (7.0 in.)

95 mm (3.75 in.)

CENTER OF GRAVITY OF COMPRESSOR

DISCHARGE END

GEAR COVER END

MINIMUM 381 mm (15 in.)

COMPRESSOR LIFTING MECHANISM

NOTE: Locatestrapfrom center ofgravitylifting ring andsupportmotor casing to provide 3-point level rigging.

Fig. 19 — Compressor Lifting Diagrams

COMPRESSOR LIFTING MECHANISM

ONE LUG AT OUTSIDE EDGE, RING AT

DISCHARGE CENTER

LIFTING LUGS BOTH OUTSIDE EDGES

RED

PL1-5

HPS

RRS

RED

PL1-6

LEGEND

HPS — High-Pressure Switch PL — Plug RRS — Reverse Rotation Switch

Fig. 20 — High-Pressure Switch Wiring

Page 58

22. Restore main and control power to the machine. Using the HSIO, enter the quick test function by pressing

(for compressor A1 or A2 replacement) or

(for compressor B1 replacement). Test the op-

eration of the solenoids. Press totesteachloader solenoid, then use the key to ﬁnd the motor cool-

ing and oil solenoids and test them in the same manner. Pressing the key after each output turns the solenoid off (or press ). It is important that the

loaders are located properly (loader 1 on right hand side when viewed from side opposite control box on 30HX units, on left hand side when reaching over compressor to far side on 30GX units).

23. Start the compressor using the Manual mode. Press

at the HSIO.Press to enable the Manual

mode. When display changes to ‘‘Enable,’’ switch the Local-Off-Remote switch to the Local position. Select the desired compressor using the down arrow key. Press

to start the compressor. Use the down arrow

key and press to energize both loaders. Let the circuit stabilize with both loaders energized. Refer to the

Refrigerant and Oil Charging sections of this document for recharging procedures and performance criteria.

BURNOUT CLEANUP PROCEDURE — If a screw compressor motorburnsouton a 30GX,HX chiller,asimplecleanup should be performed. The following procedure provides the minimum steps to be taken before restarting the circuit.

1. Remove the oil from the oil separator. This can be facilitated by connecting a hose to the port located on the service valve entering the external oil ﬁlter.Run the hose to a container(s) that can hold up to 5 to 6 gallons of oil. To force out most of the oil in the separator pressurize the circuit. To remove the remaining oil, the pre-lube

pump can be run in mode from the HSIO. To prevent wear to the gears, do not allow the pre-lube pump

to operate ‘‘dry.’’

2. Remove the failed compressor following the Compressor Changeout Sequence procedure above.

3. Oncethecompressoris removed access the oil catch pan through the cooler-compressor mounting ﬂange. Clean out any debris which may have collected in the oil catch pan.

4. Install a new compressor.

5. To dilute and remove any residual oil left in the separator, pump approximately

⁄2gallon of compressor oil into the oil separator using the Schrader port located on top oftheseparator(30GX) or on the dischargeline(30HX) and remove using the pre-lube pump described in Step 1.

6. Disconnect the hose from the external oil ﬁlter service valve.

7. Install a new ﬁlter drier and compressor external oil ﬁlter.

8. Measure in the amount of Castrol SW 220 Polyolester oil as speciﬁed on the nameplate of the chiller.

9. Leak check, evacuate and recharge the machine as described in this manual with the amount of R-134a stated on the chiller nameplate.

10. Perform periodic acid checks on the circuit and change the ﬁlter drier in the motor cooling line as necessary.

Use the Carrier Standard Service Techniques Manual as a source of reference.

Moisture-Liquid Indicator — Clear ﬂow of liquid

refrigerant indicates sufficient charge in the system. Note, however, that bubbles in the sight glass do not necessarily indicate insufficient charge. Moisture in the system is measured in parts per million (ppm), changes of color of indicator are:

Green — moisture is below 80 ppm; Yellow-green (chartreuse) — 80 to 225 ppm (caution); Yellow (wet) — above 225 ppm.

Change ﬁlter drier at the ﬁrst sign of moisture in the

system.

IMPORTANT: Unit must in operation for at least 12 hours before moisture indicator can give an accurate reading. With the unit running, the indicating element must be in contact with liquid refrigerant to give true reading.

Filter Drier — Whenever moisture-liquid indicator shows

presence of moisture, replace ﬁlter drier. Refer to Carrier Standards Service Technique Manual, Chapter 1, Refrigerants, for details on servicing ﬁlter driers.

Liquid Line Service Valve — This valve is located

ahead of the ﬁlter drier and provides a1⁄4-in. Schrader connection (30GX only) for ﬁeld charging. In combination with compressor dischargeservicevalve,each circuit can be pumped down into the high side for servicing.

Thermistors — To aid in verifying thermistor perfor-

mance, resistances at various temperatures are listed for all thermistors (except motor thermistors) inTables 39Aand39B. See Table 40 for motor thermistor values.

LOCATION — General location of thermistor sensors and terminal connections in the control box are listed in Table 2.

THERMISTOR REPLACEMENT

Liquid level thermistors are installed in the top of the cooler using compression ﬁttings. All other thermistors are installed in wells and will slide out of the wells easily. The wells are under refrigerant pressure (cooler EWT and LWT are under waterside pressure) and do not need to be removed to replace a faulty thermistor.

To replace thermistors T1, T2, T5, or T6 (Entering,

Leaving Water; Discharge Gas Temperature):

Disconnect appropriate wires from PSIO-2 in unit control box. Remove thermistor cable from harness. Remove and discard original thermistor from well. Insert new thermistor in well body to its full depth. Add a small amount of thermal conductive grease to thermistor probe and well. Thermistors are friction-ﬁt thermistors and will slip back into well located at the cooler head (T1, T2) or at the top of the condenser shell (T5, T6). Secure thermistor to well body with a wire tie to prevent thermistor from working its way out of the well. See Fig. 21.

To replace thermistors T3 or T4 (Liquid Level Sensors):

See the Inspecting/Opening Economizers section on page 51 for information on transferring the refrigerant charge

Page 59

to the high side. Transfer refrigerant and reclaim any refrigerant remaining in the low side.

NOTE: A new packing nut and ferrule will be required as the old one is not removable from the old thermistor.

For 30GX080-176 and all 30HX units cut wire nuts apart to appropriate blue leads at PSIO-1 (J7-5,6 for T3; J7-8,9 for T4) and red leads connecting wires to TRAN-7. Remove old leads from control box harness. For 30GX205-265 units, disconnect plug assembly at liquid level sensor .Loosen the packing nut fully from the well threads. Remove and discard old thermistor and packing nut. Slide new packing nut then ferrule up onto new thermistor probe from inserted end. Insertion depth is dependent on unit model number. See Fig. 22 and Table 41.

Hand tighten packing nut to position ferrule while holding thermistor in position. With wrench, tighten enough to ﬁrmly secure thermistor in place in well. Run new harness wires into main control box for 30GX080-176 and all 30HX units. Reconnect blue wires at PSIO-1 for thermistor reading and red wires to TRAN-7. Reconnect plug assembly to new liquid level sensor for 30GX205-265 units. Restore unit control power only and verify that level thermistor is reading correctly. Check system low side for leaks and repair as necessary.Evacuate low side and open circuit discharge and liquid valves.

To service compressor motor thermistors:

Two thermistors are factory installed in each compressor. Connections for the thermistors are located in the compressor junction box. There are 3 terminals for the thermistors: S1, S2, and C. Motor temperature is measured by leads connected to one of the S terminals and the C terminal. If a compressor motor thermistor failure occurs, verify that there is a true short or open circuit at these terminals. If one of the thermistors fails, disconnect and relocate the wire on one of the S terminals to the other S terminal (S1 to S2 or S2 to S1). The thermistors are not serviceable in the ﬁeld. If both of the compressor motor thermistors fail, compressor replacement is required. See Table 40 for motor thermistor temperature and resistance values.

Pressure Transducers — A single style of pressure

transducer is used for both high- and low-pressure sensing on the 30GX,HX chillers. The transducers operate on a 5 vdc supply. The power supply for this is a 24 vac to 5 vdc full wave rectiﬁed power supply, PS1. See unit component arrangement label for mounting location and terminal connections in the control box. Refer to Fig. 23A and 23B for pressure transducer locations.

PRESSURE TRANSDUCER CALIBRATION — Pressure transducers are factory installed on all models to read Discharge, Suction, Economizer (reads leaving condenser pressure on models without economizer), and Oil pressure. DO NOT attempt to calibrate any of these transducers by the pressure gage method unless the transducer is connected to a fully charged refrigerant system. A more accurate method of calibration is used by the 30GX,HX software and corrects for

ambient temperature when calibrating. Calibrating a transducer when the system is under nitrogen charge will result in an incorrect offset being applied to the reading (due to temperature correction).Althoughthese transducers are calibrated at the factory, replacement transducers require calibration for accurate readings.Calibrationisalsorequiredwhen replacing a PSIO. Access to the transducer calibration area is through the Service function and the transducers can be calibrated at the current system pressure using a pressure gage at the same point or exposed to atmospheric pressure. In the example in Table 42, the CircuitADischarge Pressure transducer has been replaced and needs to be calibrated. A pressure gage has been installed at the transducer and reads 85 psi (must be in the range of −5.0 to 185.0 psi). See Table 42.

Use care when removingtheoilpressuretransducersfrom the compressor ﬁtting. The ﬁtting that the transducers mount in is sealed with an O-ring Schrader ﬁtting into the compressor casting. Do NOT overtigthen the transducer when replacing after calibration. Hold both ﬁttings with wrenches when removing and reinstalling.

The control will apply the 0.8 psi offset from the calibration example in Table 42 to all future readings. The calibration process for any of the other pressure transducers is done in a similar manner.Atransducer can also be calibrated at atmospheric pressure by removing the transducer from the system. To do this, carefully unplug the transducer connector. Unscrew the transducer from its mounting location and reconnect the connector. Follow the steps in Table 42 to read the current pressure and enter 0.0 psig as the gage pressure. Remove the connector from the transducer, thread the transducer back onto the ﬁtting from which it was removed (do NOT use thread sealant/compound), and reinstall the connector.

If it is necessary, all of the transducers may be calibrated at 0.0 psig. All of the transducers must be removed from the system and reconnected in atmosphere as described.

When complete, scroll down under to ‘‘Calibrate All at 0 PSIG’’ and press . A ‘‘Yes’’ will be dis-

played at this stepandwillautomaticallychangebackto‘‘No’’ once all transducers have been successfully calibrated. Reconnect the transducers and connectors as described above. All transducers are mounted on Schrader ﬁttings. Therefore, it is NOT necessary to remove system refrigerant charge. Use a catch pan when removing the oil pressure transducer for calibration as oil will leak out through the Schrader ﬁtting.

TROUBLESHOOTING — If transducer is suspected of being faulty, ﬁrst check supply voltage to transducer. Supply voltage should be 5 vdc ± .2 v. If supply voltage is correct, compare pressure reading displayed on keypad and display module against pressure shown on a calibrated pressure gage. If the 2 pressure readings are not reasonably close, replace pressure transducer.

Page 60

Table 39A — Thermistor Temperatures (°F) vs Resistance/Voltage Drop

(NOTE: These values do NOT Apply to the Motor Temperature Thermistors )

TEMP

(F)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

−25 4.821 98,010

−24 4.818 94,707

−23 4.814 91,522

−22 4.806 88,449

−21 4.800 85,486

−20 4.793 82,627

−19 4.786 79,871

−18 4.779 77,212

−17 4.772 74,648

−16 4.764 72,175

−15 4.757 69,790

−14 4.749 67,490

−13 4.740 65,272

−12 4.734 63,133

−11 4.724 61,070

−10 4.715 59,081

−9 4.705 57,162

−8 4.696 55,311

−7 4.688 53,526

−6 4.676 51,804

−5 4.666 50,143

−4 4.657 48,541

−3 4.648 46,996

−2 4.636 45,505

−1 4.624 44,066 0 4.613 42,679 1 4.602 41,339 2 4.592 40,047 3 4.579 38,800 4 4.567 37,596 5 4.554 36,435 6 4.540 35,313 7 4.527 34,231 8 4.514 33,185 9 4.501 32,176

10 4.487 31,202 11 4.472 30,260 12 4.457 29,351 13 4.442 28,473 14 4.427 27,624 15 4.413 26,804 16 4.397 26,011 17 4.381 25,245 18 4.366 24,505 19 4.348 23,789 20 4.330 23,096 21 4.313 22,427 22 4.295 21,779 23 4.278 21,153 24 4.258 20,547 25 4.241 19,960 26 4.223 19,393 27 4.202 18,843 28 4.184 18,311 29 4.165 17,796 30 4.145 17,297 31 4.125 16,814 32 4.103 16,346 33 4.082 15,892 34 4.059 15,453 35 4.037 15,027 36 4.017 14,614 37 3.994 14,214 38 3.968 13,826 39 3.948 13,449 40 3.927 13,084 41 3.902 12,730 42 3.878 12,387 43 3.854 12,053 44 3.828 11,730 45 3.805 11,416 46 3.781 11,112 47 3.757 10,816 48 3.729 10,529 49 3.705 10,250 50 3.679 9,979 51 3.653 9,717 52 3.627 9,461 53 3.600 9,213 54 3.575 8,973 55 3.547 8,739 56 3.520 8,511 57 3.493 8,291 58 3.464 8,076

TEMP

(F)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

59 3.437 7,868 60 3.409 7,665 61 3.382 7,468 62 3.353 7,277 63 3.323 7,091 64 3.295 6,911 65 3.267 6,735 66 3.238 6,564 67 3.210 6,399 68 3.181 6,238 69 3.152 6,081 70 3.123 5,929 71 3.093 5,781 72 3.064 5,637 73 3.034 5,497 74 3.005 5,361 75 2.977 5,229 76 2.947 5,101 77 2.917 4,976 78 2.884 4,855 79 2.857 4,737 80 2.827 4,622 81 2.797 4,511 82 2.766 4,403 83 2.738 4,298 84 2.708 4,196 85 2.679 4,096 86 2.650 4,000 87 2.622 3,906 88 2.593 3,814 89 2.563 3,726 90 2.533 3,640 91 2.505 3,556 92 2.476 3,474 93 2.447 3,395 94 2.417 3,318 95 2.388 3,243 96 2.360 3,170 97 2.332 3,099 98 2.305 3,031

99 2.277 2,964 100 2.251 2,898 101 2.217 2,835 102 2.189 2,773 103 2.162 2,713 104 2.136 2,655 105 2.107 2,597 106 2.080 2,542 107 2.053 2,488 108 2.028 2,436 109 2.001 2,385 110 1.973 2,335 111 1.946 2,286 112 1.919 2,239 113 1.897 2,192 114 1.870 2,147 115 1.846 2,103 116 1.822 2,060 117 1.792 2,018 118 1.771 1,977 119 1.748 1,937 120 1.724 1,898 121 1.702 1,860 122 1.676 1,822 123 1.653 1,786 124 1.630 1,750 125 1.607 1,715 126 1.585 1,680 127 1.562 1,647 128 1.538 1,614 129 1.517 1,582 130 1.496 1,550 131 1.474 1,519 132 1.453 1,489 133 1.431 1,459 134 1.408 1,430 135 1.389 1,401 136 1.369 1,373 137 1.348 1,345 138 1.327 1,318 139 1.308 1,291 140 1.291 1,265 141 1.289 1,240 142 1.269 1,214

TEMP

(F)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

143 1.250 1,190 144 1.230 1,165 145 1.211 1,141 146 1.192 1,118 147 1.173 1,095 148 1.155 1,072 149 1.136 1,050 150 1.118 1,029 151 1.100 1,007 152 1.082 986 153 1.064 965 154 1.047 945 155 1.029 925 156 1.012 906 157 0.995 887 158 0.978 868 159 0.962 850 160 0.945 832 161 0.929 815 162 0.914 798 163 0.898 782 164 0.883 765 165 0.868 750 166 0.853 734 167 0.838 719 168 0.824 705 169 0.810 690 170 0.797 677 171 0.783 663 172 0.770 650 173 0.758 638 174 0.745 626 175 0.734 614 176 0.722 602 177 0.710 591 178 0.700 581 179 0.689 570 180 0.678 561 181 0.668 551 182 0.659 542 183 0.649 533 184 0.640 524 185 0.632 516 186 0.623 508 187 0.615 501 188 0.607 494 189 0.600 487 190 0.592 480 191 0.585 473 192 0.579 467 193 0.572 461 194 0.566 456 195 0.560 450 196 0.554 445 197 0.548 439 198 0.542 434 199 0.537 429 200 0.531 424 201 0.526 419 202 0.520 415 203 0.515 410 204 0.510 405 205 0.505 401 206 0.499 396 207 0.494 391 208 0.488 386 209 0.483 382 210 0.477 377 211 0.471 372 212 0.465 367 213 0.459 361 214 0.453 356 215 0.446 350 216 9.439 344 217 0.432 338 218 0.425 332 219 0.417 325 220 0.409 318 221 0.401 311 222 0.393 304 223 0.384 297 224 0.375 289 225 0.366 282

Page 61

Table 39B — Thermistor Temperatures (°C) vs Resistance/Voltage Drop

(NOTE: These Values do NOT Apply to the Motor Temperature Thermistors)

TEMP

(C)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

−40 4.896 168 230

−39 4.889 157 440

−38 4.882 147 410

−37 4.874 138 090

−36 4.866 129 410

−35 4.857 121 330

−34 4.848 113 810

−33 4.838 106 880

−32 4.828 100 260

−31 4.817 94 165

−30 4.806 88 480

−29 4.794 83 170

−28 4.782 78 125

−27 4.769 73 580

−26 4.755 69 250

−25 4.740 65 205

−24 4.725 61 420

−23 4.710 57 875

−22 4.693 54 555

−21 4.676 51 450

−20 4.657 48 536

−19 4.639 45 807

−18 4.619 43 247

−17 4.598 40 845

−16 4.577 38 592

−15 4.554 38 476

−14 4.531 34 489

−13 4.507 32 621

−12 4.482 30 866

−11 4.456 29 216

−10 4.428 27 633

−9 4.400 26 202

−8 4.371 24 827

−7 4.341 23 532

−6 4.310 22 313

−5 4.278 21 163

−4 4.245 20 079

−3 4.211 19 058

−2 4.176 18 094

−1 4.140 17 184 0 4.103 16 325 1 4.065 15 515 2 4.026 14 749 3 3.986 14 026 4 3.945 13 342 5 3.903 12 696 6 3.860 12 085 7 3.816 11 506 8 3.771 10 959 9 3.726 10 441

TEMP

(C)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

10 3.680 9 949 11 3.633 9 485 12 3.585 9 044 13 3.537 8 627 14 3.487 8 231 15 3.438 7 855 16 3.387 7 499 17 3.337 7 161 18 3.285 6 840 19 3.234 6 536 20 3.181 6 246 21 3.129 5 971 22 3.076 5 710 23 3.023 5 461 24 2.970 5 225 25 2.917 5 000 26 2.864 4 786 27 2.810 4 583 28 2.757 4 389 29 2.704 4 204 30 2.651 4 028 31 2.598 3 861 32 2.545 3 701 33 2.493 3 549 34 2.441 3 404 35 2.389 3 266 36 2.337 3 134 37 2.286 3 008 38 2.236 2 888 39 2.186 2 773 40 2.137 2 663 41 2.087 2 559 42 2.039 2 459 43 1.991 2 363 44 1.944 2 272 45 1.898 2 184 46 1.852 2 101 47 1.807 2 021 48 1.763 1 944 49 1.719 1 871 50 1.677 1 801 51 1.635 1 734 52 1.594 1 670 53 1.553 1 609 54 1.513 1 550 55 1.474 1 493 56 1.436 1 439 57 1.399 1 387 58 1.363 1 337 59 1.327 1 290

TEMP

(C)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

60 1.291 1 244 61 1.258 1 200 62 1.225 1 158 63 1.192 1 118 64 1.160 1 079 65 1.129 1 041 66 1.099 1 006 67 1.069 971 68 1.040 938 69 1.012 906 70 0.984 876 71 0.949 836 72 0.920 805 73 0.892 775 74 0.865 747 75 0.838 719 76 0.813 693 77 0.789 669 78 0.765 645 79 0.743 623 80 0.722 602 81 0.702 583 82 0.683 564 83 0.665 547 84 0.648 531 85 0.632 516 86 0.617 502 87 0.603 489 88 0.590 477 89 0.577 466 90 0.566 456 91 0.555 446 92 0.545 436 93 0.535 427 94 0.525 419 95 0.515 410 96 0.506 402 97 0.496 393 98 0.486 385

99 0.476 376 100 0.466 367 101 0.454 357 102 0.442 346 103 0.429 335 104 0.416 324 105 0.401 312 106 0.386 299 107 0.370 285

THERMISTOR JACKETED CABLE SENSOR TUBE BEND SLIGHTLY BEFORE WELL INSERTION

3/16 in.

4 in.

THERMISTOR WELL

Fig. 21 — Thermistor Replacement (T1, T2, T5, or T6)

COOLER

MEASURE TO TOP OF WELD COUPLING FOR PROPER INSERTION (SEE TABLE 41)

PACKING NUT

FERRULE

LEAD END (30GX080-176, ALL 30HX) PLUG END (30GX205-265)

Fig. 22 — Thermistor (Liquid Level Sensor) Replacement

Page 62

Table 40 — Thermistor Temperatures vs

Resistance, Motor Temperature Thermistors

TEMP

(F)

TEMP

(C)

RESISTANCE

(Ohms)

−22 −30 88,480.0

−13 −25 65,205.0

−4 −20 48,536.0 5 −15 36,476.0

14 −10 27,663.0 23 −5 21,163.0 32 0 16,325.0 41 5 12,696.0 50 10 9,949.5 59 15 7,855.5 68 20 6,246.0 77 25 5,000.0 86 30 4,028.4 95 35 3,265.7

104 40 2,663.2

113 45 2,184.2 122 50 1,801.2 131 55 1,493.1 140 60 1,243.9 149 65 1,041.4 158 70 875.8 167 75 739.7 176 80 627.6 185 85 534.9 194 90 457.7 203 95 393.3 212 100 339.3 221 105 293.8 230 110 255.3 239 115 222.6 248 120 194.8

NOTE: Motor temperature thermistor values must be veriﬁed using resistance. Voltage drop cannot be used.

Table 41 — Thermistor Depth

UNIT MODEL

NUMBER

THERMISTOR DEPTH

‘‘X’’-in. (mm)

30GX080-090 6.00 (152.4) 30GX105-115 4.25 (108.0) 30GX125-136 5.56 (141.2) 30GX150,151 6.00 (152.4) 30GX160,161 4.25 (108.0) 30GX175,176 4.25 (108.0) 30GX205-226 3.94 (100.0) 30GX250-265 4.82 (122.4) 30HXA,C076-086 5.13 (130.3) 30HXA,C096 6.00 (152.4) 30HXA,C106 4.25 (108.0) 30HXA,C116-126 5.13 (130.3) 30HXA,C136-146 6.00 (152.4) 30HXA,C161-171 4.25 (108.0) 30HXA,C186 5.56 (141.2) 30HXA,C206 3.94 (100.0) 30HXA,C246-271 4.82 (122.4)

Table 42 — Calibrating Pressure Transducers

(Pressure Gage Installed)

KEYPAD ENTRY DISPLAY RESPONSE COMMENTS

CALIBRATION OFFSET

CIRCUIT A PRESSURE

Discharge Pressure

84.2 PSI

Current reading is displayed.

Discharge Pressure

85.0 PSI

Enter gage pressure reading to nearest tenth. Control will allow offset of up to 6 psig. Transducer calibration is now complete.

Safety Devices — The 30GX/HX chillers contain many

safety devices and protection logic built into the electronic control. Following is a description of the major safeties.

COMPRESSOR PROTECTION Motor Overload — One factory preset solid-state overload

protects each compressor against overcurrent. Do not bypass the overload or make any changes to the overload setting. Determine the cause for trouble and correct the problem before resetting a tripped overload. In addition to the overload, each compressor is further protected by the Compressor Protection Module. Each module has a factory installed and conﬁgured 8-pin header. The conﬁguration of this header deﬁnes the must-trip amps at which the CPM will turn the compressor off. SeeAppendixD for correct setting of overload and conﬁguration headers.

Each CPM board also reads the status of each compressor’s high-pressure switch. All compressors have factoryinstalled high-pressure switches. For 30GX units, the switch is set to trip at 303 ± 7 psig (2089 ± 48 kPa). The setting for 30HXA units is 275 ± 7 psig (1896 ± 48 kPa) and for 30HXC units the setting is 191 ± 7 psig (1317 ± 48 kPa). If the switch opens during operation, the compressor will be shut down. The CPM will reset automatically when the switch closes, however, a manual reset is required to restart the compressor.

OIL SEPARATOR HEATERS(30GX)— Each oil separator circuit has a heater mounted on the underside of the vessel. The heater is energized with control circuit power. After a prolonged shutdown or service job, additional time may be required before starting the unit. Oil heaters are energized when the discharge gas temperature falls below 105 F (40.6 C). The heaters are deenergized when the discharge gas temperature rises above 110 F (43.3 C). The control will allow the chiller to attempt to start with the heaters energized and will keep the heaters on, even when running, until the discharge gas temperature reaches 110 F (43.3 C). Note that the oil heaters are deenergized if the oil level switch is open.

COOLER PROTECTION Low Water Temperature — Microprocessor is programmed to shut the chiller down if the leaving ﬂuid temperature drops below 34 F (1.1 C) for water or more than 8° F (4.4° C) below set point for brine units. When the ﬂuid temperature rises 6° F (3.3° C) above the leaving ﬂuid set point, the safety resets and the chiller restarts. Reset is automatic as long as this is the ﬁrst occurrence of the day.

IMPORTANT: If the unit is installed in an area where ambient temperatures fall below 32 F (0° C), inhibited ethylene glycol or other suitable solution must be used in the chilled ﬂuid circuit.

Relief Devices — Fusible plugs are located in each cir-

cuit (30GX only) between the condenser and the liquid line shutoff valve.

PRESSURE RELIEFVALVES — Valves are installed in each circuit and are located on all coolers. One relief valve is also installed on each 30HXC condenser. Both circuits’ oil separators on 30GX and 30HXA units have factory-installed relief valves as well. These valves are designed to relieve if an abnormal pressure condition arises. Relief valves on all coolers and 30HXC condensers relieve at 220 psi (1517 kPa). Relief valves on 30GX and 30HXA oil separators relieve at 320 psi (2206 kPa). Units with factory-installed suction service valves also have a relief valve in each compressor discharge line. These valves are designed to relieve at 350 psig (2413 kPa). These valves should not be capped. If a valve relieves, it should be replaced. If the valve is not replaced, it may relieve at a lower pressure, or leak due to trapped dirt from the system which may prevent resealing.

Page 63

COMPRESSOR A1

COMPRESSOR B1

COOLER

CONDENSER (30HXC MODEL) OIL SEPARATOR (30HXA MODEL)

1 2

DISCHARGE PRESSURE SUCTION PRESSURE

OIL PRESSURE

ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE)

COMPRESSOR A2

(206-271 ONLY)

Fig. 23A — 30HX Pressure Transducer Locations

COMPRESSOR A1

COMPRESSOR B1

COOLER

OIL SEPARATORS (ONE VESSEL ON SMALL GX'S, TWO SEPARATE ON LARGER UNITS)

DISCHARGE PRESSURE SUCTION PRESSURE

OIL PRESSURE

ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE)

COMPRESSOR A2 (205-265 ONLY)

Fig. 23B — 30GX Pressure Transducer Locations

Page 64

Pressure relief valves locatedoncoolerandcondensershells and 30HXA oil separator shells have3⁄4-in. NPT connections for relief. The 30GX oil separators have1⁄2-in. male ﬂare connections. Some local building codes require that relieved gases be removed. This connection allows conformance to this requirement.

Control Modules

Turn controller power offbeforeservicingcontrols.This ensures safety and prevents damage to controller.

PROCESSOR MODULE (PSIO-1), HIGH-VOLTAGE RELAY MODULE (DSIO-HV), AND EXV DRIVER MODULE (DSIO-EXV), 12/6 MODULE (PSIO-2) — The PSIO and DSIO modules all perform continuous diagnostic evaluations of the condition of the hardware. Proper operation of these modules is indicated by LEDs on the front surface of the DSIOs, and on the top horizontal surface of the PSIOs.

RED LED — Blinking continuously ata1to2second rate indicates proper operation. Lighted continuously indicates a problem requiring replacement of module. Off continuously indicates power should be checked. If there is no input power, check fuses. If fuse is bad, check for shorted secondary of transformer, tripped circuit breaker or bad module. On the PSIO module, if the light is blinking at a rate of twice per second, the module should be replaced.

GREEN LED — On a PSIO module, this is the green LED closest to COMM connectors. The other green LED on module indicates externalcommunications,whenused.GreenLED should always be blinking when power is on. It indicates modules are communicating properly. If green LED is not blinking, check red LED. If red LED is normal, check module address switches. Correct addresses are as follows:

PSIO-1 (Processor Module) — 01 CPM-A1 (Protection Module) — 21 CPM-A2 (Protection Module) — 29 CPM-B1 (Protection Module) — 37 DSIO (EXV Driver Module) — 50 DSIO-HV (Relay Module) — 62 PSIO-2 (12/6 I/O Module) — 74

The ﬁrst number of the address for a DSIO module should

be set on the switch closest to the silver mounting plate.

If all modules indicate communication failure, check COMM plug on PSIO-1 module for proper seating. If a good connection is assured and condition persists, replace PSIO-1 module.

If only a DSIO module indicates communication failure, check COMM plug on that module for proper seating. If a good connection is assured and the condition persists, replace the DSIO module.

All system operating intelligence rests in the PSIO-1 module, the module that controls unit. This module monitors conditions through input and output ports and through DSIO modules (high-voltage relay module and EXV driver module).

The machine operator communicates with microprocessor through keypad and display module. Communication between PSIO and other modules is accomplished by a 3-wire sensor bus. These 3 wires run in parallel from module to module.

On sensor bus terminal strips, terminal 1 of PSIO module is connected to terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner. See Fig. 24. If a terminal 2 wire is connected to terminal 1, system does not work.

In the 30GX,HX control box, the processor module (PSIO-1), DSIO-HV, keypad and display module and 5 vdc power supply are all powered from a common 21 vac power source (PSIO-1 and HSIO powered from 24 vac source on 30HX units) which connects to terminals 1 and 2 of the power connector on each module.Aseparate source of 21 vac power is used to power the PSIO-2 module and liquid level sensor heaters. A separate 12.5 vdc power source is used for the DSIO-EXV module through terminals 1 and 2 on the power connector.TheCPMmodulesareconnected to 24 vac power sources. Refer to Table 43 for control troubleshooting information.

Carrier Comfort Network (CCN) Interface — The

30GX,HX chiller units can be connected to the CCN if desired.Thecommunicationbuswiringis a shielded, 3-conductor cable with drain wire and is supplied and installed in the ﬁeld. The system elements are connected to the communication bus in a daisy chain arrangement as shown in Fig. 24. The positive pin of each system element communication connector must be wired to the positive pins of the system elements on either side of it. This is also required for the negative and signal ground pins of each system element. Wiring connections for CCN should be made at the COMM1 plug on the PSIO-1 module. Consult the CCN Contractor’sManual for further information.

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

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

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

1. Turn off power to the control box.

2. Cut the CCN wire and strip the ends of the red (+), white

(ground), and black (−) conductors. (Substitute appropriate colors for different colored cables.)

Page 65

Table 43 — Compressor Control Troubleshooting

SYMPTOMS CAUSE REMEDY

COMPRESSOR DOES NOT RUN

Power line open Check main disconnect. Control fuse open Check control circuit for ground or short. Replace fuse. High-Pressure Switch (HPS) tripped Move LOCAL/OFF/REMOTE switch to OFF position

then back to LOCAL or REMOTE position. Tripped motor overload Check the controls. Find cause of trip. Reset overload. Loose terminal connection Check connections. Improperly wired controls Check wiring and rewire. Low line voltage Check line voltage. Determine location of voltage drop

and remedy deﬁciency. Compressor motor defective Check motor winding for open or short. Replace com-

pressor if necessary. Seized compressor Replace compressor. Pre-lubrication not successful Check oil pump operation, oil pressure transducer, verify

oil level/ﬂow switch operation.

COMPRESSOR CYCLES OFF ON LOW PRESSURE

Loss of charge Repair leak and recharge. Bad transducer Replace transducer. Low refrigerant charge Add refrigerant. Failed expansion device Repair/replace as needed.

COMPRESSOR SHUTS DOWN ON HIGH PRESSURE CONTROL

High-pressure switch erratic in action Replace switch. Compressor discharge valve partially closed Open valve or replace if defective. Condenser fan(s) not operating (air cooled units) Check wiring. Repair or replace motor(s) if defective. Condenser coil plugged or dirty (air cooled units) Clean coil. Condenser water valve not operating (water

cooled units)

Check wiring. Repair or replace valve if defective Circuit overcharged Clean condenser.

Liquid valve closed* Open valve or replace if defective.

UNIT OPERATES LONG OR CONTINUOUSLY

Low refrigerant charge Add refrigerant. Control contacts fused Replace control. Partially plugged or plugged expansion valve or

ﬁlter drier

Clean or replace. Defective insulation Replace or repair.

Service load exceeding design capacity Keep doors and windows closed. Inefficient compressor Check loader solenoid valves. Replace if necessary.

SYSTEM NOISES Piping vibration Support piping as required.

Expansion valve hissing Add refrigerant.

Check for plugged liquid line ﬁlter drier. Compressor noisy Replace compressor (worn bearings).

Check for loose compressor bolts securing compressor

to cooler.

COMPRESSOR LOSES OIL Leak in system Find and repair leak.

Mechanical damage to rotors Replace compressor.

HOT LIQUID LINE Shortage of refrigerant due to leak Repair leak and recharge. FROSTED LIQUID LINE Shutoff valve partially closed or restricted Open valve or remove restriction. COMPRESSOR LOADERS

NOT WORKING PROPERLY

Burned out coil Replace coil. Defective capacity control valve Replace valve. Miswired solenoid Rewire correctly.

*30GX251, 265 sizes have two Circuit A discharge and liquid valves.

CPM-B1CPM-A1HSIO-IIPSIO-2-J8DSIO-EXV-J2

DSIO-HV-J2

PSIO-1-J8

Fig. 24 — Sensor Bus Wiring (Communications)

Page 66

3. Removethe 4-pin female plug from the PSIO-1 COMM1 plug and connect the red wire to terminal 1 of the plug, the white wire to terminal 2, and the black wire to terminal 3.

4. Insert the plug back into the COMM1 plug.

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, unplug the connector.Ifconditions return to normal, check the CCN connector and cable. Run new cable if necessary. A short in one section of the bus can cause problems with all system elements on the bus.

PROCESSOR MODULE (PSIO-1) Inputs — Each input channel has 3 terminals; only 2 of the

terminals are used.Applicationofmachinedetermineswhich terminals are used. Always refer to the individual unit wiring for terminal numbers.

Outputs — Output is 20 vdc or 4 to 20 mA. There are 3 terminals, only 2 of which are used, depending on the application. Refer to unit the wiring diagram.

NOTE: The 12/6 Input/Output module (PSIO-2) has identical input and output conﬁgurations as the PSIO-1. There is NO operating software in the PSIO-2 module.

HIGH VOLTAGE RELAY MODULE (DSIO-HV) Inputs — Inputs on strip J3 are discrete inputs (ON/OFF).

When 24-vac power is applied across the 2 terminals in a channel it reads the input as an On signal. Zero volts input is read as an Off signal.

Outputs — TerminalstripsJ4andJ5areinternalrelayswhose coils are signaled to be turned on and off by the microprocessor (PSIO-1). The relays switch the circuit to which they are connected. No power is supplied to these connections by DSIO-HV module.

Replacing Defective Processor Module — The

PSIO-1 module replacement part number is 30GX500110. The unit model and serial numbers are printed on the unit nameplate located on an exterior corner post (30GX) or the corner of the control box (30HX). The proper software and unit conﬁguration data is factory installed by Carrier in the replacement module. Therefore, when ordering a replacement processor module (PSIO-1), specify the replacement part number, full unit model number, and serial number. If these numbers are not provided, the replacement module will be downloaded with the base software. The base software settings must be reconﬁgured by the installer in the ﬁeld.

Verify the existing PSIO-1 module is defective by using

the procedure described in the Control Modules section.

Refer to Start-up Checklist for 30GX,HX Liquid Chillers (completed at time of original start-up) found in the job folder . This information is needed later in this procedure. If the checklist does not exist, ﬁll out the current factory and

service conﬁgurationcodes( ) sectionsonanew checklist. Tailor the various options and conﬁgurations as needed

for this particular installation.

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

1. Check that all power to unit is off. Carefully disconnect all wires from defective module by unplugging the 6 connectors. It is not necessary to remove any of the individual wires from the connectors. Remove the screws securing the green ground wire and communication drain wire. Save the screws.

2. Remove the defective PSIO-1 module by removing its mounting screws with a Phillips screwdriver, and removing the module from the control box. Save thescrews for later use.

3. Use a small screwdriver to set the address switches S1 and S2 on the new PSIO module to exactly match the settings on the defective module.

4. Package the defective module in the carton of the new module for return to Carrier.

5. Mount the new module in the unit control box using a Phillips screwdriver and the screws saved in Step 2.

6. Reinstall all 6 wire connectors, the green ground wire, and the communications drain wire.

7. Carefully check all wiring connections before restoring power.

8. Verify the LOCAL/OFF/REMOTE switch is in the OFF position.

9. Restore control power. Verify the red and green lights on top of the PSIO-1 and on front of each DSIO module respond as described in Control Modules section. The keypad and display module should also begin its rotating display.

Using the keypad and display module, press to verify that the software version number matches the

ER (engineering requirement) number shown on the PSIO-1 label.

10. Press , scroll down one level at a time, and check the 3 factory and 2 service conﬁguration codes as re-

corded on checklist. These codes must exactly match the codes stored in the previous PSIO-1 module for proper unit operation. These should already be downloaded if the proper information was supplied when ordering the replacement module. If the codes do not match, the codes must be entered by the procedure described in the factory service code section of Table 22.

11. Once all codes have been veriﬁed, and all conﬁgurations, set points, and schedules re-entered, return the LOCAL/OFF/REMOTE switch to its previous position.

WinterShutdown Preparation — At the end of each

cooling season the ﬂuid should be drained from the system. However, due to the cooler circuiting, some ﬂuid will remain in the cooler after draining. To prevent freeze-up damage to the cooler tubes perform the following procedure.

1. If accessory cooler heaters have been installed, deener-

gize the heaters to prevent damage and possible safety hazards when draining, or when there is no liquid in the system. Remove Fuse 1 to deenergize the heaters. Drain the ﬂuid from the system.

2. Isolate the cooler from the rest of the system with water

shut off valves.

3. Fill the cooler with an appropriate amount of unhibited

ethylene glycol solution (or other suitable corrosioninhibitive antifreeze) for 15° F (8.3° C) below the expected low ambient conditions.

4. Leavethe cooler ﬁlled with the antifreeze solution for the

winter, or drain if desired. Be sure to deenergize heaters (if installed) as explained in Step 1 to prevent damage. Use an approved method of disposal when removing the antifreeze solution.

Page 67

PRE-START-UP PROCEDURE

IMPORTANT: Before beginning Pre-Start-Up or StartUp, complete the Start-Up Checklist for the 30GX,HX Liquid Chillers on pages CL-1 to CL-8. This Checklist assures proper start-up of the chiller, and provides a record of unit condition, application requirements, system information and operation at initial start-up. The checklist should be removed from the manual and kept with the job ﬁle for future reference.

IMPORTANT: DO NOTATTEMPTTOSTARTTHE CHILLER UNTILTHE FOLLOWING CHECKSHAVE BEEN COMPLETED.

System Check

1. Check all auxiliary components such as the chilled ﬂuid circulating pump, air-handlingequipment,orotherequipment to which the chiller supplies liquid. Consult the manufacturer’s instructions. If the unit has field-installed accessories, be sure all are properly installed and wired correctly. Refer to the unit wiring diagrams.

2. Check the cooler ﬂow switch for proper conﬁguration and operation ( from HSIO). Ensure the switch

closes when the pump is on and opens when the pump is turned off. A ﬂow switch must be installed.

3. Openthedischargeandliquidvalvesineach circuit. The discharge shutof fvalvesarein-lineballtypeandareopen when parallel with the refrigerant ﬂow.

4. If factory-installed option is installed, open the suction service valves in each circuit. Service valve is located below the compressor in the cooler suction connection ﬂange.

5. Open the oil shutoff valves located by the oil pre-ﬁlter. Open bubbler tube valve on 30HX machines equipped with economizers.

6. Check the tightness of all electrical connections. Check incoming power supply for proper nameplate voltage.

7. Check to ensure the unit is level per the installation instructions.

8. Check the incoming power supply for proper phasing. This can be done by turning on both the line voltage and control voltage power supplies. Leave the LOCAL/OFF/ REMOTE switch in the OFF position. If the incoming power is not phased correctly, the CPM will generate

an alarm for voltage phase reversal. Press for CircuitAand for Circuit B at the HSIOtocheck

for this alarm. Scroll up and locate the Feedback value (displayed in units of volts). If a value of 7.0 appears, a voltage phase reversal has been identiﬁed and requires incoming power supply phase change. If this is the case, shut down all power supplies and switch any 2 incoming power leads at the control box terminal block.

DO NOT make any changes to the factory installed compressor power wiring in the control box or at the compressor junction box. Doing so will cause permanent damage to the compressor and will require compressor replacement. Proper phasing has already been checked at the factory.

For those units with 2 incoming terminal blocks, the voltage sequence is sensed at one terminal block only.Check the phasing to ensure that both circuits match. If the incoming power is still phased incorrectly at the

second terminal block, a current phase reversal alarm will be generated when an attempt is made to start this compressor. The compressor will be shut down within 15 milliseconds. To correct this, interchange 2 power leads at this terminal block only.

9. Check all ﬁeld conﬁguration data and set points.

10. Enter correct date, time, and operating schedule(s).

11. Verify operation of solenoids, pumps, valves, compressors, fans, etc. as listed in the Checklist.

12. Open condenser water valves. Check condenser water pump for proper operation (30HX).

START-UP AND OPERATION

Actual Start-Up —

Actual start-up should be done only under supervision of a qualiﬁed refrigeration mechanic and qualiﬁed Carrier Comfort Network personnel.

1. Set leaving ﬂuid temperature. No cooling range adjust-

ment is necessary.

2. Start chilled ﬂuid pump and condenser pump (30HXC) if

not controlled by unit.

3. Switch LOCAL/OFF/REMOTE switch to LOCAL or

REMOTE.

4. Provided there is a load on the chiller, allow the machine

to operate and conﬁrm that everything is functioning properly.Verify that the leaving ﬂuid temperature agrees with the cooling set point (1 or 2), or if reset is being used, the modiﬁed set point. Chiller is controlling to the Control

Point displayed under .

OperatingSequence— The chiller is started by switch-

ing the LOCAL/OFF/REMOTE switch to either LOCAL or REMOTE. On a command for cooling, the oil pump is turned on to start the pre-lubrication process. After 20 seconds, the oil solenoid is opened and the control reads the oil pressure from the transducer and determines if sufﬁcient pressure has been built up. If there is not sufﬁcient pressure, an alarm is generated after the second attempt and the compressor is not started.

Upon building pressure, the compressor is allowed to start. For across-the-line (XL) start chillers, the compressor starts and comes up to full speed within 1 to 3 seconds. For WyeDelta start chillers, contactors 1M and S (starter contactor assembly) are closed and the compressor is started in a Wye conﬁguration. This method reduces the locked rotor current requirements by approximately60%whilemaintainingenough torque to bring the compressor up to full speed.

After 5 seconds, the CPM module switches out contactor S and brings in contactor 2M, which runs the motor in a Delta conﬁguration (same conﬁguration in which XL units run). The oil pump will shut off within 10 seconds after the compressor is started. Once the compressor is successfully running, the control loads the compressor and adds additional stages of capacity as needed to satisfy the leaving fluid set point. Head pressure is controlled by fan cycling (30GX) or can be controlled with a ﬁeld installed accessory Motormastert III controller (30GX) or ﬁeld installed condenser water valves (30HX).

If cooler pump controlisenabled,thecoolerpumpis started. If condenser pump control (30HXC) is enabled, the condenser pump is started (Type 1).

Page 68

FIELD WIRING

Field wiring is shown in Fig. 25-37.

LEGEND FOR FIG. 25-37

ALM — Alarm C—Contactor CFC — Condenser Fan Contactor CPR — Condenser Pump Relay CWP — Chilled Water Pump DSIO — High Voltage Relay Module EQUIP — Equipment EXV — Electronic Expansion Valve FU — Fuse GFI-CO — Ground Fault Interrupter Convenience Outlet GND — Ground NEC — National Electrical Code PL — Plug PSIO — Processor Sensor Input/Output Module RB — Relay Board

TB — Terminal Block

Field-Wired Factory Wired

FIELD CONTROL POWER SUPPLY

NEC FUSED DISCONNECT

230 V CONTROL CIRCUITS USE 15 AMP MAXIMUM FROM SEPARATE POWER SUPPLY

115 V CONTROL CIRCUITS USE 30 AMP MAXIMUM FROM SEPARATE POWER SUPPLY

GND

TB4

Fig. 25 — Power Supply Wiring

EQUIP GND

TB2

BLK

SEPARATE 115 OR 230 V FIELD POWER SUPPLY

RELAY BOARD 1

ALM

MAX. LOAD ALLOWED FOR THE ALARM RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT.

FIELD SUPPLIED

Fig. 26 — Remote Alarm Relay Accessory Wiring; 30HXA,C

RELAY BOARD 2

SEPARATE 115 OR 230 V FIELD POWER SUPPLY

EQUIP GND

ALM

MAX. LOAD ALLOWED FOR THE ALARM RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT.

FIELD SUPPLIED

Fig. 27 — Remote Alarm Relay Accessory Wiring; 30GX

Page 69

RELAY BOARD 1

BLK

TB2

EQUIP GND

SEPARATE 115 OR 230 V FIELD POWER SUPPLY

CWP

MAX. LOAD ALLOWED FOR THE CWP RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT.

ACCESSORY ONLY

Fig. 28 — Chilled Water Pump Relay Wiring; 30HXA,C

SEPARATE 115 OR 230 V FIELD POWER SUPPLY

RELAY BOARD 1

EQUIP GND

C2C1

CWP

MAX. LOAD ALLOWED FOR THE CWP RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT.

ACCESSORY ONLY

Fig. 29 — Chilled Water Pump Relay Wiring; 30GX

Page 70

GFI-CO

GRN/YEL

SILVER SCREWSBRASS SCREWS

BLK

BLU

15 AMPS

FU1

TEST

RESET

ACCESSORY

TB4

WHT

TB4

Fig. 30 — Ground Fault Interrupter-Convenience Outlet Accessory Wiring

BRN

VIO

PNK

ORN BLU

BLU

RED

REDBLU

ORN

BLK

230V CONTROL CIRCUIT WIRING 115V CONTROL CIRCUIT WIRING

Fig. 31 — Oil Pump Motor Junction Box Wiring

TB4

WHT

MINIMUM LOAD CONTROL CIRCUIT B

MINIMUM LOAD CONTROL CIRCUIT A

GRA

PNK

RELAY BOARD 2

NOTE: Gray, Pink, and White wires are included in the control box as part of the factory wire harness. Field supplied and installed wire is needed from control box to solenoid valves.

Fig. 32 — Minimum Load Valve Accessory Wiring

Page 71

BLK

RB2PL2-3

RELAY BOARD 2

RB2PL2-5

TB2

CPR/

CFCB

BLK

CFCA

TB4

FIELD SUPPLIED

Fig. 33 — Condenser Pump Relay Wiring, 30HXC and Remote Condenser Fan On/Off Wiring, 30HXA

COOLER FLOW SWITCH

RED

CHILLED WATER PUMP INTERLOCK CONTACTS

TB2

DSIO (EXV)-J3

TB2

Fig. 34 — Chilled Water Interlock and Flow Switch Input Wiring

13 14

RED

OFF

REMOTE ON/OFF CONTACTS

REMOTE

TB2 TB2

TB2

RED

DSIO (EXV)-J3

Fig. 35 — Remote On/Off Switch Input Wiring

MAX. LOAD ALLOWED AT TB2-1 AND TB2-6 IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLTS.

Page 72

FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL

OUTDOOR AIR THERMISTOR FIELD SUPPLIED

4-20 mA WATER VALVE

4-20 mA SIGNAL GENERATOR TEMPERATURE RESET

4-20 mA SIGNAL GENERATOR DEMAND LIMIT

CONDENSER ENTERING WA TER THERMIST OR FIELD SUPPLIED

CONDENSER LEAVING WA TER THERMIST OR FIELD SUPPLIED

FIELD SUPPLIED 4-20 mA WATER VALVE (30HXC ONLY)

PSIO-2, J6 PLUG

TOP

PSIO-2, J7 PLUGS

REMOTE DUAL SETPOINT

ICE DONE

500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR

CONDENSER FLOW SWITCH

BOTTOM

FIELD SUPPLIED 24 VAC

Fig. 36 — PSIO-2 Wiring for Accessories and Field-Installed Options, 30HX Units

Page 73

FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL

TOP

PSIO-2, J7 PLUGS

BOTTOM

4-20 mA SIGNAL GENERATOR TEMPERATURE RESET

500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR

OUTDOOR AIR THERMISTOR FIELD SUPPLIED

4-20 mA SIGNAL GENERATOR DEMAND LIMIT

500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR

PSIO-2, J6 PLUG

VIO

GRA

VIO

GRA

VIO

GRA

VIO

GRA

MOTORMASTER® OPTION (080-150, 160) CIRCUIT A (151, 161-265)

MOTORMASTER OPTION CIRCUIT B (151, 161-265)

REMOTE DUAL SETPOINT

ICE DONE

STAGE 2

STAGE 1

DEMAND LIMIT EXTERNAL SWITCH

FIELD SUPPLIED 24 VAC

SPACE TEMPERATURE SENSOR FIELD SUPPLIED

Fig. 37 — PSIO-2 Wiring for Accessories and Field-Installed Options, 30GX Units

Page 74

APPENDIX A

Compressor Must Trip Amps (Determined by CPM Modules)

COMPRESSOR MUST TRIP AMPS

2-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, B1

Must Trip Amps

30GX080

575-3-60 98, 82 380-3-60 148,124

208/230-3-60 270,226

460-3-60 122,102 230-3-50 256,212

380/415-3-50 156,128

30GX090

575-3-60 120, 82 380-3-60 180,124

208/230-3-60 328,226

460-3-60 148,102 230-3-50 310,212

380/415-3-50 188,128

30GX105

230-3-50 344,238

380/415-3-50 208,144

30GX106

575-3-60 134, 92 380-3-60 202,140

208/230-3-60 368,254

460-3-60 168,114 230-3-50 344,238

380/415-3-50 208,144

30GX115

575-3-60 162, 92 380-3-60 246,140

208/230-3-60 448,254

460-3-60 204,114 230-3-50 418,238

380/415-3-50 254,144

30GX125

575-3-60 162,110 380-3-60 246,168

208/230-3-60 448,306

460-3-60 204,138 230-3-50 418,288

380/415-3-50 254,174

30GX136

575-3-60 162,134 380-3-60 246,202

208/230-3-60 448,368

460-3-60 204,168 230-3-50 418,344

380/415-3-50 254,208

30GX150

230-3-50 344,520

380/415-3-50 208,314

30GX151

575-3-60 198,134 380-3-60 300,202

208/230-3-60 546,368

460-3-60 240,168

30GX160

230-3-50 418,520

380/415-3-50 254,314

30GX161

575-3-60 198,162 380-3-60 300,246

208/230-3-60 546,448

460-3-60 248,204 230-3-50 520,418

380/415-3-50 314,254

30GX175

230-3-50 520,520

380/415-3-50 314,314

30GX176

575-3-60 198,198 380-3-60 300,300

208/230-3-60 546,546

460-3-60 248,248

30HXA076

575-3-60 82, 82 380-3-60 124,124 346-3-50 140,140

208/230-3-60 226,226

460-3-60 102,102 230-3-50 212,212

380/415-3-50 128,128

30HXA086

575-3-60 98, 82 380-3-60 148,124 346-3-50 170,140

208/230-3-60 270,226

460-3-60 122,102 230-3-50 256,212

380/415-3-50 156,128

COMPRESSOR MUST TRIP AMPS

2-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, B1

Must Trip Amps

30HXA096

575-3-60 120, 82 380-3-60 180,124 346-3-50 206,140

208/230-3-60 328,226

460-3-60 148,102 230-3-50 310,212

380/415-3-50 188,128

30HXA106

575-3-60 144, 82 380-3-60 218,124 346-3-50 250,140

208/230-3-60 400,226

460-3-60 180,102 230-3-50 376,212

380/415-3-50 228,128

30HXA116

575-3-60 144, 98 380-3-60 218,148 346-3-50 250,170

208/230-3-60 400,270

460-3-60 180,122 230-3-50 376,256

380/415-3-50 228,156

30HXA126

575-3-60 144,120 380-3-60 218,180 346-3-50 250,206

208/230-3-60 400,328

460-3-60 180,148 230-3-50 376,310

380/415-3-50 228,188

30HXA136

575-3-60 176,120 380-3-60 266,180 346-3-50 306,206

208/230-3-60 486,328

460-3-60 220,148 230-3-50 462,310

380/415-3-50 280,188

30HXA146

575-3-60 176,144 380-3-60 266,218 346-3-50 306,250

208/230-3-60 486,400

460-3-60 220,180 230-3-50 462,376

380/415-3-50 280,228

30HXA161

575-3-60 198,134 380-3-60 300,202 346-3-50 344,228

208/230-3-60 546,368

460-3-60 248,168 230-3-50 520,344

380/415-3-50 314,208

30HXA171

575-3-60 162,198 380-3-60 246,300 346-3-50 278,344

208/230-3-60 448,546

460-3-60 204,248 230-3-50 418,520

380/415-3-50 254,314

30HXA186

575-3-60 198,198 380-3-60 300,300 346-3-50 344,344

208/230-3-60 546,546

460-3-60 248,248 230-3-50 520,520

380/415-3-50 314,314

Page 75

APPENDIX A (cont)

Compressor Must Trip Amps (Determined by CPM Modules) (cont)

COMPRESSOR MUST TRIP AMPS

2-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, B1

Must Trip Amps

30HXC076

575-3-60 56, 56 380-3-60 84, 84 346-3-50 96, 96

208/230-3-60 154,154

460-3-60 70, 70 230-3-50 144,144

380/415-3-50 88, 88

30HXC086

575-3-60 68, 56 380-3-60 102, 84 346-3-50 116, 96

208/230-3-60 186,154

460-3-60 84, 70 230-3-50 176,144

380/415-3-50 106, 88

30HXC096

575-3-60 82, 56 380-3-60 124, 84 346-3-50 140, 96

208/230-3-60 226,154

460-3-60 104, 70 230-3-50 212,144

380/415-3-50 128, 88

30HXC106

575-3-60 100, 56 380-3-60 150, 84 346-3-50 168, 96

208/230-3-60 274,154

460-3-60 124, 70 230-3-50 254,144

380/415-3-50 154, 88

30HXC116

575-3-60 100, 68 380-3-60 150,102 346-3-50 168,116

208/230-3-60 274,186

460-3-60 124, 84 230-3-50 254,176

380/415-3-50 154,106

30HXC126

575-3-60 100, 82 380-3-60 150,124 346-3-50 168,140

208/230-3-60 274,226

460-3-60 124,104 230-3-50 254,212

380/415-3-50 154,128

COMPRESSOR MUST TRIP AMPS

2-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, B1

Must Trip Amps

30HXC136

575-3-60 120, 82 380-3-60 180,124 346-3-50 204,140

208/230-3-60 328,226

460-3-60 148,104 230-3-50 308,212

380/415-3-50 186,128

30HXC146

575-3-60 120,100 380-3-60 180,150 346-3-50 204,168

208/230-3-60 328,274

460-3-60 148,124 230-3-50 308,254

380/415-3-50 186,154

30HXC161

575-3-60 130, 90 380-3-60 196,136 346-3-50 220,152

208/230-3-60 358,246

460-3-60 162,112 230-3-50 332,228

380/415-3-50 202,138

30HXC171

575-3-60 108,130 380-3-60 164,196 346-3-50 182,220

208/230-3-60 298,358

460-3-60 136,162 230-3-50 274,332

380/415-3-50 166,202

30HXC186

575-3-60 130,130 380-3-60 196,196 346-3-50 220,220

208/230-3-60 358,358

460-3-60 162,162 230-3-50 332,332

380/415-3-50 202,202

Page 76

APPENDIX A (cont)

Compressor Must Trip Amps (Determined by CPM Modules) (cont)

COMPRESSOR MUST TRIP AMPS

3-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, A2, B1

Must Trip Amps

30GX205

230-3-50 418,238,520

380/415-3-50 254,144,314

30GX206

575-3-60 198, 92,162 380-3-60 300,140,246

208/230-3-60 546,254,448

460-3-60 248,114,204

30GX225

230-3-50 520,288,520

380/415-3-50 314,174,314

30GX226

575-3-60 198,110,198 380-3-60 300,168,300

208/230-3-60 546,306,546

460-3-60 248,138,248 230-3-50 520,288,520

380/415-3-50 314,174,314

30GX250

230-3-50 520,418,520

380/415-3-50 314,254,314

30GX251

575-3-60 198,198,162 380-3-60 300,300,246

208/230-3-60 546,546,448

460-3-60 248,248,204

30GX265

575-3-60 198,198,198 380-3-60 300,300,300

208/230-3-60 546,546,546

460-3-60 248,248,248 230-3-50 520,520,520

380/415-3-50 314,314,314

30HXA206

575-3-60 162, 92,198 380-3-60 246,138,300 346-3-50 278,158,344

208/230-3-60 448,254,546

460-3-60 204,116,248 230-3-50 418,238,520

380/415-3-50 254,144,314

30HXA246

575-3-60 198,134,198 380-3-60 300,202,300 346-3-50 344,228,344

208/230-3-60 546,368,546

460-3-60 248,168,248 230-3-50 520,344,520

380/415-3-50 314,208,314

COMPRESSOR MUST TRIP AMPS

3-COMPRESSOR UNITS

Unit Size Unit Voltage

Compressor A1, A2, B1

Must Trip Amps

30HXA261

575-3-60 198,162,198 380-3-60 300,246,300 346-3-50 344,278,344

208/230-3-60 546,448,546

460-3-60 248,204,248 230-3-50 520,418,520

380/415-3-50 314,254,314

30HXA271

575-3-60 198,198,198 380-3-60 300,300,300 346-3-50 344,344,344

208/230-3-60 546,546,546

460-3-60 248,248,248 230-3-50 520,520,520

380/415-3-50 314,314,314

30HXC206

575-3-60 108, 62,130 380-3-60 164, 92,196 346-3-50 182,104,220

208/230-3-60 298,168,358

460-3-60 136, 76,162 230-3-50 274,156,332

380/415-3-50 166, 94,202

30HXC246

575-3-60 130, 90,130 380-3-60 196,136,196 346-3-50 220,152,220

208/230-3-60 358,246,358

460-3-60 162,112,162 230-3-50 332,228,332

380/415-3-50 202,138,202

30HXC261

575-3-60 130,108,130 380-3-60 196,164,196 346-3-50 220,182,220

208/230-3-60 358,298,358

460-3-60 162,136,162 230-3-50 332,274,332

380/415-3-50 202,166,202

30HXC271

575-3-60 130,130,130 380-3-60 196,196,196 346-3-50 220,220,220

208/230-3-60 358,358,358

460-3-60 162,162,162 230-3-50 332,332,332

380/415-3-50 202,202,202

Page 77

APPENDIX B

CapacityLoading Sequence Example — The fol-

lowing tables show the loading sequence for a 30HX186 (50/50 split) and a 30HX161 (59/41 split) chiller. Each

compressor has 2 loaders. There is no difference in operation between ‘ ‘Staged’’and ‘‘Equal’’ circuit loadingon2compressor chillers.

STANDARD LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 2-COMPRESSOR UNIT)

STAGE

COMP

LOADER

COMP

LOADER

% TOTAL

CAPACITY

(50/50 Split)

% TOTAL

CAPACITY

(59/41 Split)

0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 20.0 23.5 2 1 1 0 0 0 0 35.0 41.1 3 1 1 1 0 0 0 50.0 58.8 4 1 1 0 1 1 0 70.0 70.0 5 1 1 0 1 1 1 85.0 82.4 6 1 1 1 1 1 1 100.0 100.0

CLOSE CONTROL LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 2-COMPRESSOR UNIT)

STAGE

COMP

LOADER

COMP

LOADER

% TOTAL

CAPACITY

(50/50 Split)

% TOTAL

CAPACITY

(59/41 Split)

0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 20.0 23.5 2 1 1 0 0 0 0 35.0 41.1

3 1 1 1 0 0 0 50.0 58.8 3A 1 0 0 1 0 0 40.0 40.0 3B 1 0 0 1 1 0 55.0 52.4

4 1 0 0 1 1 1 70.0 64.7

5 1 1 0 1 1 1 85.0 82.4

6 1 1 1 1 1 1 100.0 100.0

LEGEND

0—Off 1—On

NOTES:

1. Stage 3A(and 3Bfor59/41 split) isnotused bythealgorithm when increasing stages.Stage3 (and 2for59/41 split) isnotused when decreasing stages.

2. The % Total Capacities above are calculated based on compressor nominal tons. For the case of the 59/41 split above, the 30HX uses compressors with ﬂow rates of 250 and 174 cfm (from compressor model numbers 06N_1250 and 06N_1174), which represent nominal tons of 80 and 56 (respectively) at 60 Hz.A factor of 40% is used when no loaders are energized and a factor of 70% is usedwhen Loader 1isenergized. Thecapacityshown for Stage 3B above is calculated as follows:

% Total Capacity = [(0.40 x 80 + 0.70 x 56)/(80 + 56)] x 100%

= 52.4%

Nominal Tons

COMPRESSOR

PART NO.

60 Hz NOM.

TONS

50 Hz NOM.

TONS

06N_1123 39 — 06N_1146 46 39 06N_1174 56 46 06N_1209 66 56 06N_1250 80 66 06N_1300 —80

Page 78

APPENDIX B (cont)

The followingtablesshowthe loading sequence for 30HX206

(57/43 split) and 30HX271 (67/33 split) chillers. All

compressors have two loaders and the chillers are conﬁgured for equal circuit loading. See Note 2.

STANDARD LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 3-COMPRESSOR UNIT)

STAGE

COMPA1LOADERA1LOADERA2COMPA2COMPB1LOADERB1LOADER

% TOTAL

CAPACITY

(57/43 Split)

% TOTAL

CAPACITY

(67/33 Split)

0 0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 0 14.3 13.3 2 1 1 0 0 0 0 0 25.0 23.3 3 1 1 1 0 0 0 0 35.7 33.3 4 1 1 0 0 1 1 0 55.2 46.7 5 1 1 0 0 1 1 1 68.2 56.7 6 1 1 1 0 1 1 1 78.9 66.7 7 1 1 0 1 1 1 1 83.0 80.0 8 1 1 1 1 1 1 1 100.0 100.0

CLOSE CONTROL LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 3-COMPRESSOR UNIT)

STAGE

COMPA1LOADERA1LOADERA2COMPA2COMPB1LOADERB1LOADER

% TOTAL

CAPACITY

(57/43 Split)

% TOTAL

CAPACITY

(67/33 Split)

0 0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 0 14.3 13.3 2 1 1 0 0 0 0 0 25.0 23.3 3 1 1 1 0 0 0 0 35.7 33.3

3A 1 0 0 0 1 0 0 31.6 26.7

4 1 0 0 0 1 1 0 44.5 36.7 5 1 0 0 0 1 1 1 57.5 46.7 6 1 1 0 0 1 1 1 68.2 56.7 7 1 1 1 0 1 1 1 78.9 66.7

7A 1 0 0 1 1 1 1 65.9 60.0

8 1 1 0 1 1 1 1 83.0 80.0 9 1 1 1 1 1 1 1 100.0 100.0

LEGEND

0—Off 1—On

NOTES:

1. Stages 3A and 7A are not used by the algorithm when increasing stages. Stages 3 and 7 are not used by the algorithm when decreasing stages.

2. The loadingsequencefor 30GX205-265unitsis the sameas those shown for the 30HZ206,271 above.

Page 79

APPENDIX B (cont)

The followingtablesshowthe loading sequence for 30HX206 (57/43 split) and 30HX271 (67/33 split) chillers. All compressors have two loaders and the chiller is conﬁgured for

staged circuit loading. Loaders A1 on compressors A1 and A2 are energized in parallel. The same is true for Loaders A2 on both compressors A1 and A2. See Note 3.

STANDARD LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 3-COMPRESSOR UNIT)

STAGE

COMPA1LOADERA1LOADERA2COMPA2COMP

LOADERB1LOADER

% TOTAL

CAPACITY

(57/43 Split)

% TOTAL

CAPACITY

(67/33 Split)

0 0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 0 14.3 13.3 2 1 1 0 0 0 0 0 25.0 23.3 3 1 1 1 0 0 0 0 35.7 33.3 4 1 1 0 1 0 0 0 39.7 46.7 5 1 1 1 1 0 0 0 56.8 66.7 6 1 1 1 1 1 1 0 87.0 90.0 7 1 1 1 1 1 1 1 100.0 100.0

CLOSE CONTROL LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 3-COMPRESSOR UNIT)

STAGE

COMPA1LOADERA1LOADERA2COMPA2COMP

LOADERB1LOADER

% TOTAL

CAPACITY

(57/43 Split)

% TOTAL

CAPACITY

(67/33 Split)

0 0 0 0 0 0 0 0 0.0 0.0 1 1 0 0 0 0 0 0 14.3 13.3 2 1 1 0 0 0 0 0 25.0 23.3 3 1 1 1 0 0 0 0 35.7 33.3

3A 1 0 0 1 0 0 0 22.7 26.7

4 1 1 0 1 0 0 0 39.7 46.7 5 1 1 1 1 0 0 0 56.8 66.7 6 1 1 1 1 1 0 0 74.1 80.0 7 1 1 1 1 1 1 0 87.0 90.0 8 1 1 1 1 1 1 1 100.0 100.0

LEGEND

0—Off 1—On

NOTES:

1. Stage 3A is not used by the algorithm when increasing stages.

Stage 3 is not used by the algorithm when decreasing stages.

2. The % Total Capacities above are calculated based on compres-

sor nominal tons. For the case of the 57/43 split above, the 30HX uses compressors with ﬂow rates of 209, 123 and 250 cfm (from compressormodelnumbers 06N_1209, 06N_123and 06N_1250),

which represent nominal tons of 66, 39 and 80 (respectively) at 60 Hz.Afactorof 40% is usedwhenno loaders are energizedand a factor of 70% is usedwhenLoader1is energized. The capacity shown for Stage 4 above is calculated as follows:

% Total Capacity = [0.70 x 66 + 0.70 x 39 + 0.0 x 80)/(66 + 39 +

80)] x 100% = 39.7%

3. The loadingsequencefor 30GX205-265unitsis the sameas those shown for the 30HX206,271 above.

Page 80

APPENDIX C

The following are the available accessories for 30GX/HXA/HXC units.

ACCESSORY

PART NUMBER

USED ON DESCRIPTION OF ACCESSORY COMMENTS

30GX-900-001 30GX080-105 Condenser Grille Package 30GX-900-002 30GX106-125 Condenser Grille Package 30GX-900-003 30GX136, 150, 160 Condenser Grille Package 30GX-900-013 30GX151, 161, 175, 205, 225 Condenser Grille Package 30GX-900-024 30GX176 Condenser Grille Package 30GX-900-009 30GX206, 226, 250 Condenser Grille Package 30GX-900-010 30GX251, 265 Condenser Grille Package 30GX-900-004 30GX (115 V Control) Minimum Load Valve both circuits 30GX-900-005 30GX (230 V Control) Minimum Load Valve both circuits 30GX-900-006 30GX (460 V) Control Transformer 30GX-900-007 30GX (575 V) Control Transformer 30GX-900-008 30GX (208 V) Control Transformer 30GX-900-012 30GX080-150, 160 3-Phase MotormasterT Control single controller 30GX-900-014 30GX151, 161-265 3-Phase Motormaster Control two controllers 30GX-900-015 30GX080-265 Sound Enclosure/Hail Guard/Wind Baffle header end only 30GX-900-016 30GX080-105 Sound Enclosure/Hail Guard/Wind Baffle one side per package 30GX-900-017 30GX106-125 Sound Enclosure/Hail Guard/Wind Baffle one side per package 30GX-900-018 30GX136, 150, 160 Sound Enclosure/Hail Guard/Wind Baffle one side per package

30GX-900-019 30GX151, 161, 175, 205, 225 Sound Enclosure/Hail Guard/Wind Baffle

one side per package (151, 161, 175) cooler side only (205, 225)

30GX-900-020 30GX176, 206, 226, 250 Sound Enclosure/Hail Guard/Wind Baffle

one side per package (176) cooler side only (206, 226, 250)

30GX-900-028 30GX205, 225 Sound Enclosure/Hail Guard/Wind Baffle control box side only 30GX-900-029 30GX206, 226, 250 Sound Enclosure/Hail Guard/Wind Baffle control box side only 30GX-900-030 30GX251, 265 Sound Enclosure/Hail Guard/Wind Baffle cooler side only 30GX-900-031 30GX251, 265 Sound Enclosure/Hail Guard/Wind Baffle control box side only 30GX-900-021 30GX (230 V Control) Cooler Heater 30GX-900-022 30GX (115 V Control) Cooler Heater 30GX-900-023 30GX080-265 Vibration Isolation Pads

30GX-900-025 30GX105-136, 160-176

Insulation Kit (169, 3 Pass Cooler with Economizer)

tubesheets/heads/economizer

30GX-900-026 30GX150, 151

Insulation Kit (149, 2 Pass Cooler with Economizer)

tubesheets/heads/economizer

30GX-900-027 30GX150, 151

Insulation Kit (149, 1 Pass Cooler with Economizer)

tubesheets/heads/economizer

30HX-900-001 30HX116-271 Sound Enclosure Panels 30HX-900-011 30HX076-106 Sound Enclosure Panels

30HX-900-002

30GX080-090, 150, 151 30HX076-096, 116-146

Victaulic Cooler Connections (14 in.)

30HX-900-003

30GX105-136, 160-176 30HX106, 161-186

Victaulic Cooler Connections (16 in.)

30HX-900-014

30GX205-265 30HX206-271

Victaulic Cooler Connections (18 in.)

30HX-900-015 30HX206-271 Victaulic Condenser Connection (22 in.) 30HX-900-004 30HX076-146 Victaulic Condenser (18 in.) 30HX-900-005 30HX161-186 Victaulic Condenser (20 in.) 30HX-900-006 30HX (230, 460 V) Control Transformer 30HX-900-013 30HX (575 V) Control Transformer 30HX-900-007 30GX,HX all LID 2B Enhanced Remote Controller 30HX-900-008 30HX (115 V Control) Minimum Load Valve single circuit 30HX-900-009 30HX (230 V Control) Minimum Load Valve single circuit 30HX-900-010 30HX076-271 Vibration Isolation Pad

30HX-900-016

30GX080,090 30HX076-096

Insulation Kit (149, 3 Pass Cooler no Economizer)

tubesheets/heads

30HX-900-017

30GX080,090 30HX076-096

Insulation Kit (149, 2 Pass Cooler no Economizer)

tubesheets/heads

30HX-900-020

30GX105-136,160-176 30HX161-186

Insulation Kit (169, 2 Pass Cooler with Economizer)

tubesheets/heads/economizer

30HX-900-021

30GX160-176 30HX161-186

Insulation Kit (169, 1 Pass Cooler with Economizer)

tubesheets/heads/economizer

30HX-900-022

30GX205-265 30GX206-271

Insulation Kit (189, 2 Pass Cooler with Economizer)

tubesheets/heads/economizer

30HX-900-023

30GX205-265 30HX206-271

Insulation Kit (189, 1 Pass Cooler with Economizer)

tubesheets/heads/economizer

Page 81

APPENDIX D

Compressor Protection Module Conﬁguration Header Punch-Outs and Overload Settings

2-Compressor Units

UNIT

MODEL NUMBER

PUNCH OUTS

FOR CPM-A

PUNCH OUTS

FOR CPM-B

COMP A1

OVERLOAD SETTING

COMP B1

OVERLOAD SETTING

30GX-080---1 1,2,3,6,7,8 1,2,3,5,6,7,8 85 71 30GX-080---2 1,2,5,6,7 1,2,4,5,7 128 107 30GX-080---5 1,4,8 1,3,6,7,8 234 195 30GX-080---6 1,2,4,5,7,8 1,2,3,6,8 106 88 30GX-080---8 1,4,5 1,3,5,6,7 223 183 30GX-080---9 1,2,5,7 1,2,4,5 135 111

30GX-090---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71 30GX-090---2 1,3,4,5,6,7 1,2,4,5,7 156 107 30GX-090---5 2,3,4,6 1,3,5,7,8 285 195 30GX-090---6 1,2,5,6,7 1,2,3,6,8 129 88 30GX-090---8 2,3,4,5,6,8 1,3,5,6,7 269 183 30GX-090---9 1,3,4,5,7 1,2,4,5 163 111

30GX-105---8 2,3,5,6 1,3,8 299 207 30GX-105---9 1,3,4 1,2,4 181 125

30GX-106---1 1,2,4,6,8 1,2,3,5,7 116 80 30GX-106---2 1,3,4,7,8 1,2,4,7 175 120 30GX-106---5 2,3 1,4,5,8 320 220 30GX-106---6 1,2,6 1,2,4,5,6,7,8 145 100 30GX-106---8 2,3,5,6 1,3,8 299 207 30GX-106---9 1,3,4 1,2,4 181 125

30GX-115---1 1,2,6,7,8 1,2,3,5,7 141 80 30GX-115---2 1,4,5,6,8 1,2,4,7 213 120 30GX-115---5 3,4,5 1,4,5,8 390 220 30GX-115---6 1,3,4,7 1,2,4,5,6,7,8 176 100 30GX-115---8 2,6,7,8 1,3,8 363 207 30GX-115---9 1,4,5,8 1,2,4 220 125

30GX-125---1 1,2,6,7,8 1,2,3,8 141 96 30GX-125---2 1,4,5,6,8 1,2,6 213 145 30GX-125---5 3,4,5 2,3,4,5,6,7,8 390 265 30GX-125---6 1,3,4,7 1,2,4,7,8 176 120 30GX-125---8 2,6,7,8 1,5 363 250 30GX-125---9 1,4,5,8 1,2,8 220 151

30GX-136---1 1,2,6,7,8 1,2,4,6,8 141 116 30GX-136---2 1,4,5,6,8 1,3,4,7,8 213 175 30GX-136---5 3,4,5 2,3 390 320 30GX-136---6 1,3,4,7 1,2,6 176 145 30GX-136---8 2,6,7,8 2,3,5,6 363 299 30GX-136---9 1,4,5,8 1,3,4 220 181

30GX-150---8 2,3,5,6 4,6 299 451 30GX-150---9 1,3,4 2,3,4,5,7,8 181 273

30GX-151---1 1,3,4,6,8 1,2,4,6,8 172 116 30GX-151---2 1,7 1,3,4,7,8 260 175 30GX-151---5 6,7,8 2,3 475 320 30GX-151---6 1,4,5,6 1,2,6 215 145

30GX-160---8 2,6,7,8 4,6 363 451 30GX-160---9 1,4,5,8 2,3,4,5,7,8 220 273

30GX-161---1 1,3,4,6,8 1,2,6,7,8 172 141 30GX-161---2 1,7 1,4,5,6,8 260 213 30GX-161---5 6,7,8 3,4,5 475 390 30GX-161---6 1,4,5,6 1,3,4,7 215 176 30GX-161---8 4,6 2,6,7,8 451 363 30GX-161---9 2,3,4,5,7,8 1,4,5,8 273 220

30GX-175---8 4,6 4,6 451 451 30GX-175---9 2,3,4,5,7,8 2,3,4,5,7,8 273 273

30GX-176---1 1,3,4,6,8 1,3,4,6,8 172 172 30GX-176---2 1,7 1,7 260 260 30GX-176---5 6,7,8 6,7,8 475 475 30GX-176---6 1,4,5,6 1,4,5,6 215 215

30HXA076---1 1,2,3,5,6,7,8 1,2,3,5,6,7,8 71 71 30HXA076---2 1,2,4,5,7 1,2,4,5,7 107 107 30HXA076---3 1,2,4,7 1,2,4,7 122 122 30HXA076---5 1,3,6,7,8 1,3,6,7,8 195 195 30HXA076---6 1,2,3,6,8 1,2,3,6,8 88 88 30HXA076---8 1,3,5,6,7 1,3,5,6,7 183 183 30HXA076---9 1,2,4,5 1,2,4,5 111 111

30HXA086---1 1,2,3,6,7,8 1,2,3,5,6,7,8 85 71 30HXA086---2 1,2,5,6,7 1,2,4,5,7 128 107 30HXA086---3 1,2,7,8 1,2,4,7 148 122 30HXA086---5 1,4,8 1,3,6,7,8 234 195 30HXA086---6 1,2,4,5,7,8 1,2,3,6,8 106 88 30HXA086---8 1,4,5 1,3,5,6,7 223 183 30HXA086---9 1,2,5,7 1,2,4,5 135 111

Page 82

APPENDIX D (cont)

Compressor Protection Module Conﬁguration Header Punch-Outs and Overload Settings (cont)

2-Compressor Units

UNIT

MODEL NUMBER

PUNCH OUTS

FOR CPM-A

PUNCH OUTS

FOR CPM-B

COMP A1

OVERLOAD SETTING

COMP B1

OVERLOAD SETTING

30HXA096---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71 30HXA096---2 1,3,4,5,6,7 1,2,4,5,7 156 107 30HXA096---3 1,3,4,8 1,2,4,7 179 122 30HXA096---5 2,3,4,6 1,3,6,7,8 285 195 30HXA096---6 1,2,5,6,7 1,2,3,6,8 129 88 30HXA096---8 2,3,4,5,6,8 1,3,5,6,7 269 183 30HXA096---9 1,3,4,5,7 1,2,4,5 163 111

30HXA106---1 1,2,4 1,2,3,5,6,7,8 125 71 30HXA106---2 1,3,5,7,8 1,2,4,5,7 190 107 30HXA106---3 1,4,5,7,8 1,2,4,7 217 122 30HXA106---5 2,4 1,3,6,7,8 347 195 30HXA106---6 1,3,4,5,6,7 1,2,3,6,8 157 88 30HXA106---8 2,4,5,6 1,3,5,6,7 326 183 30HXA106---9 1,3,6,7 1,2,4,5 198 111

30HXA116---1 1,2,4 1,2,3,6,7,8 125 85 30HXA116---2 1,3,5,7,8 1,2,5,6,7 190 128 30HXA116---3 1,4,5,6,8 1,2,7,8 217 148 30HXA116---5 2,4 1,4,8 347 234 30HXA116---6 1,3,4,5,6,7 1,2,4,5,7,8 157 106 30HXA116---8 2,4,5,6 1,4,5 326 223 30HXA116---9 1,3,6,7 1,2,5,7 198 135

30HXA126---1 1,2,4 1,2,4,5,6 125 103 30HXA126---2 1,3,5,7,8 1,3,4,5,6,7 190 156 30HXA126---3 1,4,5,7,8 1,3,4,8 217 179 30HXA126---5 2,4 2,3,4,6 347 285 30HXA126---6 1,3,4,5,6,7 1,2,5,6,7 157 129 30HXA126---8 2,4,5,6 2,3,4,5,6,8 326 269 30HXA126---9 1,3,6,7 1,3,4,5,7 198 163

30HXA136---1 1,2 1,2,4,5,6 153 103 30HXA136---2 1,4,7,8 1,3,4,5,6,7 231 156 30HXA136---3 2,3,4,5,6,7,8 1,3,4,8 266 179 30HXA136---5 3,6,8 2,3,4,6 423 285 30HXA136---6 1,3,5,7 1,2,5,6,7 191 129 30HXA136---8 3,4,8 2,3,4,5,6,8 401 269 30HXA136---9 1,5,6 1,3,4,5,7 243 163

30HXA146---1 1,2 1,2,4 153 125 30HXA146---2 1,4,7,8 1,3,5,7,8 231 190 30HXA146---3 2,3,4,5,6,7,8 1,4,5,7,8 266 217 30HXA146---5 3,6,8 2,4 423 347 30HXA146---6 1,3,5,7 1,3,4,5,6,7 191 157 30HXA146---8 3,4,8 2,4,5,6 401 326 30HXA146---9 1,5,6 1,3,6,7 243 198

30HXA161---1 1,3,4,6,8 1,2,4,6,8 172 116 30HXA161---2 1,7 1,3,4,7,8 260 175 30HXA161---3 2,3,4,5 1,3,6,7 299 199 30HXA161---5 6,7,8 2,3 475 320 30HXA161---6 1,4,5,6 1,2,6 215 145 30HXA161---8 4,6 2,3,5,6 451 299 30HXA161---9 2,3,4,5,7,8 1,3,4 273 181

30HXA171---1 1,2,6,7,8 1,3,4,6,8 141 172 30HXA171---2 1,4,5,6,8 1,7 213 260 30HXA171---3 1,5,6,8 2,3,5,6 241 299 30HXA171---5 3,4,5 6,7,8 390 475 30HXA171---6 1,3,4,7 1,4,5,6 176 215 30HXA171---8 2,6,7,8 4,6 363 451 30HXA171---9 1,4,5,8 2,3,4,5,7,8 220 273

30HXA186---1 1,3,4,6,8 1,3,4,6,8 172 172 30HXA186---2 1,7 1,7 260 260 30HXA186---3 2,3,5,6 2,3,5,6 299 299 30HXA186---5 6,7,8 6,7,8 475 475 30HXA186---6 1,4,5,6 1,4,5,6 215 215 30HXA186---8 4,6 4,6 451 451 30HXA186---9 2,3,4,5,7,8 2,3,4,5,7,8 273 273

30HXC076---1 1,2,3,4,5,6 1,2,3,4,5,6 50 50 30HXC076---2 1,2,3,5,6,7 1,2,3,5,6,7 73 73 30HXC076---3 1,2,3,5 1,2,3,5 83 83 30HXC076---5 1,2,5,7,8 1,2,5,7,8 133 133 30HXC076---6 1,2,3,4,6,8 1,2,3,4,6,8 60 60 30HXC076---8 1,2,4 1,2,4 125 125 30HXC076---9 1,2,3,5,6 1,2,3,5,6 76 76

30HXC086---1 1,2,3,4,6,7 1,2,3,4,5,6 58 50 30HXC086---2 1,2,3,6,8 1,2,3,5,6,7 88 73 30HXC086---3 1,2,4,5,6,7 1,2,3,5 101 83 30HXC086---5 1,3,4,5,7,8 1,2,5,7,8 161 133 30HXC086---6 1,2,3,5,6,7 1,2,3,4,6,8 73 60 30HXC086---8 1,2 1,2,4 152 125 30HXC086---9 1,2,3,7,8 1,2,3,5,6 92 76

Page 83

APPENDIX D (cont)

Compressor Protection Module Conﬁguration Header Punch-Outs and Overload Settings (cont)

2-Compressor Units

UNIT

MODEL NUMBER

PUNCH OUTS

FOR CPM-A

PUNCH OUTS

FOR CPM-B

COMP A1

OVERLOAD SETTING

COMP B1

OVERLOAD SETTING

30HXC096---1 1,2,3,5,6,7,8 1,2,3,4,5,6 71 50 30HXC096---2 1,2,4,5,7 1,2,3,5,6,7 108 73 30HXC096---3 1,2,4,7 1,2,3,5 122 83 30HXC096---5 1,3,6,7,8 1,2,5,7,8 197 133 30HXC096---6 1,2,3,6 1,2,3,4,6,8 89 60 30HXC096---8 1,3,5,6,7 1,2,4 183 125 30HXC096---9 1,2,4,5 1,2,3,5,6 111 76

30HXC106---1 1,2,3,6,7 1,2,3,4,5,6 86 50 30HXC106---2 1,2,5,6,8 1,2,3,5,6,7 130 73 30HXC106---3 1,2,6 1,2,3,5 146 83 30HXC106---5 1,5,6,7,8 1,2,5,7,8 238 133 30HXC106---6 1,2,4,5,7 1,2,3,4,6,8 108 60 30HXC106---8 1,4,5,8 1,2,4 220 125 30HXC106---9 1,2,5,7,8 1,2,3,5,6 133 76

30HXC116---1 1,2,3,6,7 1,2,3,4,6,7 86 58 30HXC116---2 1,2,5,6,8 1,2,3,6,8 130 88 30HXC116---3 1,2,6 1,2,4,5,6,7 146 101 30HXC116---5 1,5,6,7,8 1,3,4,5,7,8 238 161 30HXC116---6 1,2,4,5,7 1,2,3,5,6,7 108 73 30HXC116---8 1,4,5,8 1,2 220 152 30HXC116---9 1,2,5,7,8 1,2,3,7,8 133 92

30HXC126---1 1,2,3,6,7 1,2,3,5,6,7,8 86 71 30HXC126---2 1,2,5,6,8 1,2,4,5,7 130 108 30HXC126---3 1,2,6 1,2,4,7 146 122 30HXC126---5 1,5,6,7,8 1,3,6,7,8 238 197 30HXC126---6 1,2,4,5,7 1,2,3,6 108 89 30HXC126---8 1,4,5,8 1,3,5,6,7 220 183 30HXC126---9 1,2,5,7,8 1,2,4,5 133 111

30HXC136---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71 30HXC136---2 1,3,4,5,6,7 1,2,4,5,7 156 108 30HXC136---3 1,3,4,7 1,2,4,7 177 122 30HXC136---5 2,3,4,6 1,3,6,7,8 285 197 30HXC136---6 1,2,5,6,7 1,2,3,6 129 89 30HXC136---8 2,3,4,5,6,7 1,3,5,6,7 267 183 30HXC136---9 1,3,4,5,7,8 1,2,4,5 162 111

30HXC146---1 1,2,4,5,6 1,2,3,6,7 103 86 30HXC146---2 1,3,4,5,6,7 1,2,5,6,8 156 130 30HXC146---3 1,3,4,7 1,2,6 177 146 30HXC146---5 2,3,4,6 1,5,6,7,8 285 238 30HXC146---6 1,2,5,6,7 1,2,4,5,7 129 108 30HXC146---8 2,3,4,5,6,7 1,4,5,8 267 220 30HXC146---9 1,3,4,5,7,8 1,2,5,7,8 162 133

30HXC161---1 1,2,4,6,7,8 1,2,3,5,7,8 112 78 30HXC161---2 1,3,4,6,7 1,2,4,6 170 117 30HXC161---3 1,3,5,7 1,2,5,6 192 132 30HXC161---5 2,3,6,8 1,4,5,6,8 310 214 30HXC161---6 1,2,6,7,8 1,2,3 140 97 30HXC161---8 2,4,5,7 1,3,6,7 289 198 30HXC161---9 1,3,4,7,8 1,2,4,7,8 175 120

30HXC171---1 1,2,3,7 1,2,4,6,7,8 94 112 30HXC171---2 1,2,6,7 1,3,4,6,7 142 170 30HXC171---3 1,3,4,5,6,8 1,3,5,7 158 192 30HXC171---5 1,7,8 2,3,6,8 259 310 30HXC171---6 1,2,4,6 1,2,6,7,8 117 140 30HXC171---8 1,5,6,7,8 2,3,4,7 237 289 30HXC171---9 1,2,6,8 1,3,4,7,8 144 175

30HXC186---1 1,2,4,6,7,8 1,2,4,6,7,8 112 112 30HXC186---2 1,3,4,6,7 1,3,4,6,7 170 170 30HXC186---3 1,3,5,7 1,3,5,7 192 192 30HXC186---5 2,3,6,8 2,3,6,8 310 310 30HXC186---6 1,2,6,7,8 1,2,6,7,8 140 140 30HXC186---8 2,3,4,7 2,3,4,7 289 289 30HXC186---9 1,3,4,7,8 1,3,4,7,8 175 175

Page 84

APPENDIX D (cont)

Compressor Protection Module Conﬁguration Header Punch-Outs and Overload Settings (cont)

3-Compressor Units

UNIT

MODEL NUMBER

PUNCH OUTS

FOR CPM-A1

PUNCH OUTS

FOR CPM-A2

PUNCH OUTS

FOR CPM-B1

COMP A1

OVERLOAD

SETTING

COMP A2

OVERLOAD

SETTING

COMP B1

OVERLOAD

SETTING

30GX205---8 2,6,7,8 1,3,8 4,6 363 207 451 30GX205---9 1,4,5,8 1,2,4 2,3,4,5,7,8 220 125 273

30GX206---1 1,3,4,6,8 1,2,3,5,7 1,2,6,7,8 172 80 141 30GX206---2 1,7 1,2,4,7 1,4,5,6,8 260 120 213 30GX206---5 6,7,8 1,4,5,8 3,4,5 475 220 390 30GX206---6 1,4,5,6 1,2,4,5,6,7,8 1,3,4,7 215 100 176

30GX225---8 4,6 1,5 4,6 451 250 451 30GX225---9 2,3,4,5,7,8 1,2,8 2,3,4,5,7,8 273 151 273

30GX226---1 1,3,4,6,8 1,2,3,8 1,3,4,6,8 172 96 172 30GX226---2 1,7 1,2,6 1,7 260 145 260 30GX226---5 6,7,8 2,3,4,5,6,7,8 6,7,8 475 265 475 30GX226---6 1,4,5,6 1,2,4,7,8 1,4,5,6 215 120 215 30GX226---8 4,6 1,5 4,6 451 250 451 30GX226---9 2,3,4,5,7,8 1,2,8 2,3,4,5,7,8 273 151 273

30GX250---8 4,6 2,6,7,8 4,6 451 363 451 30GX250---9 2,3,4,5,7,8 1,4,5,6 2,3,4,5,7,8 273 220 273

30GX251---1 1,3,4,6,8 1,3,4,6,8 1,2,6,7,8 172 172 141 30GX251---2 1,7 1,7 1,4,5,6,8 260 260 213 30GX251---5 6,7,8 6,7,8 3,4,5 475 475 390 30GX251---6 1,4,5,6 1,4,5,6 1,3,4,7 215 215 176

30GX265---1 1,3,4,6,8 1,3,4,6,8 1,3,4,6,8 172 172 172 30GX265---2 1,7 1,7 1,7 260 260 260 30GX265---5 6,7,8 6,7,8 6,7,8 475 475 475 30GX265---6 1,4,5,6 1,4,5,6 1,4,5,6 215 215 215 30GX265---8 4,6 4,6 4,6 451 451 451 30GX265---9 2,3,4,5,7,8 2,3,4,5,7,8 2,3,4,5,7,8 273 273 273

30HXA206---1 1,2,6,7,8 1,2,3,5,7 1,3,4,6,8 141 80 172 30HXA206---2 1,4,5,6,8 1,2,4,7 1,7 213 120 260 30HXA206---3 1,5,6,8 1,2,5,8 2,3,5,6 241 137 299 30HXA206---5 3,4,5 1,4,5,8 6,7,8 390 220 475 30HXA206---6 1,3,4,7 1,2,4,5,6,7,8 1,4,5,6 176 100 215 30HXA206---8 2,6,7,8 1,3,8 4,6 363 207 451 30HXA206---9 1,4,5,8 1,2,4 2,3,4,5,7,8 220 125 273

30HXA246---1 1,3,4,6,8 1,2,4,6,8 1,3,4,6,8 172 116 172 30HXA246---2 1,7 1,3,4,7,8 1,7 260 175 260 30HXA246---3 2,3,5,6 1,3,6,7 2,3,5,6 299 199 299 30HXA246---5 6,7,8 2,3 6,7,8 475 320 475 30HXA246---6 1,4,5,6 1,2,6 1,4,5,6 215 145 215 30HXA246---8 4,6 2,3,5,6 4,6 451 299 451 30HXA246---9 2,3,4,5,7,8 1,3,4 2,3,4,5,7,8 273 181 273

Page 85

APPENDIX D (cont)

Compressor Protection Module Conﬁguration Header Punch-Outs and Overload Settings (cont)

3-Compressor Units

UNIT

MODEL NUMBER

PUNCH OUTS

FOR CPM-A1

PUNCH OUTS

FOR CPM-A2

PUNCH OUTS

FOR CPM-B1

COMP A1

OVERLOAD

SETTING

COMP A2

OVERLOAD

SETTING

COMP B1

OVERLOAD

SETTING

30HXA261---1 1,3,4,6,8 1,2,6,7,8 1,3,4,6,8 172 141 172 30HXA261---2 1,7 1,4,5,6,8 1,7 260 213 260 30HXA261---3 2,3,5,6 1,5,6,8 2,3,5,6 299 241 299 30HXA261---5 6,7,8 3,4,5 6,7,8 475 390 475 30HXA261---6 1,4,5,6 1,3,4,7 1,4,5,6 215 176 215 30HXA261---8 4,6 2,6,7,8 4,6 451 363 451 30HXA261---9 2,3,4,5,7,8 1,4,5,8 2,3,4,5,7,8 273 220 273

30HXA271---1 1,3,4,6,8 1,3,4,6,8 1,3,4,6,8 172 172 172 30HXA271---2 1,7 1,7 1,7 260 260 260 30HXA271---3 2,3,5,6 2,3,5,6 2,3,5,6 299 299 299 30HXA271---5 6,7,8 6,7,8 6,7,8 475 475 475 30HXA271---6 1,4,5,6 1,4,5,6 1,4,5,6 215 215 215 30HXA271---8 4,6 4,6 4,6 451 451 451 30HXA271---9 2,3,4,5,7,8 2,3,4,5,7,8 2,3,4,5,7,8 273 273 273

30HXC206---1 1,2,3,7 1,2,3,4,5,8 1,2,4,6,7,8 94 53 112 30HXC206---2 1,2,6,7 1,2,3,5,7 1,3,4,6,7 142 80 170 30HXC206---3 1,3,4,5,6,8 1,2,3,6 1,3,5,7 158 90 192 30HXC206---5 1,7,8 1,2,6 2,3,6,8 259 145 310 30HXC206---6 1,2,4,6 1,2,3,4,7 1,2,6,7,8 117 66 140 30HXC206---8 1,5,6,7,8 1,2,5,7 2,3,4,7 237 135 289 30HXC206---9 1,2,6,8 1,2,3,5,8 1,3,4,7,8 144 82 175

30HXC246---1 1,2,4,6,7,8 1,2,3,5,7,8 1,2,4,6,7,8 112 78 112 30HXC246---2 1,3,4,6,7 1,2,4,6 1,3,4,6,7 170 117 170 30HXC246---3 1,3,5,7 1,2,5,6 1,3,5,7 192 132 192 30HXC246---5 2,3,6,8 1,4,5,6,8 2,3,6,8 310 214 310 30HXC246---6 1,2,6,7,8 1,2,3 1,2,6,7,8 140 97 140 30HXC246---8 2,3,4,7 1,3,6,7 2,3,4,7 289 198 289 30HXC246---9 1,3,4,7,8 1,2,4,7,8 1,3,4,7,8 175 120 175

30HXC261---1 1,2,4,6,7,8 1,2,3,7 1,2,4,6,7,8 112 94 112 30HXC261---2 1,3,4,6,7 1,2,6,7 1,3,4,6,7 170 142 170 30HXC261---3 1,3,5,7 1,3,4,5,6,8 1,3,5,7 192 158 192 30HXC261---5 2,3,6,8 1,7,8 2,3,6,8 310 259 310 30HXC261---6 1,2,6,7,8 1,2,4,6 1,2,6,7,8 140 117 140 30HXC261---8 2,3,4,7 1,5,6,7,8 2,3,4,7 289 237 289 30HXC261---9 1,3,4,7,8 1,2,6,8 1,3,4,7,8 175 144 175

30HXC271---1 1,2,4,6,7,8 1,2,4,6,7,8 1,2,4,6,7,8 112 112 112 30HXC271---2 1,3,4,6,7 1,3,4,6,7 1,3,4,6,7 170 170 170 30HXC271---3 1,3,5,7 1,3,5,7 1,3,5,7 192 192 192 30HXC271---5 2,3,6,8 2,3,6,8 2,3,6,8 310 310 310 30HXC271---6 1,2,6,7,8 1,2,6,7,8 1,2,6,7,8 140 140 140 30HXC271---8 2,3,4,7 2,3,4,7 2,3,4,7 289 289 289 30HXC271---9 1,3,4,7,8 1,3,4,7,8 1,3,4,7,8 175 175 175

Page 86

APPENDIX E

The following charts list pressure drops for coolers and condensers.

076, 086

116, 126

136, 146

161, 171

246-271

096

106

186

206

100

1000

COOLER FLOW RATE (GPM)

PRESSURE DROP (FT WG)

30HX COOLER PRESSURE DROP — ENGLISH

Unit Size Range

NOTE: Ft of water = 2.31 x change in psig.

076, 086

096

106

116, 126

136, 146

161, 171

186

206 246-271

1000

100

COOLER FLOW RATE (L/S)

PRESSURE DROP (KPA)

30HX COOLER PRESSURE DROP — SI

Unit Size Range

Page 87

APPENDIX E (cont)

30HX CONDENSER PRESSURE DROP — ENGLISH

Unit Size Range

NOTE: Ft of water = 2.31 x change in psig.

30HX CONDENSER PRESSURE DROP — SI

Unit Size Range

Page 88

APPENDIX E (cont)

30GX080-176 COOLER PRESSURE DROP —

ENGLISH

NOTE: Ft of water = 2.31 x change in psig.

30GX080-176 COOLER PRESSURE DROP —

100

1000

COOLER FLOW RATE (GPM)

PRESSURE DROP (ft wg)

30GX205, 206

30GX225, 226

30GX250, 251, 265

30GX205-265 COOLER PRESSURE DROP —

ENGLISH

1000

100

COOLER FLOW RATE (L/s)

PRESSURE DROP (kpa)

30GX205, 206

30GX225, 226

30GX250, 251, 265

30GX205-265 COOLER PRESSURE DROP —

Page 89

Typical System Components, 30GX, With Economizer

LEGEND

EXV — Electronic Expansion Valve

HPS — High Pressure Switch

APPENDIX F

Page 90

Typical System Components, 30HX, Without Economizer

LEGEND

EXV — Electronic Expansion Valve

HPS — High Pressure Switch

APPENDIX F (cont)

Page 91

INDEX

Accessing Functions and Subfunctions, 13 Actual Start-Up, 67 Adjusting PID Routines, 10 Alarms and Alerts, 43 Automatic Default Display, 13 Back Pressure Valve, 4 Burnout Clean-Up Procedure, 58 Capacity Control Overrides, 7 Capacity Control, 6 Capacity Sequence Determination, 7 Carrier Comfort Network (CCN) Interface, 64 Checking Display Codes, 43 Close Control, 7 Coil Cleaning, 53 Complete Unit Stoppage, 43 Compressor Alarm/Alert Circuit, 43 Compressor Changeout Sequence, 56 Compressor Protection Module (CPM), 3, 4 Compressor Protection, 62 Condenser Coils (30GX Only), 53 Condenser Fans (30GX Only), 54 Condenser Pump Control, 12 Control (LOR) Switch, 3 Control Modules, 64 Cooler and Condenser (30HXC) Pump Control, 10 Cooler Heater Control, 13 Cooler Protection, 62 Cooler Pump Control, 10 Demand Limit, 39 Demand Limit, (CCN Loadshed Controlled), 42 DSIO-HV Relay Module, 3, 64 Economizer Operation, 4 Electronic Expansion Device (EXD), 3 Electronic Expansion Device Module, 3 EXD Troubleshooting Procedure, 50 External Temperature Reset, 39 Externally Powered Demand Limit, 42 Externally Powered Reset, 39 EXV Driver Module (DSIO-EXV), 64 EXV Operation, 3 Field Wiring, 68 Filter Drier, 58 Head Pressure Control, 8 High Voltage Relay Module (DSIO-HV), 64, 66 History Function, 25 Inspecting/Cleaning Heat Exchangers, 53 Inspecting/Opening Economizers, 51 Inspecting/Opening Electronic Expansion Valves, 51 Keypad and Display Module (HSIO-II), 3, 13 Lead/Lag Determination, 7 Liquid Line Service Valve, 58

Loading Sequence, 6 Major System Components, 3 Minimum Load Valve, 7 Minutes Left for Start, 6 Minutes Off Time, 6 Moisture-Liquid Indicator, 58 Motor Cooling, 4 Oil Charging/Low Oil Recharging, 55 Oil Filter Maintenance, 56 Oil Pumps, 4 Oil Separator Heaters (30GX), 62 Operating Sequence, 67 Operation Data, 3 Power Failure External to the Unit, 43 Pre-Start-Up Procedure, 67 Pressure Relief Valves, 62 Pressure Transducer Calibration, 59 Pressure Transducers, 59 Processor Module (PSIO-1), 3, 64, 66 PSIO-2 (8052) Module, 3, 64 Refrigerant Charging/Adding Charge, 54 Relief Devices, 62 Replacing Defective Processor Module, 66 Replacing the External Oil Filter, 56 Replacing the Internal Oil Filter, 56 Restart Procedure, 43 Retubing, 52 Return Fluid Temperature Reset, 39 Safety Considerations, 1 Safety Devices, 62 Schedule Function, 37 Sensors, 4 Service Function, 30 Service, 52 Servicing Coolers and Condensers, 52 Set Point Function, 25 Single Circuit Stoppage, 43 Start-Up and Operation, 67 Start-Up Checklist, CL-1 Status Function, 16 System Check, 67 Temperature Reset, 39 Test Function, 25 Thermistor Replacement, 58 Thermistors, 58 Tightening Cooler/Condenser Head Bolts, 52 Troubleshooting, 43 Tube Plugging, 52 Unit Shutoff, 43 Water Treatment, 53 Winter Shutdown Preparation, 66 Wye-Delta vs. Across-the-Line (XL) Starting Option, 5

Page 92

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization

• Installation Overview

• Maintenance

• Operating Sequence

A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training which includes ‘‘hands-on’’ experience with the products in our labs that can mean increased conﬁdence that really pays dividends in faster troubleshooting and fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-962-9212

[ ] Packaged Service Training [ ] Classroom Service Training

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

Book 2 Tab5

PC903 CatalogNo.533-062 PrintedinU.S.A.Form30G,H-3TPg92 1099 1-98Replaces:30G,H-2T

Page 93

START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLERS

(Remove and use for job ﬁle.)

A. Preliminary Information

JOB NAME LOCATION INSTALLING CONTRACTOR DISTRIBUTOR START-UP PERFORMED BY

EQUIPMENT:

MODEL

S/N

COMPRESSORS:

CIRCUIT A CIRCUIT B

1) MODEL #

S/N S/N

2) MODEL # 2) MODEL # S/N S/N

COOLER:

MODEL #

S/N

CONDENSER: (30HX ONLY)

MODEL #

S/N

AIR-HANDLING EQUIPMENT:

MANUFACTURER

MODEL # S/N

ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES

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

Book 2 Tab 5c

PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg CL-1 1-98 Replaces: 30G,H-2T

Page 94

B. Preliminary Equipment Check

IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE

WILL THIS DAMAGE PREVENT UNIT START-UP?

M UNIT IS LEVEL IN ITS INSTALLATION M UNIT IS SUPPLIED WITH THE PROPER CONTROL VOLTAGE

VAC

M ELECTRICAL CIRCUIT WIRING HAS BEEN SIZED AND INSTALLED PROPERLY M UNIT GROUND WIRE HAS BEEN CONNECTED M ELECTRICAL CIRCUIT PROTECTION HAS BEEN SIZED AND INSTALLED PROPERLY M ALL TERMINALS ARE TIGHT M ALL CABLES AND THERMISTORS HAVE BEEN INSPECTED FOR CROSSED WIRES M ALL PLUG ASSEMBLIES ARE TIGHT

CHECK AIR-HANDLING SYSTEM

M ALL AIR HANDLERS ARE OPERATING M ALL CHILLED WATER VALVES ARE OPEN M ALL FLUID PIPING IS CONNECTED PROPERLY M ALL AIR HAS BEEN VENTED FROM THE SYSTEM M CHILLED WATER PUMP (CWP) IS OPERATING WITH THE CORRECT ROTATION

CWP AMPERAGE: RATED:

ACTUAL:

PUMP PRESSURES: INLET: OUTLET:

CHECK CONDENSER SYSTEM (30HX ONLY):

M ALL CONDENSER WATER VALVES ARE OPEN M ALL CONDENSER PIPING IS CONNECTED PROPERLY

ALL AIR HAS BEEN VENTED FROM THE SYSTEM M CONDENSER WATER PUMP IS OPERATING WITH THE CORRECT ROTATION

CONDENSER WATER PUMP AMP: RATED:

ACTUAL:

PUMP PRESSURES: INLET: OUTLET:

CHECK REMOTE CONDENSER SYSTEM (30HXA ONLY):

M ALL CONDENSER PIPING IS CONNECTED PROPERLY M CONDENSER LINES/CONDENSER HAS BEEN EVACUATED, AS REQUIRED

CL-2

Page 95

C. Unit Start-Up

M CWP STARTER HAS BEEN PROPERLY INTERLOCKED WITH THE CHILLER M ALL LIQUID VALVES ARE BACKSEATED M ALL DISCHARGE VALVES ARE OPEN M ALL SUCTION VALVES ARE OPEN, IF EQUIPPED M ALL OIL LINE VALVES ARE OPEN M UNIT HAS BEEN LEAK CHECKED

LOCATE, REPAIR, AND REPORT ANY REFRIGERANT LEAKS

M CHECK VOLTAGE IMBALANCE: AB AC BC

AVERAGE VOLTAGE = (SEE INSTALLATION INSTRUCTIONS) MAXIMUM DEVIATION =

(SEE INSTALLATION INSTRUCTIONS)

VOLTAGE IMBALANCE =

(SEE INSTALLATION INSTRUCTIONS) M VOLTAGE IMBALANCE IS LESS THAN 2% DO NOT START CHILLER IF VOLTAGE IMBALANCE IS GREATER THAN 2%. CONTACT LOCAL POWER

COMPANY FOR ASSISTANCE. M ALL INCOMING POWER VOLTAGE IS WITHIN RATED VOLTAGE RANGE

CHECK COMPRESSOR RUNNING CURRENT:

COMPRESSOR NO LOADERS ONE LOADER FULL LOAD

COMP A1,L1

AMPS AMPS AMPS

COMP A1,L2

AMPS AMPS AMPS

COMP A1,L3

AMPS AMPS AMPS

COMP B1,L1

AMPS AMPS AMPS

COMP B1,L2

AMPS AMPS AMPS

COMP B1,L3

AMPS AMPS AMPS

COMP A2,L1

AMPS AMPS AMPS

COMP A2,L2

AMPS AMPS AMPS

COMP A2,L3

AMPS AMPS AMPS

CHECK COOLER WATER LOOP:

WATER LOOP DESIGN VOLUME: GALLONS (LITERS) CALCULATED VOLUME

GALLONS (LITERS) 3 GALLONS/NOMINAL TON (3.32 LITERS/kW) FOR AIR CONDITIONING 6 GALLONS/NOMINAL TON (6.65 LITERS/kW) FOR PROCESS COOLING

M PROPER LOOP VOLUME ESTABLISHED M PROPER LOOP CORROSION INHIBITOR INCLUDED

GALLONS (LITERS) OF

M PROPER LOOP FREEZE PROTECTION INCLUDED, IF REQUIRED

GALLONS (LITERS) OF

M PIPING INCLUDES ELECTRIC HEATER TAPE, IF EXPOSED TO THE OUTSIDE M INLET PIPING TO COOLER INCLUDES A 40 MESH STRAINER

CL-3

Page 96

CHECK PRESSURE DROP ACROSS THE COOLER:

ENTERING COOLER:

PSIG (kPa)

LEAVING COOLER:

PSIG (kPa)

(LEAVING − ENTERING) × 2.31 FT OF H

O/PSIG = FT OF H2O

(LEAVING − ENTERING) × 0.334 M OF H

O/kPa = MOFH2O

PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (IN PRODUCT DATA LITERATURE) TO DETERMINE TOTAL GALLONS/MINUTE (GPM) OR LITERS PER SECOND (L/S) AND FIND UNIT’S MINIMUM FLOW RATE.

TOTAL GPM (L/S): GPM/NOMINAL TON (L/S PER TON) =

M TOTAL GPM (L/S) IS GREATER THAN UNIT’S MINIMUM FLOW RATE

M TOTAL GPM (L/S) MEETS JOB SPECIFIED REQUIREMENT OF

GPM (L/S)

M COOLER HEATER FUSE INSTALLED, AND HEATERS ARE ACTIVE (IF USED)

CHECK CONDENSER WATER LOOP:

M PROPER LOOP CORROSION INHIBITOR INCLUDED

GALLONS (LITERS) OF

M INLET PIPING TO CONDENSER INCLUDES A 40 MESH STRAINER

CHECK PRESSURE DROP ACROSS THE CONDENSER (30HXC ONLY):

ENTERING CONDENSER: PSIG (kPa) LEAVING CONDENSER:

PSIG (kPa)

(LEAVING − ENTERING) × 2.31 FT OF H

O= FT OF H2O

(LEAVING − ENTERING) × 0.334 M OF H

O/kPa = MOFH2O

PLOT CONDENSER PRESSURE DROP ON PERFORMANCE DATACHART (IN PRODUCT DATALITERATURE) TO DETERMINE TOTAL GALLONS/MINUTE (GPM) OR LITERS PER SECOND (L/S) AND FIND UNIT’S MINIMUM FLOW RATE.

TOTAL GPM (L/S): GPM/NOMINAL TON (L/S PER TON) =

M TOTAL CONDENSER GPM (L/S) IS GREATER THAN UNIT’S MINIMUM FLOW RATE

M TOTAL GPM MEETS JOB SPECIFIED REQUIREMENT OF

GPM (L/S)

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PERFORM TEST FUNCTION (INDICATE POSITIVE RESULT):

ONCE POWER IS SUPPLIED TO THE UNIT, CHECK THE DISPLAY FOR ANY ALARMS, SUCH AS PHASE REVERSAL. FOLLOW THE TEST FUNCTION INSTRUCTIONS IN THE CONTROLS AND TROUBLESHOOTING LITERATURE. BE SURE TO CHECK FOR PROPER FAN ROTATION WITH THE FAN TEST SECTIONS. BE SURE ALL SERVICE VALVES ARE OPEN BEFORE BEGINNING THE COMPRESSOR TEST SECTION. ITEMS MARKED WITH ‘‘†’’ CAN BE TESTED ONLY IF THE UNIT IS CONFIGURED FOR THIS OPTION. DO NOT RUN OIL PUMPS FOR MORE THAN 20 SECONDS.

M LOADER A1 M LOADER B1

M LOADER A2 M LOADER B2

M MINIMUM LOAD VALVE A† M MINIMUM LOAD VALVE B†

M CIRCUIT A OIL HEATER M CIRCUIT B OIL HEATER

M A1 MOTOR COOLING SOLENOID M B1 MOTOR COOLING SOLENOID

M A2 MOTOR COOLING SOLENOID† M B2 MOTOR COOLING SOLENOID†

M CIRCUIT A OIL PUMP M CIRCUIT B OIL PUMP

M OIL SOLENOID A1 M OIL SOLENOID B1

M OIL SOLENOID A2† M OIL SOLENOID B2†

M CIRCUIT A EXV M FAN 1 (30GX)†

M CIRCUIT B EXV M FAN 2 (30GX)†

M CIRCUIT A WATER VALVE† M FAN 3 (30GX)†

M CIRCUIT A% FAN SPEED (GX)† M FAN 4 (30GX)†

M CIRCUIT B% FAN SPEED (GX)† M FAN 5 (30GX)†

M FAN 6 (30GX)†

M COOLER PUMP†

M COMPRESSOR A1 M CONDENSER PUMP†

M COMPRESSOR A2† M COOLER HEATER†

M COMPRESSOR B1 M ALARM RELAY†

M COMPRESSOR B2†

M CHECK FOR COMMUNICATING MODULES (BLINKING RED AND GREED LEDs) M CORRECT FLUID SET POINTS ARE ENTERED

COOL SET POINT 1 COOL SET POINT 2

M CORRECT DATE, TIME, AND OPERATING SCHEDULE(S) ARE SET

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M REVIEW AND RECORD FACTORY CONFIGURATION CODES,

CONFIGURATION CODE 1: CONFIGURATION CODE 2: CONFIGURATION CODE 3: CONFIGURATION CODE 4: CONFIGURATION CODE 5:

M REVIEW AND RECORD SOFTWARE VERSION,

SOFTWARE CESR500100 VERSION

M REVIEW AND RECORD FIELD CONFIGURATION,

COOLER FLUID SELECT MIN LOAD VALVE SELECT LOADING SEQ. SELECT LEAD/LAG SEQ. SELECT HEAD PRESSURE CONTROL MOTORMASTER SELECT WATER VALVE TYPE EXTERNAL RESET SENSOR COOLER PUMP INTERLOCK

COOLER PUMP CONTROL CONDENSER PUMP CONTROL CONDENSER FLOW SWITCH CONDENSER WATER SENSORS

TO START THE CHILLER:

BE SURE THAT ALL SERVICE VALVESARE OPEN, AND ALL PUMPS ARE ON BEFORE ATTEMPTING TO START THIS MACHINE. ONCE ALL CHECKS HAVE BEEN MADE, MOVE THE SWITCH TO ‘‘LOCAL’’ OR ‘‘REMOTE’’ FROM ‘‘STOP.’’

M UNIT STARTS AND OPERATES PROPERLY.

TEMPERATURES AND PRESSURES:

ONCE THE MACHINE HAS BEEN OPERATING FOR AWHILEAND THE TEMPERATURES AND PRESSURES HAVE STABLIZED, RECORD THE FOLLOWING:

COOLER EWT COOLER LWT AMBIENT TEMPERATURE CONDENSER EWT

(ENTERING WATER TEMP) CONDENSER LWT

(LEAVING WATER TEMP) CIR. A OIL PRESS CIR. A SUCTION PRESS CIR. A DISCHARGE PRESS

CIR. A DISCHARGE TEMP CIR. A LIQUID LINE TEMP CIR. B OIL PRESS CIR. B SUCTION PRESS CIR. B DISCHARGE PRESS CIR. B DISCHARGE TEMP CIR. B LIQUID LINE TEMP

NOTE: OIL FILTER PRESSURE DROPS MUST BE CHECKED AFTER INITIAL 200-300 HOURS OF COMPRESSOR OPERATION. SEE OIL FILTER MAINTENANCE SECTION, PAGE 56.

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NOTES:

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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 Tab 5c

PC903 CatalogNo.533-062 PrintedinU.S.A. Form30G,H-3T PgCL-8 1099 1-98 Replaces:30G,H-2T