Carrier Air Conditioner Operation And Service manual

Controls Start-Up, Operation,

Service, and Troubleshooting

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.

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

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

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

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

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

30GTN,GTR040-420

30GUN,GUR040-420

Air-Cooled Reciprocating Liquid Chillers

with

Comfort

Link™ Controls

50/60 Hz

DO NOT attempt to unbraze factory joints 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 GENERAL INTRODUCTION MAJOR SYSTEM COMPONENTS

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

OPERATING DATA Sensors

• T1 — COOLER LEAVING FLUID SENSOR

• T2 — COOLER ENTERING FLUID SENSOR

• T3,T4 — SATURATED CONDENSING TEMPERATURE SENSORS

• T5,T6 — COOLER SUCTION TEMPERATURE SENSORS

• T7,T8 — COMPRESSOR SUCTION GAS TEMPERATURE SENSORS

• T9 — OUTDOOR-AIR TEMPERATURE SENSOR

• T10 — REMOTE SPACE TEMPERATURE SENSOR

Thermostatic Expansion Valves (TXV) Compressor Protection Control System

(CPCS) or Control Relay (CR)

Compressor Ground Current Protection Board

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

• ADDING ADDITIONAL UNLOADERS

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LOADING SEQUENCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . 3-10

. . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . 4

. . . . . . . . . . . 15

. . . . . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . 16

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

Book 2 Tab 5 c

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

CONTENTS (cont)

• LEAD/LAG DETERMINATION

• CAPACITY SEQUENCE DETERMINATION

• CAPACITY CONTROL OVERRIDES

Head Pressure Control

• COMFORTLINK™ UNITS (With EXV)

• UNITS WITH TXV

Pumpout

• EXV UNITS

• TXV UNITS

Marquee Display Usage Service Test Configuring and Operating Dual Chiller

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

• DEMAND LIMIT (2-Stage Switch Controlled)

• EXTERNALLY POWERED DEMAND LIMIT

(4 to 20 mA Controlled)

• DEMAND LIMIT (CCN Loadshed Controlled)

TROUBLESHOOTING Compressor Protection Control System

(CPCS) Board Compressor Ground Current (CGF) Board

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

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

• STEP 1 — CHECK PROCESSOR EXV OUTPUTS

• STEP 2 — CHECK EXV WIRING

• STEP 3 — CHECK RESISTANCE OF EXV MOTOR

WINDINGS

• STEP 4 — CHECK THERMISTORS THAT

CONTROL EXV

• STEP 5 — CHECK OPERATION OF THE EXV

Alarms and Alerts SERVICE

Electronic Components Compressors

• COMPRESSOR REMOVAL

• OIL CHARGE

Cooler

•COOLER REMOVAL

• REPLACING COOLER

• SERVICING THE COOLER

Condenser Coils Condenser Fans Refrigerant Feed Components

• ELECTRONIC EXPANSION VALVE (EXV)

• MOISTURE-LIQUID INDICATOR

• FILTER DRIER

• LIQUID LINE SOLENOID VALVE

• LIQUID LINE SERVICE VALVE

Thermistors

•LOCATION

• REPLACING THERMISTOR T2

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

• THERMISTORS T3 AND T4

• THERMISTOR/TEMPERATURE SENSOR CHECK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-65

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

. . . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . 47-52

. . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

. . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

. . . . . . . . . . . . . . . . . . . 58

Page

Safety Devices

• COMPRESSOR PROTECTION

• LOW OIL PRESSURE PROTECTION

• CRANKCASE HEATERS

• COOLER PROTECTION

Relief Devices

• HIGH-SIDE PROTECTION

• LOW-SIDE PROTECTION

• PRESSURE RELIEF VALVES

Other Safeties PRE-START-UP

System Check START-UP AND OPERATION

Actual Start-Up Operating Limitations

• TEMPERATURES

• VOLTAGE

• MINIMUM FLUID LOOP VOLUME

• FLOW RATE REQUIREMENTS

Operation Sequence Refrigerant Circuit

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

CURVES

START-UP CHECKLIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

. . . . . . . . . . . . . . . . . . 66,67

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-70

. . . . . . . . . . . . . . . . 71-79

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-87

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

GENERAL

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

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

INTRODUCTION

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

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

NOTE: TXVs are not available on modular units.

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

Table 1A — Unit Sizes and Modular Combinations

(30GTN,R)

UNIT

30GTN,R

040

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

*60 Hz units/50 Hz units.

NOMINAL

TONS

40 — —

SECTION A

UNIT 30GTN,R

SECTION B

UNIT 30GTN,R

Table 1B — Unit Sizes and Modular Combinations

(30GUN,R)

UNIT

30GUN,R

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

*60 Hz units/50 Hz units.

NOMINAL

TONS

SECTION A

UNIT 30GUN,R

SECTION B

UNIT 30GUN,R

MAJOR SYSTEM COMPONENTS

General —

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

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

Main Base Board (MBB) —

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

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

See Fig. 5. The MBB is

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

Expansion Valve (EXV) Board —

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

Compressor Expansion Board (CXB) —

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

Scrolling Marquee Display —

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

Energy Management Module (EMM) —

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

Enable/Off/Remote Contact Switch —

The Enable/Off/Remote Contact switch is a 3-position switch used to control the chiller. When switched to the Enable position the chiller is under its own control. Move the switch to the Off position to shut the chiller down. Move the switch to the Remote Contact position and a field installed dry contact can be used to start the chiller. The contacts must be rated for dry circuit application capable of handling a 24 vac load. In the Enable and Remote Contact (dry contacts closed) positions, the chiller is allowed to operate and respond to the scheduling configuration, CCN configuration and set point data. See Fig. 6.

Emergency On/Off Switch —

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

Reset Button —

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

Board Addresses —

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

Control Module Communication

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

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

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

Carrier Comfort Network (CCN) Interface —

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

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

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

At each system element, the shields of its 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.)

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

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

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

Table 2 — Thermistor Designations

THERMISTOR

NO.

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

T10

EXV — Electronic Expansion Valve MBB — Main Base Board

LEGEND

CONNECTION

POINT

J8-21,22 (MBB) Saturated Condensing

J8-15,16 (MBB) Saturated Condensing

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

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

J5-11,12 (EXV) Compressor Suction Gas

J5-9,10 (EXV) Compressor Suction Gas

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

J8-5,6 (MBB) Remote Space Temperature

THERMISTOR INPUT

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

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

Ckt A (EXV Only)

Ckt B (EXV Only)

Temperature, Ckt A (EXV Only)

Temperature, Ckt B (EXV Only)

Sensor or Dual Chiller LWT Sensors (Accessory)

Sensor (Accessory)

STATUS SWITCH

Oil Pressure, Ckt B Oil Pressure, Ckt A

Remote On/Off

Compressor Fault

Signal, B3

Compressor Fault

Signal, B2

Compressor Fault

Signal, B1

Compressor Fault

Signal, A4

Compressor Fault

Signal, A3

Compressor Fault

Signal, A2

Compressor Fault

Signal, A1

CPCS — CR — CXB — MBB — OPS —

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

Table 3 — Status Switches

CONNECTION

POINT

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

TB5-13, 14 Field-Installed Relay Closure

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

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

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

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

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

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

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

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

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

070

(50 Hz)

080, 230B

090-110,

245B-315B

†The CPCS can be added as an accessory.

130

(60 Hz)

130 (50 Hz)

150, 230A-

255A

170,190,

270A,290A,

330A/B,

360A/B, 390B

210, 315A,

390A,

420A/B

Table 4 — Output Relay

RELAY

NO.

K1(MBB)

K2 (MBB)

K3 (MBB)

K4 (MBB)

K5 (MBB)

K6 (MBB)

K7 (MBB) K8 (MBB)

K9 (MBB)

K10 (MBB)

K11 (MBB)

K1 (CXB)

K2 (CXB)

K3 (CXB)

K4 (CXB)

K5 (CXB)

K6 (CXB)

OFM —

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

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

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

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

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

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

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

Alarm Cooler Pump Energize First Stage of Condenser Fans:

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

Energize First Stage of Ckt A Condenser Fans:

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

Energize Second Stage of Condenser Fans:

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

Energize First Stage of Ckt B Condenser Fans:

130 (50 Hz), 150,170* — OFM2

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

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

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

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

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

130 (50 Hz), 150-210* — OFM4,OFM10

LEGEND

Outdoor-Fan Motor

DESCRIPTION

LEGEND FOR FIG. 1-4

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

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

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

CCN

LEN

DATA

COMMUNICATION

PORT

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

CCN

LEN

DATA

COMMUNICATION

PORT

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

CCN

LEN

DATA

COMMUNICATION

PORT

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

RED LED - STATUS GREEN LED -

LEN (LOCAL EQUIPMENT NETWORK)

CEPL130346-01

YELLOW LED CCN (CARRIER COMFORT NETWORK)

INSTANCE JUMPER

LEN

CCN

STATUS

Fig. 5 — Main Base Board

J10

EMERGENCY ON/OFF SWITCH

ENABLE/OFF/REMOTE CONTACT SWITCH

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

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

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

and Reset Button Locations

OPERATING DATA

Sensors —

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

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

T2 — COOLER ENTERING FLUID SENSOR — This thermistor is located in the cooler shell in the first baffle space in close proximity to the cooler tube bundle.

The electronic control uses 4 to 10 thermistors

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

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

T7, T8 — COMPRESSOR SUCTION GAS TEMPERATURE SENSORS — These thermistors are located in the lead compressor in each circuit in a suction passage after the refrigerant has passed over the motor and is about to enter the cylinders. These thermistors are inserted into friction-fit wells. The sensor wells are located directly in the refrigerant path. These thermistors are not used on units with TXVs.

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

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

LEGEND

AWG — EXV —

*And associated modular units.

American Wire Gage Electronic Wire Gage

1/2 NPT MALE THREADED ADAPTER

REF.

1.81

(46.0)

1/2” PVC SHIELD

3/16” DIA. THERMOWELL (S.S.)

REF.

5.75

(146.1

040-110*

130-210*

REF. .83 D (21.1)

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

040-070

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

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

Fig. 8 — Thermistor T3 and T4 Locations

Electronic Expansion Valve

EXV —

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

LEGEND

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

T10 — REMOTE SPACE TEMPERATURE SENSOR —

Fig. 11 — Typical Space Temperature

Sensor Wiring

Fig. 12 — CCN Communications Bus Wiring

to Optional Space Sensor RJ11 Connector

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

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

To connect the space temperature sensor (Fig. 11):

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

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

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

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

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

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

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

SPT (T10) PART NO. HH51BX006

SENSOR

SEN

TB5

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

MANUFACTURER

Alpha American Belden Columbia Manhattan Quabik

Regular Wiring Plenum Wiring

A21451 A48301

D6451 —

M13402 M64430

PART NO.

1895 —

8205 884421

6130 —

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

TO CCN TERMINALS ON TB3 AT UNIT

CCN+

CCN GND

CCN-

T-55 SPACE SENSOR

Thermostatic Expansion Valves (TXV) —

Fig. 13 — Compressor Protection Control

System Module — Sizes 040-110

Fig. 14 — Compressor Ground Fault Module

— Sizes 130-210

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

NOTE: This option is not available for modular units.

The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler by metering the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless abso- lutely necessary. When TXV is used, thermistors T5, T6, T7, and T8 are not required.

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

Model

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

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

• compressor contactor control/crankcase heater

• crankcase heater control

• compressor ground current protection (CPCS only)

• status communication to processor board

• high-pressure protection

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

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

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

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

Each

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

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

The

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

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

Electronic Expansion Valve (EXV) (See

Fig. 15 — Electronic Expansion Valve (EXV)

Fig. 15) —

EXV. This device eliminates the use of the liquid line solenoid pumpdown at unit shutdown. An O-ring has been added to bottom of orifice assembly to complete a seal in the valve on shutdown. This is not a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system.

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

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

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

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

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

Energy Management Module (Fig. 16) —

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

• 4 to 20 mA leaving fluid temperature reset (requires

field-supplied 4 to 20 mA generator)

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

supplied 4 to 20 mA generator)

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

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

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

20 mA generator)

• Discrete input for Ice Done switch (requires field-

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

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

Capacity Control —

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

Standard units are equipped with a bottom seal

This

The control system cycles com-

STEPPER MOTOR (12 VDC)

LEAD SCREW

PISTON SLEEVE

ORIFICE ASSEMBLY (INSIDE PISTON SLEEVE)

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

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

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

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

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

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

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

For units with TXVs

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

For units with EXVs

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

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

CEBD430351-0396-01C

PWR

J4 J3

RED LED - STATUS

LEN

STATUS

GREEN LED LEN (LOCAL EQUIPMENT NETWORK)

Fig. 16 — Energy Management Module

ADDRESS DIP SWITCH

TEST 1

CEPL130351-01

TEST 2

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

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

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

UNIT

30GTN,R

30GUN,R

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz) 050 (60 Hz)

050 (50 Hz) 060 (60 Hz)

060 (50 Hz) 070 (60 Hz)

070 (50 Hz)

080, 230B (60 Hz)

080, 230B (50 Hz)

090, 245B (60 Hz)

090, 245B (50 Hz)

100, 255B,

270B (60 Hz)

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

CONTROL

STEPS

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

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

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

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

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

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

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

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

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

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

114A114B1*

221A121B1

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

4 36 A1*,B1 36 A1,B1*

5 43 A1,B1 43 A1,B1

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

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

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

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

1 16 A1* 16 A1*

223A123A1

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

4 39 A1*,B1 39 A1*,B1

5 46 A1,B1 46 A1,B1

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

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

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

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

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

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

UNIT 30GTN,R 30GUN,R

100, 255B

270B (50 Hz)

110, 290B,

315B (60 Hz)

110, 290B,

315B (50 Hz)

130 (60 Hz)

130 (50 Hz)

150, 230A, 245A,

255A (60 Hz)

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

CONTROL

STEPS

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

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

1 14 A1* 14 B1*

221A121B1

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

4 36 A1*,B1 36 A1,B1*

5 43 A1,B 43 A1,B1

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

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

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

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

1 17 A1* 17 B1*

225A125B1

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

4 42 A1*,B1 42 A1,B1*

5 50 A1,B1 50 A1,B1

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

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

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

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

1 14 A1* 14 B1*

221A121B1

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

4 35 A1*,B1 35 A1,B1*

5 42 A1,B1 42 B1,B1

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

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

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

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

1 10 A1* 16 B1*

214A125B1

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

4 35 A1*,B1 31 A1,B1*

5 39 A1,B1 39 A1,B1

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

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

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

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

1 11 A1* 18 B1*

215A127B1

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

4 38 A1*,B1 33 A1,B1*

5 42 A1,B1 42 A1,B1

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

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

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

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

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

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

UNITT

30GTN,R

30GUN,R

150, 230A, 245A,

255A (50 Hz)

170, 270A,

330A/B (60 Hz)

170, 270A,

330A/B,

360B (50 Hz)

190, 290A, 360A/B,

390B (60 Hz)

190, 290A, 360A,

390B (50 Hz)

210, 315A, 390A,

420A/B (60 Hz)

210, 315A, 390A,

420A/B (50 Hz)

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

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14

9 10 11 12 13 14 15 16 17

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

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

100

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

100

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

100

13 25 41 56 78

100

17 33 50 67 83

100

11 25 36 56 67 86

100

9 26 35 51 67 84

100

Compressors

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

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

A1,A2,A3,B1,B2,B3

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

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

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

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

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

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

A1*

% Displacement

(Approx)

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

100

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

100

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

100

13 25 41 56 78

100

17 33 50 67 83

100

14 25 44 56 75 86

100

16 26 42 51 67 84

100

Compressors

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

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

A1,A2,A3,B1,B2,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

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

A1,A2,A3,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

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

A1,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

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

UNIT 30GTN,R 30GUN,R

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz) 050 (60 Hz)

050 (50 Hz) 060 (60 Hz)

060 (50 Hz) 070 (60 Hz)

070 (50 Hz)

080, 230B (60 Hz)

080, 230B (50 Hz)

090, 245B (60 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

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

CONTROL

STEPS

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

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

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

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

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

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

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

111A1† 15 B1†

2 22 A1* 30 B1*

334A144B1

441A1†,B1* 48 A1,B1†

555A1†,B1 63 A1,B1*

6 67 A1*,B1 78 A1,B1

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

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

9 100 A1,A2,B1 ——

18A1† 13 B1†

2 17 A1* 25 B1*

325A138B1

433A1†,B1* 50 A1,B1*

546A1†,B1 62 A1,B1

6 54 A1*,B1 67 A1*,A2,B1†

7 62 A1,B1 75 A1,A2,B1†

871A1†,A2,B1* 88 A1,A2,B1*

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

19A1† 9B1†

2 18 A1* 18 B1*

327A127B1

435A1†,B1 35 A1,B1†

5 44 A1*,B1 44 A1,B1*

6 53 A1,B1 53 A1,B1

756A1†,A2,B1 62 A1,B1†,B2

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

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

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

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

UNIT

30GTN,R

30GUN,R

090, 245B (50 Hz)

100, 255B,

270B (60 Hz)

100, 255B,

270B (50 Hz)

110, 290B,

315B (60 Hz)

110, 290B,

315B (50 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

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

CONTROL

STEPS

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

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

18A1† 8B1†

2 16 A1* 16 B1*

323A123B1

431A1†,B1 31 A1,B1†

5 39 A1*,B1 39 A1,B1*

6 46 A1,B1 46 A1,B1

750A1†,A2,B1* 50 A1*,B1†,B2

858A1†,A2,B1 58 A1,B1†,B2

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

17A1† 7B1†

2 13 A1* 13 B1*

320A120B1

426A1†,B1 26 A1,B1†

5 33 A1*,B1 33 A1,B1*

6 40 A1,B1 40 A1,B1

743A1†,A2,B1† 43 A1†,B1†,B2

850A1†,A2,B1* 50 A1*,B1†,B2

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

17A1† 7B1†

2 14 A1* 14 B1*

321A121B1

429A1†,B1 29 A1,B1†

5 36 A1*,B1 36 A1,B1*

6 43 A1,B1 43 A1,B1

747A1†,A2,B1† 46 A1*,B1†,B2

854A1†A2,B1* 53 A1,B1†,B2

18A1† 8B1†

2 17 A1* 17 B1*

325A125B1

433A1†,B1 33 A1,B1†

5 42 A1*,B1 42 A1,B1*

6 50 A1,B1 50 A1,B1

758A1†,A2,B1 58 A1,B1†,B2

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

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

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

Compressors

% Displacement

(Approx)

Compressors

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

UNIT 30GTN,R 30GUN,R

130 (60 Hz)

130 (50 Hz)

150, 230A, 245A,

255A (60 Hz)

150, 230A, 245A,

255A (50 Hz)

*Unloaded compressor. Two unloaders, both unloaded.

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

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

9 10 11 12 13 14 15 16 17 18 19

9 10 11 12 13 14 15 16 17

9 10 11 12 13 14 15

LOADING SEQUENCE A LOADING SEQUENCE B

% Displacement

(Approx)

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

100

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

100

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

100

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

100

Compressors

A1†,A2,B1†

A1†,A2,B1*

A1†,A2,B1†,B2 A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,B1*

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1† A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1,A2,B1

A1,A2,B1†

A1† A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1† A1*

A1†,B1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1† A1*

A1†,B1

A1*,B1

A1,B1

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

% Displacement

(Approx)

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

100

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

100

— — — —

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

100

— — — —

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

100

Compressors

B1†

B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1

A1†,B1†,B2

A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2 A1†,A2,B1†,B2 A1*,A2,B1†,B2

A1,A2,B1†,B2 A1,A2,B1*,B2

A1,A2,B1,B2

B1†

B1*

A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1†,B2 A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1†,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

— — — —

B1†

B1*

A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

— — — —

B1†

B1*

B1 A1,B1† A1,B1*

A1,B1

A1,B1†,B2

A1,B1*,B2

A1,B1,B2 A1,A2,B1†,B2 A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1†,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

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

UNIT 30GTN,R 30GUN,R

170, 270A,

330A/B (60 Hz)

170, 270A,

330A/B, 360B (50 Hz)

190, 290A, 360A/B,

390B (60 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

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

CONTROL

STEPS

1 2 3 4 5 6 7 8

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

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

9 10 11 12 13 14 15 16 17

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

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

100

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

100

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

100

Compressors

A1†,B1*

A1†,B1 A1*,B1

A1†,A2,B1*

A1†,A2,B1

A1*,A2,B1

A1,A2,B1

A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2 A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1†,A2,A3,B1*,B2,B3

A1†,A2,A3,B1,B2,B3

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

A1,A2,A3,B1,B2,B3

A1†,B1*

A1†B1 A1*,B1

A1†,A2,B1*

A1†,A2,B1

A1*,A2,B1

A1,A2,B1 A1†,A2,B1†,B2 A1†,A2,B1*,B2

A1†,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1†A2,A3,B1†,B2

A1†,A2,A3,B1*,B2

A1†,A2,A3,B1,B2 A1*,A2,A3,B1,B2

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

A1†,A2,A3,B1,B2,B3

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

A1,A2,A3,B1,B2,B3

A1*,B1*

A1*,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

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

A1,A2,A3,B1,B2,B3

A1†

A1*

A1,B1

A1†

A1*

A1,B1

A1*

A1,B1

% Displacement

(Approx)

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

100

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

100

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

100

Compressors

B1† B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1

A1*,B1†,B2

A1,B1†,B2 A1,B1*,B2

A1,B1,B2

A1*,A2,B1†,B2

A1,A2,B1†,B2 A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1†,B2,B3

A1,A2,B1†,B2,B3 A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1†,B2,B3

A1,A2,A3,B1†,B2,B3

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

A1,A2,A3,B1,B2,B3

B1† B1*

A1*,B1†

A1,B1† A1,B1*

A1,B1 A1†,B1†,B2 A1*,B1†,B2

A1,B1†,B2 A1,B1*,B2

A1,B1,B2

A1*,A2,B1†,B2

A1,A2,B1†,B2 A1,A2,B1*,B2

A1,A2,B1,B2

A1†,A2,B1†,B2,B3

A1*,A2,B1†,B2,B3

A1,A2,B1†,B2,B3 A1,A2,B1*,B2,B3

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

A1,A2,A3,B1†,B2,B3

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

A1,A2,A3,B1,B3,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

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

A1,A2,A3,B1,B2,B3

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

UNIT 30GTN,R 30GUN,R

190, 290A, 360A,

390B (50 Hz)

210, 315A, 390A,

420A/B (60 Hz)

210, 315A, 390A,

420A/B (50 Hz)

*Unloaded compressor. †Two unloaders, both unloaded.

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

CONTROL

STEPS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

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

% Displacement

LOADING SEQUENCE A LOADING SEQUENCE B

(Approx)

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

100

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

100

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

100

Compressors

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

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

A1,A2,A3,B1,B2,B3

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

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

A1,A2,A3,B1,B2,B3

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

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

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

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

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

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

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

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

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

A1,A2,A3,B1,B2,B3

% Displacement

(Approx)

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

100

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

100

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

100

Compressors

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

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

A1,A2,A3,B1,B2,B3

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

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

A1,A2,A3,B1,B2,B3

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

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

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

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

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

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

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

B1*

A1*,B1*

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

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

A1,A2,A3,B1,B2,B3

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

Follow accessory instructions for installation. Connect unloader coil leads to PINK wires in compressor A1/B1 junction box. Configuration items CA.UN and CB.UN in the OPT1 sub-mode of the configuration mode must be changed to match the new number of unloaders. Two unloaders cannot be used with hot gas bypass on a single circuit.

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

MINUTES OFF TIME (DELY, Configuration Mode under OPT2) — This user configurable time period is used by the control to determine how long unit operation is delayed after power is applied/restored to the unit. 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 30GTN,R and 30GUN,R compressor efficiency is greatest at partial load. Therefore, the following sequence list applies to capacity control.

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

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

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

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

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

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

Deadband Multiplier

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

First Stage Override

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

Slow Change Override

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

Ramp Loading

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

Low Entering Fluid Temperature Unloading

— When the entering fluid temperature is below the control point, the control will attempt to remove 25% of the current stages 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.

UNIT

30GTN,GTR,GUN,GUR

040 (60 Hz)

040 (50 Hz) 045 (60 Hz)

045 (50 Hz)

050-070

080-110**

130 (60 Hz)

130 (50 Hz)

150-210**

CBX — Compressor Expansion Board

LEGEND

Table 6 — Required Hardware for Additional Unloaders

COMP.

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

B1 0

A1 1 1

B1 0

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

FAC TORY

STANDARD

ADDITIONAL UNLOADERS

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

UNLOADER PAC K AGE *

06EA-660---138

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

06EA-660---138 EF19ZE024 Not Required

*Requires one per additional unloader.

†2 solenoid coils are included in the CXB Accessory.

**And associated modular units.

SOLENOID

COIL

EF19ZE024

EF19ZE024 Not Required

CXB ACCESSORY†

Not Required

LEGEND

Leaving Water Temperature

LWT —

(C)

LWT

DEADBAND EXAMPLE

(F)

0 200 400 600 800 1000

TIME (SECONDS)

STANDARD DEADBAND

2 STARTS

MODIFIED DEADBAND

3 STARTS

Fig. 17 — Deadband Multiplier

Low Cooler Suction Temperature

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

Cooler Freeze Protection

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

MOP (Maximum Operating Pressure) Override

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

Head Pressure Control

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

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

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

Motormaster® Option

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

Pumpout

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

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

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

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

FAN ARRANGEMENT

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

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

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

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

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

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

POWER

FA N

NO.

1 — Compressor No. A1

2 — Compressor No. B1

3 1 First Stage of Condenser Fans

4 2 Second Stage of Condenser Fans

1 — Compressor No. A1

2 — Compressor No. B1

3, 4 1 First Stage of Condenser Fans

5, 6 2 Second Stage of Condenser Fans

1 — Compressor No. A1

2 — Compressor No. B1

3, 4 1 First Stage of Condenser Fans

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

5, 7 — Compressor No. A1

6, 8 — Compressor No. B1

1, 2 1 First Stage of Condenser Fans

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

5, 7 — Compressor No. A1

6, 8 — Compressor No. B1

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

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

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

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

FAN RELAY NORMAL CONTROL

Fig. 18 — Condenser Fan Sequence

Marquee Display Usage (See Fig. 19 and

ENTER

Tables 7-25) —

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

ENTER

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

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

ESCAPE

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

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

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

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

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

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

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

ENTER ENTER

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

row keys to change the value or state of an item and press the

ENTER ESCAPE

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

See Tables 7-25 for further details.

Service Test (See Table 9) —

control circuit power must be on.

Run Status

Service Test

Temperature

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

Fig. 19 — Scrolling Marquee Display

The Marquee display module provides the

ESCAPE

ESCAPE ENTER

Both main power and

MODE

Alarm Status

ESCAPE

ENTER

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

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

ESCAPE

or COMP sub-mode.

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

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

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

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

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

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

The dual chiller routine is avail-

RETURN FLUID

CHILLER

*Depending on piping sizes, use either:

— HH79NZ014 sensor and 10HB50106801 well (3-in. sensor/well) — HH79NZ029 sensor and 10HB50106802 well (4-in. sensor/well)

Fig. 20 — Dual Chiller Thermistor Location

Table 7 — Marquee Display Menu Structure

RUN

STATUS

Auto Display (VIEW)

Machine

Hours/Starts

(RUN)

Compressor

Run Hours

(HOUR)

Compressor

Starts

(STRT)

Software

Versi on (VERS)

LEGEND

Ckt — Circuit

SERVICE

TEST

Manual

Mode

On/Off

(TEST)

Ckt A/B Outputs (OUTS)

Compressor

Tests

(COMP)

TEMPERATURES PRESSURES

Unit

Temperatures

(UNIT)

Ckt A

Temperatures

(CIR.A)

Ckt B

Temperatures

(CIR.B)

Ckt A

Pressures

(PRC.A)

Ckt B

Pressures

(PRC.B)

SET

POINTS

Cooling (COOL)

Heating (HEAT)

Head

Pressure

(HEAD)

THERMISTOR WIRING*

MASTER CHILLER

SLAVE

INPUTS OUTPUTS CONFIGURATION

Unit Discrete (GEN.I)

Ckt A/B (CRCT)

Unit

Analog

(4-20)

INSTALL DUAL CHILLER LEAVING FLUID THERMISTOR (T9) HERE

Unit

Discrete

(GEN.O)

Ckt A

(CIR.A)

Ckt B

(CIR.B)

LEAVING FLUID

Display

(DISP)

Machine

(UNIT)

Options 1

(OPT1)

Options 2

(OPT2)

Temperature

Reset

(RSET)

Set Point

Select

(SLCT)

TIME

CLOCK

Unit Time

(TIME)

Unit Date

(DATE)

Schedule

(SCHD)

OPERATING

MODES

Modes

(MODE)

ALARMS

Current (CRNT)

Reset

Alarms

(RCRN)

Alarm History (HIST)

Reset

History

(RHIS)

Table 8 — Run Status Mode and Sub-Mode Directory

SUB-MODE

VIEW

RUN HRS.U 0 - 999999 MACHINE OPERATING HOURS

HOUR HRS.A 0 - 999999 CIRCUIT A RUN HOURS

STRT ST.A1 0 - 999999 COMPRESSOR A1 STARTS

VERS MBB CESR-131170-XX-XX

KEYPAD

ENTRY

ENTER

ITEM RANGE ITEM EXPANSION COMMENT

EWT

LWT

SETP

CTPT

0 - 100 F

(–18 - 38 C)

0 - 100 F

(–18 - 38 C)

0 - 100 F

(–18 - 38 C)

0 - 100 F

(–18 - 38 C)

ENTERING FLUID TEMP

LEAVING FLUID TEMP

ACTIVE SETPOINT

CONTROL POINT

STAT 0 - 7 CONTROL MODE 0 = Service Test

OCC NO-YES OCCUPIED

MODE NO-YES OVERRIDE MODE IN EFFECT

CAP 0 - 100% PERCENT TOTAL CAPACITY

STGE 0 - 30 REQUESTED STAGE

ALRM 0 - 25 CURRENT ALARMS & ALERTS

TIME 00.00 - 23.59 TIME OF DAY

MNTH 1 - 12 MONTH OF YEAR 1 = Jan., 2 = Feb

DATE 1 - 31 DAY OF MONTH

YEAR 0 - 9999 YEAR OF CENTURY

STR.U 0 - 999999 MACHINE STARTS

HRS.B 0 - 999999 CIRCUIT B RUN HOURS

HR.A1 0 - 999999 COMPRESSOR A1 RUN HOURS

HR.A2 0 - 999999 COMPRESSOR A2 RUN HOURS

HR.A3 0 - 999999 COMPRESSOR A3 RUN HOURS

HR.A4 0 - 999999 COMPRESSOR A4 RUN HOURS

HR.B1 0 - 999999 COMPRESSOR B1 RUN HOURS

HR.B2 0 - 999999 COMPRESSOR B2 RUN HOURS

HR.B3 0 - 999999 COMPRESSOR B3 RUN HOURS

HR.B4 0 - 999999 COMPRESSOR B4 RUN HOURS

ST.A2 0 - 999999 COMPRESSOR A2 STARTS

ST.A3 0 - 999999 COMPRESSOR A3 STARTS

ST.A4 0 - 999999 COMPRESSOR A4 STARTS

ST.B1 0 - 999999 COMPRESSOR B1 STARTS

ST.B2 0 - 999999 COMPRESSOR B2 STARTS

ST.B3 0 - 999999 COMPRESSOR B3 STARTS

ST.B4 0 - 999999 COMPRESSOR B4 STARTS

EXV CESR-131172-XX-XX

CXB CESR-131173-XX-XX

EMM CESR-131174-XX-XX

MARQ CESR-131171-XX-XX

NAV CESR-131227-XX-XX

1 = Off Local 2 = Off CCN 3 = Off Time Clock 4 = Off Emergency 5 = On Local 6 = On CCN 7 = On Time Clock

Table 9 — Service Test Mode and Sub-Mode Directory

SUB-MODE

TEST TEST OFF-ON SERVICE TEST MODE Use to Enable/Disable Manual Mode

OUTS

KEYPAD

ENTRY

ENTER

ITEM RANGE ITEM EXPANSION COMMENT

LLS.A OPEN-CLSE LIQ. LINE SOLENOID VALVE TXV units only

EXV.A 0 - 100% EXV % OPEN

LLS.B OPEN-CLSE LIQ. LINE SOLENOID VALVE TXV units only

EXV.B 0 - 100% EXV % OPEN

FAN1 OFF-ON FAN 1 RELAY Fan 3:

FAN2 OFF-ON FAN 2 RELAY Fan 4:

FAN3 OFF-ON FAN 3 RELAY

FAN4 OFF-ON FAN 4 RELAY

(040-050)

(060-110, 230B-315B)

Fans 3, 4: Fans 1, 2:

(130 [60 Hz])

Fans 1:

(130 [50 Hz], 150, 170, 230A-270A, 330A/B, 360B [50 Hz]) Fans 1, 11: 360A, 360B [60 Hz], 390A/B-420A/B)

Fans 5, 6: Fans 5, 6, 7, 8: Fans 3, 4, 9, 10: Fan 2: 230A-270A, 330A/B, 360B [50 Hz]) Fans 2, 12: 360A, 360B [60 Hz], 390A/B-420A/B)

Fans 3, 9: 230A-315A, 330A/B-420A/B)

Fans 4, 10: 230A-315A, 330A/B-420A/B)

(190-210, 290A, 315A,

(040-050)

(060-090, 230B-245B)

(100, 110, 255B-315B)

(130 [60 Hz])

(130 [50 Hz], 150, 170,

(190-210, 290A, 315A,

(130 [50 Hz], 150-210,

CLR.P OFF-ON COOLER PUMP RELAY

CND.P OFF-ON CONDENSER PUMP RELAY

RMT.A OFF-ON REMOTE ALARM RELAY

COMP

ENTER

CC.A1 OFF-ON COMPRESSOR A1 RELAY

CC.A2 OFF-ON COMPRESSOR A2 RELAY

CC.A3 OFF-ON COMPRESSOR A3 RELAY

CC.A4 OFF-ON COMPRESSOR A4 RELAY

UL.A1 OFF-ON UNLOADER A1 RELAY

UL.A2 OFF-ON UNLOADER A2 RELAY

HGBP OFF-ON HOT GAS BYPASS RELAY

CC.B1 OFF-ON COMPRESSOR B1 RELAY

CC.B2 OFF-ON COMPRESSOR B2 RELAY

CC.B3 OFF-ON COMPRESSOR B3 RELAY

CC.B4 OFF-ON COMPRESSOR B4 RELAY

UL.B1 OFF-ON UNLOADER B1 RELAY

UL.B2 OFF-ON UNLOADER B2 RELAY

LEGEND

EXV — Electronic Expansion Valve

SUB-MODE

UNIT

CIR.A

CIR.B

KEYPAD

ENTRY

ENTER

Table 10 — Temperature Mode and Sub-Mode Directory

ITEM RANGE ITEM EXPANSION COMMENT

CEWT

CLWT

OAT

SPT

CNDE –40 - 245 F

CNDL –40 - 245 F

DLWT –40 - 245 F

SCT.A

SST.A

SGT.A

SUP.A

SCT.B

SST.B

SGT.B

SUP.B

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 ∆ F

(–40 - 118 ∆ C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 F

(–40 - 118 C)

–40 - 245 ∆ F

(–40 - 118 ∆ C)

COOLER ENTERING FLUID

COOLER LEAVING FLUID

OUTSIDE AIR TEMPERATURE

SPACE TEMPERATURE

CONDENSER ENTERING FLUID

CONDENSER LEAVING FLUID

LEAD/LAG LEAVING FLUID

SATURATED CONDENSING TMP

SATURATED SUCTION TEMP

COMPRESSOR SUCTION GAS TEMP

SUCTION SUPERHEAT TEMP

SATURATED CONDENSING TMP

SATURATED SUCTION TEMP

COMPRESSOR SUCTION GAS TEMP

SUCTION SUPERHEAT TEMP

Table 11 — Pressure Mode and Sub-Mode Directory

SUB-MODE KEYPAD ENTRY ITEM RANGE ITEM EXPANSION COMMENT

PRC.A

PRC.B

ENTER

DP.A

SP.A

DP.B

SP.B

0-900

Psig

0-900

Psig

0-900

Psig

0-900

Psig

DISCHARGE PRESSURE Pressure is converted from SCT.A.

SUCTION PRESSURE Pressure is converted from SST.A.

DISCHARGE PRESSURE Pressure is converted from SCT.B.

SUCTION PRESSURE Pressure is converted from SST.B.

Table 12 — Set Point Mode and Sub-Mode Directory

SUB-MODE

COOL

HEAT

HEAD

KEYPAD

ENTRY

ENTER

ITEM RANGE ITEM EXPANSION COMMENT

CSP.1

CSP.2

CSP.3

HSP.1

HSP.2

HD.P.A

HD.P.B

–20 - 70 F

(–29 - 21 C)

–20 - 70 F

(–29 - 21 C)

–20 - 32 F

(–29 - 0° C)

80 - 140 F

(27 - 60 C)

80 - 140 F

(27 - 60 C)

80 - 140 F

(27 - 60 C)

80 - 140 F

(27 - 60 C)

COOLING SETPOINT 1 Default 44 F

COOLING SETPOINT 2 Default 44 F

ICE SETPOINT Default 32 F

HEATING SETPOINT 1 Not Supported

HEATING SETPOINT 2 Not Supported

HEAD PRESSURE SETPOINT A Default 113 F

HEAD PRESSURE SETPOINT B Default 113 F

Table 13 — Reading and Changing Chilled Fluid Set Point

SUB-MODE KEYPAD ENTRY ITEM DISPLAY RANGE ITEM EXPANSION COMMENT

COOL

ENTER

CSP.1 44.0 °F –20-70 F COOLING SETPOINT 1

44.0 °F –20-70 F Scrolling stops

44.0 °F –20-70 F Value flashes

Default: 44 F 38-70 F Flud = 1 14-70 F Flud = 2

–20-70 F Flud = 3

–20-70 F Select 46.0

ENTER

CSP.1 46.0 °F –20-70 F COOLING SETPOINT 1 Item/Value/Units scrolls again

46.0 °F –20-70 F Change accepted

Table 14 — Inputs Mode and Sub-Mode Directory

SUB-MODE

GEN.I

CRCT

4-20

KEYPAD

ENTRY

ENTER

ITEM RANGE ITEM EXPANSION COMMENT

STST STRT-STOP START/STOP SWITCH

Enable/Off/Remote Contact Switch Input

FLOW OFF-ON COOLER FLOW SWITCH

CND.F OFF-ON CONDENSER FLOW SWITCH

DLS1 OFF-ON DEMAND LIMIT SWITCH 1

DLS2 OFF-ON DEMAND LIMIT SWITCH 2

ICED OFF-ON ICE DONE

DUAL OFF-ON DUAL SETPOINT SWITCH

FKA1 OFF-ON COMPRESSOR A1 FEED BACK

FKA2 OFF-ON COMPRESSOR A2 FEED BACK

FKA3 OFF-ON COMPRESSOR A3 FEED BACK

FKA4 OFF-ON COMPRESSOR A4 FEED BACK

OIL.A OPEN-CLSE OIL PRESSURE SWITCH A

LPS.A OPEN-CLSE LOW PRESSURE SWITCH Not applicable (040-420)

FKB1 OFF-ON COMPRESSOR B1 FEED BACK

FKB2 OFF-ON COMPRESSOR B2 FEED BACK

FKB3 OFF-ON COMPRESSOR B3 FEED BACK

FKB4 OFF-ON COMPRESSOR B4 FEED BACK

OIL.B OPEN-CLSE OIL PRESSURE SWITCH B

LPS.B OPEN-CLSE LOW PRESSURE SWITCH Not applicable (040-420)

DMND 0 - 24 mA 4-20 mA DEMAND SIGNAL

RSET 0 - 24 mA 4-20 mA RESET SIGNAL

CSP 0 - 24 mA 4-20 mA COOLING SETPOINT

HSP 0 - 24 mA 4-20 mA HEATING SETPOINT

Table 15 — Outputs Mode and Sub-Mode Directory

SUB-MODE

GEN.O FAN1 OFF-ON FAN 1 RELAY

CIR.A

CIR.B

LEGEND

EXV — Electronic Expansion Valve TXV — Thermostatic Expansion Valve

KEYPAD

ENTRY

ENTER

ITEM RANGE ITEM EXPANSION COMMENT

FAN2 OFF-ON FAN 2 RELAY

FAN3 OFF-ON FAN 3 RELAY

FAN4 OFF-ON FAN 4 RELAY

C.PMP OFF-ON COOLER PUMP RELAY

H.GAS OFF-ON HOT GAS BYPASS RELAY

CNDP OFF-ON CONDENSER PUMP RELAY

CC.A1 OFF-ON COMPRESSOR A1 RELAY

CC.A2 OFF-ON COMPRESSOR A2 RELAY

CC.A3 OFF-ON COMPRESSOR A3 RELAY

CC.A4 OFF-ON COMPRESSOR A4 RELAY

ULA1 OFF-ON UNLOADER A1 RELAY

ULA2 OFF-ON UNLOADER A2 RELAY TXV units only

LLS.A OPEN-CLSE LIQUID LINE SOLENOID VLV EXV units only

EXV.A 0 - 100% EXV % OPEN

CC.B1 OFF-ON COMPRESSOR B1 RELAY

CC.B2 OFF-ON COMPRESSOR B2 RELAY

CC.B3 OFF-ON COMPRESSOR B3 RELAY

CC.B4 OFF-ON COMPRESSOR B4 RELAY

ULB1 OFF-ON UNLOADER B1 RELAY

ULB2 OFF-ON UNLOADER B2 RELAY

LLS.B OPEN-CLSE LIQUID LINE SOLENOID VLV TXV units only

EXV.B 0 - 100% EXV % OPEN EXV units only

SUB-MODE

DISP

KEYPAD

ENTRY

ENTER

LEGEND

CCN — Carrier Comfor t Network EMM — Energy Management Module EXV — Electronic Expansion Valve LCW — Leaving Chilled Water

Table 16 — Configuration Mode and Sub-Mode Directory

ITEM

MARQUEE

DISPLAY RANGE

TEST OFF-ON OFF-ON

METR OFF-ON OFF-ON METRIC DISPLAY

LANG 0 - 3 ENGLISH

NAVIGATOR

DISPLAY RANGE

ESPANOL

FRANCAIS

PORTUGUES

ITEM EXPANSION COMMENT

TEST DISPLAY

LEDS

LANGUAGE

SELECTION

Off = English On = Metric

Default: 0 0 = English 1 = Espanol 2 = Francais 3 = Portugues

Table 16 — Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE

UNIT TYPE 1 - 5

OPT1

OPT2

CCN — Carrier Comfor t Network EMM — Energy Management Module EXV — Electronic Expansion Valve LCW — Leaving Chilled Water

KEYPAD

ENTRY

ENTER

LEGEND

ITEM

TONS 15 - 300 15 - 300 UNIT SIZE

CAP.A 0 - 100% 0 - 100% CIRCUIT A % CAPACITY

CMP.A 1 - 4 1 - 4 NUMBER CIRC A COMPRESSOR

CYL.A 4, 6 4, 6 COMPRESSOR A1 CYLINDERS

CMP.B 1 - 4 1 - 4 NUMBER CIRC B COMPRESSOR

CYL.B 4, 6 4, 6 COMPRESSOR B1 CYLINDERS

EXV NO-YES NO-YES EXV MODULE INSTALLED

SH.SP

SH.OF

REFG 1, 2 1, 2 REFRIGERANT

FAN . S 1 - 4

FLUD 1 - 3 1 - 3 COOLER FLUID 1 = Water

HGB.S NO-YES NO-YES HOT GAS BYPASS SELECT

HPCM 1 - 4

HPCT 0 - 2

MMR.S NO-YES NO-YES MOTORMASTER SELECT

PRTS NO-YES NO-YES

PMP.I OFF-ON OFF-ON COOLER PUMP INTERLOCK Default: ON

CPC OFF-ON OFF-ON COOLER PUMP CONTROL Default: OFF

CNP.I OFF-ON OFF-ON CONDENSER PUMP INTERLOCK

CNPC 0 - 2 NO CONTROL

CWT.S NO-YES NO-YES CONDENSER FLUID SENSORS

CA.UN 0 - 2 0 - 2 NO. CIRCUIT A UNLOADERS

CB.UN 0 - 2 0 - 2 NO. CIRCUIT B UNLOADERS

EMM NO-YES NO-YES EMM MODULE INSTALLED

CTRL 0 - 3 SWITCH

CCNA 1 - 239 1 - 239 CCN ADDRESS Default: 1

CCNB 0 - 239 0 - 239 CCN BUS NUMBER Default: 0

MARQUEE

DISPLAY RANGE

10 - 40 ∆ F

(6 - 22 ∆ C)

–20 - 20 ∆ F

(–11 - 11 ∆ C)

NAVIGATOR

DISPLAY RANGE

AIR COOLED WATER COOLED SPLIT HEAT MACHINE HEAT RECLAIM

10 - 40 ∆ F

(6 - 22 ∆ C)

–20 - 20 ∆ F

(–11 - 11 ∆ C)

2 STAGE IND

3 STAGE IND 2 STAGE COM 3 STAGE CO

EXV CONTROL

SETPOINT CONTROL

SET A EXV B

EXV A SET B

NO CONTROL

AIR COOLED

WATER COOLED

ON WITH MODE ON WITH COMP

7 DAY OCC

OCCUPANCY

CCN

ITEM EXPANSION COMMENT

UNIT TYPE Default: 1

EXV SUPERHEAT SETPOINT

1 = Air Cooled 2 = Water Cooled 3 = Split System 4 = Heat Machine 5 = Heat Reclaim

Default 29 = 30GTN,R 23 = 30GUN,R

EXV SUPERHEAT OFFSET Default: 0

1 = R-22 (30GTN,R) 2 = R-134a (30GUN,R)

FAN STAGING SELECT 1 = 2 Stage Independent

HEAD PRESS. CONT. METHOD Default:2

HEAD PRESS. CONTROL TYPE Default: 1

PRESSURE

TRANSDUCERS

CONDENSER PUMP CONTROL Default: 0

CONTROL METHOD 0 = Switch

2 = 3 Stage Independent 3 = 2 Stage Common 4 = 3 Stage Common (Not supported

for air cooled)

2 = Med. Brine 3 = Low Brine

1 = EXV Control 2 = Set Point Control 3 = Set Point Circuit A, EXV Circuit B 4 = Set Point Circuit B, EXV Circuit A

0 = No Control 1 = Air Cooled 2 = Water Cooled

Default: NO Not Supported

Default: OFF Not Applicable

0 = Not Controlled 1 = On with Occupied Mode 2 = On with Compressors

Default: NO Not Applicable

1 = 7-Day Schedule 2 = Occupancy Schedule 3 = CCN

SUB-MODE

OPT2

(cont)

RSET

KEYPAD

ENTRY

ENTER

Table 16 — Configuration Mode and Sub-Mode Directory (cont)

ITEM

BAUD 1 - 5

LOAD 1 - 2

LLCS 1 - 3 AUTOMATIC

LCWT

DELY 0 - 15 0 - 15 MINUTES OFF TIME Default: 0

ICE.M ENBL-DSBL ENBL-DSBL ICE MODE ENABLE Default: DSBL

CRST 0 - 4

CRT1

CRT2

DGRC

HRST 0 - 4 0 - 4

HRT1

HRT2

DGRH

DMDC 0 - 3 0 - 3

DM20 0 - 100% 0 - 100%

SHNM 0 - 99 0 - 99

SHDL 0 - 60% 0 - 60%

SHTM 0 - 120 0 - 120

DLS1 0 - 100% 0 - 100%

DLS2 0 - 100% 0 - 100%

LLEN ENBL-DSBL ENBL-DSBL

MSSL SLVE-MAST SLVE-MAST

SLVA 0 - 239 0 - 239 SLAVE ADDRESS Default: 0

LLBL ENBL-DSBL ENBL-DSBL

LLBD 40 - 400HRS 40 - 400HRS

LLDY 0 - 30 MIN 0 - 30 MIN LAG START DELAY Default: 5 minutes

MARQUEE

DISPLAY RANGE

2 - 60 ∆ F

(–16 - 16 ∆ C)

0° - 125 F

(–18 - 52 C)

0° - 125 F

(–18 - 52 C)

–30 - 30 ∆ F

(–17 - 17 ∆ C)

0° - 125 F

(–18 - 52 C)

0° - 125 F

(–18 - 52 C)

–30 - 30 ∆ F

(–17 - 17 ∆ C)

NAVIGATOR

DISPLAY RANGE

240

4800 9600 19,200 38,4

EQUAL

STAGED

CIR A LEADS CIR B LEADS

2 - 60 ∆ F

(–16 - 16 ∆ C)

NO RESET

4-20 INPUT

OUT AIR TEMP

RETURN FLUID

SPACE TEMP

0° - 125 F

(–18 - 52 C)

0° - 125 F

(–18 - 52 C)

–30 - 30 ∆ F

(–17 - 17 ∆ C)

0° - 125 F

(–18 - 52 C)

0° - 125 F

(–18 - 52 C)

–30 - 30 ∆ F

(–17 - 17 ∆ C)

ITEM EXPANSION COMMENT

CCN BAUD RATE Default: 3

LOADING SEQUENCE

SELECT

LEAD/LAG CIRCUIT

SELECT

HIGH LCW ALERT

LIMIT

COOLING RESET

TYPE

NO COOL RESET

TEMP

FULL COOL RESET

TEMP

DEGREES COOL

RESET

HEATING RESET

TYPE

NO HEAT RESET

TEMP

FULL HEAT RESET

TEMP

DEGREES HEAT

RESET

DEMAND LIMIT

SELECT

DEMAND LIMIT

AT 2 0 m A

LOADSHED GROUP

NUMBER

LOADSHED DEMAND

DELTA

MAXIMUM LOADSHED

TIME

DEMAND LIMIT

SWITCH 1

DEMAND LIMIT

SWITCH 2

LEAD/LAG CHILLER

ENABLE

MASTER/SLAVE

SELECT

LEAD/LAG BALANCE

SELECT

LEAD/LAG BALANCE

DELTA

1 = 2400 2 = 4800 3 = 9600 4 = 19,200 5 = 38,400

Default: 1 1 = Equal 2 = Staged

Default: 1 (Size 080-420);

2 (Size 040-070) 1 = Automatic 2 = Circuit A Leads 3 = Circuit B Leads

Default: 60

0 = No report 2 = 4 to 20 mA input 3 = Return fluid 4 = Space temperature

Default: 125 F

Default: 0° F

Not Supported

Default: 0

Default: 100%

Default: 0

Default: 60 minutes

Default: 80%

Default: 50%

Default: DSBL

Default: Master

Default: DSBL

Default: 168 hours

Table 16 — Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE

SLCT

KEYPAD

ENTRY

ENTER

ITEM

CLSP 0 - 5 DUAL SWITCH

HTSP 0 - 4 0 - 4 HEATING SETPOINT SELECT Not Supported

RL.S ENBL-DSBL ENBL-DSBL RAMP LOAD SELECT Default: DSBL

CRMP

HRMP

HCSW COOL-HEAT COOL-HEAT HEAT COOL SELECT Not Supported

Z.GN 1.0 - 4.0 1.0 - 4.0 DEADBAND MULTIPLIER Default: 1.0

MARQUEE

DISPLAY RANGE

0.2 - 2.0° F

(0.1 - 1.1° C)

0.2 - 2.0° F

(0.1 - 1.1° C)

NAVIGATOR

DISPLAY RANGE

DUAL 7 DAY

DUAL CCN OCC

4-20 INPUT

EXTERNAL POT

0.2 - 2.0° F

(0.1 - 1.1° C)

0.2 - 2.0° F

(0.1 - 1.1° C)

ITEM EXPANSION COMMENT

COOLING SETPOINT

SELECT

COOLING RAMP LOADING Default: 1.0

HEATING RAMP LOADING Not Supported

Table 17 — Example of Temperature Reset (Return Fluid) Configuration

SUB-MODE

RSET CRST 0 COOLING RESET TYPE 0 = No reset

NOTE: The example above shows how to configure the chiller for temperature reset based on chiller return fluid. The chiller will be configured for no reset at a cooler ∆T (EWT-LWT) of 10 F (5.6 C) and a full reset of 8 F (4.4 C) at a cooler ∆T of 2 F (1.1 C).

KEYPAD

ENTRY

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ITEM DISPLAY ITEM EXPANSION COMMENT

CRST 3

CRT1 125 NO COOL RESET TEMP

125

CRT1 10

CRT2 0 FULL COOL RESET TEMP

CRT2 2

DGRC 0 DEGREES COOL RESET

DGRC 8

Default: 0 0 = Single 1 = Dual Switch 2 = Dual 7 Day 3 = Dual CCN Occupancy 4 = 4-20 Input 5 = Set Point Potentiometer

1 = 4 to 20 mA input 2 = Outdoor Air Temp 3 = Return Fluid 4 = Space Temperature

Scrolling stops

Value flashes

Select 3

Change accepted

Item/Value/Units scrolls again

Range: 0° to 125 F

Scrolling stops

Value flashes

Select 10

Change accepted

Item/Value/Units scrolls again

Range: 0° to 125 F

Scrolling stops

Value flashes

Select 2

Change accepted

Item/Value/Units scrolls again

Range: –30 to 30 F

Scrolling stops

Value flashes

Select 8

Change accepted

Item/Value/Units scrolls again

Table 18A — Example of Configuring Dual Chiller Control

(Master Chiller)

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

RSET

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

CRST 0 COOLING RESET TYPE

LLDY 5 LAG START DELAY

LLDY 10

LLBD 168 LEAD/LAG BALANCE DELTA

LLBL DSBL LEAD/LAG BALANCE SELECT

DSBL

ENBL

LLBL ENBL

SLVA 0 SLAVE ADDRESS

SLVA 6

MSSL MAST MASTER/SLAVE SELECT

Scrolling stops

Value flashes

Select 10

Change accepted

No change needed. Default set for weekly changeover

Scrolling stops

Value flashes

Select Enable

Change accepted

Scrolling stops

Value flashes

Select 6

Change accepted

No change needed. Default set for Master

Table 18B — Example of Configuring Dual Chiller Control

(Slave Chiller)

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

RSET

ENTER

ESCAPE

CRST 0 COOLING RESET TYPE

LLDY 5 LAG START DELAY

LLBD 168 LEAD/LAG BALANCE DELTA

LLBL DSBL LEAD/LAG BALANCE SELECT

SLVA 0 SLAVE ADDRESS

MSSL MAST MASTER/SLAVE SELECT

MAST

SLVE

MSSL

LLEN DSBL LEAD/LAG CHILLER ENABLE

DSBL

ENBL

LLEN ENBL

LLEN ENBL LEAD/LAG CHILLER ENABLE

No change needed. Default set for weekly changeover

Default set for Master

Scrolling stops

Value flashes

Select SLVE

Change accepted

Item/Value/Units scrolls again

Scrolling stops

Value flashes

Select enable

Change accepted

Item/Value/Units scrolls again

Table 19 — Example of Compressor Lead/Lag Configuration

SUB-MODE

OPT2 CTRL 0 CONTROL METHOD

KEYPAD

ENTRY

ENTER

ITEM DISPLAY ITEM EXPANSION COMMENT

CCNA 1

CCNB 0

BAUD 3

LOAD 1

LLCS 1 LEAD/LAG CIRCUIT SELECT

ENTER

1 Scrolling stops

1 Value flashes

3 Select 3 (See note below)

ENTER

ESCAPE

LLCS 3 LEAD/LAG CIRCUIT SELECT Item/Value/Units scrolls again

3 Change accepted

NOTE: Options 1 and/or 3 not valid for sizes 040-070 without Circuit B accessory unloader installed.

Table 20 — Time Clock Mode and Sub-Mode Directory

SUB-MODE KEYPAD ENTRY ITEM

TIME

DATE

ENTER

HH.MM 00.00 - 23.59 HOUR AND MINUTE

MNTH 1 - 12 MONTH

DOM 1 - 31 DATE OF MONTH

DAY 1 - 7 DAY OF WEEK

YEAR 0000 - 9999 YEAR OF CENTURY

SCHD

ENTER

MON.O 00.00 - 23.59 MONDAY OCCUPIED TIME Default: 00.00

MON.U 00.00 - 23.59 MONDAY UNOCCUPIED TIME Default: 00.00

TUE.O 00.00 - 23.59 TUESDAY OCCUPIED TIME Default: 00.00

TUE.U 00.00 - 23.59 TUESDAY UNOCCUPIED TIME Default: 00.00

WED.O 00.00 - 23.59 WEDNESDAY OCCUPIED TIME Default: 00.00

WED.U 00.00 - 23.59 WEDNESDAY UNOCC TIME Default: 00.00

THU.O 00.00 - 23.59 THURSDAY OCCUPIED TIME Default: 00.00

THU.U 00.00 - 23.59 THURSDAY UNOCCUPIED TIME Default: 00.00

FRI.O 00.00 - 23.59 FRIDAY OCCUPIED TIME Default: 00.00

FRI.U 00.00 - 23.59 FRIDAY UNOCCUPIED TIME Default: 00.00

SAT.O 00.00 - 23.59 SATURDAY OCCUPIED TIME Default: 00.00

SAT.U 00.00 - 23.59 SATURDAY UNOCCUPIED TIME Default: 00.00

SUN.O 00.00 - 23.59 SUNDAY OCCUPIED TIME Default: 00.00

SUN.U 00.00 - 23.59 SUNDAY UNOCCUPIED TIME Default: 00.00

ITEM

RANGE

DEFAULT: 1 (Size 080-420)

2 (Size 040-070)

1 = Automatic 2 = Circuit A Leads 3 = Circuit B Leads

ITEM EXPANSION COMMENT

Military (00.00-23.59)

1=Jan, 2=Feb, etc.

1=Mon, 2=Tue, etc.

Table 21 — Setting an Occupied Time Schedule

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

SCHD

ENTER

MON.O 00.00 MONDAY OCCUPIED TIME TIME IN MILITARY FORMAT (HH.MM)

00.00 Scrolling stops

00.00 Hours flash

07.00 Select 7 AM

ENTER

07.00 Change accepted, minutes flash

07.30 Select 30

ENTER

ESCAPE

MON.O 07.30 MONDAY OCCUPIED TIME Item/Value/Units scrolls again

07.30 Change accepted

Table 22 — Operating Mode and Sub-Mode Directory

SUB-MODE KEYPAD ENTRY ITEM RANGE ITEM EXPANSION COMMENT

MODE

ENTER

MD01 OFF-ON FSM CONTROLLING CHILLER

MD02 OFF-ON WSM CONTROLLING CHILLER

MD03 OFF-ON MASTER/SLAVE CONTROL

MD04 OFF-ON LOW SOURCE PROTECTION Not Supported

MD05 OFF-ON RAMP LOAD LIMITED

MD06 OFF-ON TIMED OVERRIDE IN EFFECT

MD07 OFF-ON LOW COOLER SUCTION TEMPA

MD08 OFF-ON LOW COOLER SUCTION TEMPB

MD09 OFF-ON SLOW CHANGE OVERRIDE

MD10 OFF-ON MINIMUM OFF TIME ACTIVE

MD11 OFF-ON LOW SUCTION SUPERHEAT A

MD12 OFF-ON LOW SUCTION SUPERHEAT B

MD13 OFF-ON DUAL SETPOINT

MD14 OFF-ON TEMPERATURE RESET

MD15 OFF-ON DEMAND LIMIT IN EFFECT

MD16 OFF-ON COOLER FREEZE PROTECTION

MD17 OFF-ON LO TMP COOL/HI TMP HEAT

MD18 OFF-ON HI TMP COOL/LO TMP HEAT

MD19 OFF-ON MAKING ICE

MD20 OFF-ON STORING ICE

MD21 OFF-ON HIGH SCT CIRCUIT A

MD22 OFF-ON HIGH SCT CIRCUIT B

LEGEND

FSM — Flotronic™ System Manager SCT — Saturated Condensing Temperature WSM — Water System Manager

Table 23 — Operating Modes

MODE NO. ITEM EXPANSION DESCRIPTION

01 02 03 04 05

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

WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller.

MASTER/SLAVE CONTROL Lead/Lag Chiller control is enabled.

LOW SOURCE PROTECTION Not currently supported.

RAMP LOAD LIMITED Ramp load (pulldown) limiting in effect. In this mode, the rate at which leaving

TIMED OVERRIDE IN EFFECT Timed override is in effect. This is a 1 to 4 hour temporary override of the

LOW COOLER SUCTION TEMP A Circuit A capacity may be limited due to operation of this mode. Control will

LOW COOLER SUCTION TEMP B Circuit B capacity may be limited due to operation of this mode. Control will

SLOW CHANGE OVERRIDE Slow change override is in effect. The leaving fluid temperature is close to

MINIMUM OFF TIME ACTIVE Chiller is being held off by Minutes Off Time (DELY) found under Options 2

LOW SUCTION SUPERHEAT A Circuit A capacity may be limited due to operation of this mode. Control will

LOW SUCTION SUPERHEAT B Circuit B capacity may be limited due to operation of this mode. Control will

DUAL SET POINT Dual set point mode is in effect. Chiller controls to CSP.1 during occupied

TEMPERATURE RESET Temperature reset is in effect. In this mode, chiller is using temperature

DEMAND LIMIT IN EFFECT Demand limit is in effect. This indicates that the capacity of the chiller

COOLER FREEZE PROTECTION Cooler fluid temperatures are approaching the Freeze point (see Alarms

LO TMP COOL/HI TMP HEAT Chiller is in Cooling mode and the rate of change of the leaving fluid is neg-

HI TMP COOL/LO TMP HEAT Chiller is in Cooling mode and the rate of change of the leaving fluid is positive

MAKING ICE Chiller is in an unoccupied mode and is using Ice Set Point 3 (CSP.3) to make

STORING ICE Chiller is in an unoccupied mode and is controlling to Cooling Set Point 2

HIGH SCT CIRCUIT A Chiller is in a cooling mode and the Saturated Condensing temperature read

HIGH SCT CIRCUIT B Chiller is in a cooling mode and the Saturated Condensing temperature read

fluid temperature is dropped is limited to a predetermined value to prevent compressor overloading. See CRMP set point in the Set Point Select (SLCT) section of the Configuration mode. The pulldown limit can be modified, if desired, to any rate from 0.2° F to 2° F (0.1° to 1° C)/minute.

programmed schedule, forcing unit to Occupied mode. Override can be implemented with unit under Local (Enable) or CCN control. Override expires after each use.

attempt to correct this situation for up to 10 minutes before shutting the circuit down. The control may decrease capacity when attempting to correct this problem. See Alarms and Alerts section for more information.

attempt to correct this situation for up to10 minutes before shutting the circuit down. The control may decrease capacity when attempting to correct this problem. See Alarms and Alerts section for more information.

and moving towards the control point.

(OPT2) section of Configuration mode.

attempt to correct this situation for up to 5 minutes before shutting the circuit down. See Alarms and Alerts section for more information.

periods and CSP.2 during unoccupied periods. Both CSP.1 and CSP.2 are located under COOL in the Set Point mode.

reset to adjust leaving fluid set point upward and 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.

is being limited by demand limit control option. Because of this limitation, the chiller may not be able to produce the desired leaving fluid temperature. Demand limit can be controlled by switch inputs or a 4 to 20 mA signal.

and Alerts section for definition). The chiller will be shut down when either fluid temperature falls below the Freeze point.

ative and decreasing faster than -0.5° F per minute. Error between leaving fluid and control point exceeds fixed amount. Control will automatically unload the chiller if necessary.

and increasing. Error between leaving fluid and control point exceeds fixed amount. Control will automatically load the chiller if necessary to better match the increasing load.

ice. The ice done input to the Energy Management Module (EMM) is open.

(CSP.2). The ice done input to the Energy Management Module (EMM) is closed.

by sensor T3 is greater than 140 F (60 C). No additional stages of capacity will be added. Chiller may be unloaded if SCT continues to rise to avoid highpressure switch trips by reducing condensing temperature.

by sensor T4 is greater than 140 F (60 C). No additional stages of capacity will be added. Chiller may be unloaded if SCT continues to rise to avoid highpressure switch trips by reducing condensing temperature.

Table 24 — Alarms Mode and Sub-Mode Directory

LEGEND

Fig. 21 — Standard Chilled Fluid

Temperature Control — No Reset

EWT —

Entering Water (Fluid) Temperature

LWT —

Leaving Water (Fluid) Temperature

SUB-MODE KEYPAD ENTRY ITEM ITEM EXPANSION COMMENT

CRNT

RCRN

ENTER

AXXX or TXXX CURRENTLY ACTIVE ALARMS

YES/NO RESET ALL CURRENT ALARMS

Alarms are shown as AXXX. Alerts are shown as TXXX.

HIST

RHIS

ENTER

AXXX or TXXX ALARM HISTORY

YES/NO RESET ALARM HISTORY

Table 25 — Example of Reading and Clearing Alarms

SUB-MODE

CRNT

RCRN

Temperature Reset —

KEYPAD

ENTRY

ENTER

ESCAPE

ENTER

ITEM ITEM EXPANSION COMMENT

AXXX or TXXX CURRENTLY ACTIVE ALARMS ACTIVE ALARMS (AXXX) OR

NO Use to clear active alarms/alerts

NO NO Flashes

YES Select YES

NO Alarms/alerts clear, YES changes to NO

The control system is capable of handling leaving-fluid temperature reset based on return cooler fluid temperature. Because the change in temperature through the cooler is a measure of the building load, the return temperature reset is in effect an average building load reset method. The control system is also capable of temperature reset based on outdoor-air temperature (OAT), space temperature (SPT), or from an externally powered 4 to 20 mA signal. Accessory sensors must be used for OAT and SPT reset (HH79NZ073 for OAT and HH51BX006 for SPT). The Energy Management Module (EMM) must be used for temperature reset using a 4 to 20 mA signal.

To use the return reset, four variables must be configured. In the Configuration mode under the sub-mode RSET, items CRST, CRT1, CRT2, and DGRC must be set properly. See Table 26 on page 44 for correct configuration. See Fig. 2-4 for wiring details.

Under normal operation, the chiller will maintain a constant leaving fluid temperature approximately equal to the chilled fluid set point. As the cooler load varies, the entering cooler fluid will change in proportion to the load as shown in Fig. 21. Usually the chiller size and leaving-fluid temperature set point are selected based on a full-load condition. At part load, the fluid temperature set point may be colder than required. If the leaving fluid temperature was allowed to increase at part load, the efficiency of the machine would increase.

Alarms are shown as AXXX. Alerts are shown as TXXX.

ALERTS (TXXX) DISPLAYED.

Return temperature reset allows for the leaving temperature set point to be reset upward as a function of the return fluid temperature or, in effect, the building load.

Table 26 — Configuring Temperature Reset

MODE

CONFIGURATION

KEYPAD

ENTRY

SUB-MODE

ENTER ENTER

DISP TEST ON/OFF TEST DISPLAY LEDS

UNIT TYPE UNIT TYPE

OPT1 FLUD COOLER FLUID

OPT2 CTRL CONTROL METHOD

RSET CRST COOLING RESET TYPE 0 = No Reset

KEYPAD

ENTRY

ENTER

ITEM DISPLAY

CRT1 XXX.X F NO COOL RESET TEMP

CRT2 XXX.X F FULL COOL RESET TEMP

DGRC XX.X °F DEGREES COOL RESET

The following are examples of outdoor air and space tem-

perature resets:

ITEM

EXPANSION

COMMENT

1 = 4 to 20 mA Input (EMM required)

(Connect to EMM J6-2,5)

2 = Outdoor-Air Temperature

(Connect to TB5-7,8) 3 = Return Fluid 4 = Space Temperature (Connect to

TB5-5,6)

Default: 125 F (51.7 C) Range: 0° to125 F Set to 4.0 for CRST= 1

Default: 0° F (–17.8 C) Range: 0° to 125 F Set to 20.0 for CRST=1

Default: 0° F (0° C) Range: –30 to 30° F (–16.7 to 16.7° C)

LEGEND

Leaving Water (Fluid) Temperature

LWT —

LEGEND

Leaving Water (Fluid) Temperature

LWT —

Cooling Set Point (4 to 20 mA) —

A field supplied and generated, externally powered 4 to 20 mA signal can be used to provide the leaving fluid temperature set point. Connect the signal to TB6-3,5 (+,–). See Table 27 for instructions to

100 (38)

(27)

(15)

(4.4)

SET POINT, F (C)

(-7)

(-17)

4 6.3 8.6 10.9 13.1 15.4 17.7 20

enable the function. Figure 22 shows how the 4 to 20 mA signal is linearly calculated on an overall 10 F to 80 F range for fluid types (Configuration mode, sub-mode OPT1, item FLUD) 1 or 2.

EMM —

Energy Management Module

MODE

(RED LED)

CONFIGURATION

4 TO 20 mA SIGNAL TO EMM

Fig. 22 — Cooling Set Point (4 to 20 mA)

Table 27 — Menu Configuration of 4 to 20 mA Cooling Set Point Control

KEYPAD

ENTRY

ENTER

SUB-MODE

DISP

UNIT

OPT1

OPT2

RSET

SLCT CLSP 0 COOLING SETPOINT SELECT

KEYPAD

ENTRY

ENTER

ITEM DISPLAY

0 Scrolling Stops

0 Flashing ‘0’

4Select ‘4’

4 Change Accepted

ITEM

EXPANSION

COMMENT

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 that can be configured. The first type is through 2-stage switch control, which will reduce the maximum capacity to 2 user-configurable percentages. The second type is by 4 to 20 mA signal input which will reduce the maximum capacity linearly between 100% at a 4 mA input signal (no reduction) down to the user-configurable level at a 20 mA input signal. The third type uses the CNN Loadshed module and has the ability to limit the current operating capacity to maximum and further reduce the capacity if required.

NOTE: The 2-stage switch control and 4 to 20 mA input signal types of demand limiting require the Energy Management Module (EMM).

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 (2-Stage Switch Controlled) — To configure Demand Limit for 2-stage switch control set the Demand Limit Select (DMDC) to 1. Then configure the 2 Demand Limit Switch points (DLS1 and DLS2) to the desired capacity limit. See Table 28. Capacity steps are controlled by 2 relay switch inputs field wired to TB6 as shown in Fig. 2-4.

For Demand Limit by 2-stage 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 Limit Switch 1 set point. Closing contacts on the second demand limit switch prevents the unit from exceeding the capacity entered as Demand Limit Switch

Table 28 — Configuring Demand Limit

MODE

CONFIGURATION

NOTE: Heating reset values skipped in this example.

KEYPAD

ENTRY

ENTER ENTER

SUB-MODE

DISP TEST ON/OFF Test Display LEDs

UNIT TYPE X Unit Type

OPT1 FLUD X Cooler Fluid

OPT2 CTRL X Control Method

RSET CRST X Cooling Reset Type

KEYPAD

ENTRY

ENTER

ITEM DISPLAY ITEM EXPANSION COMMENT

CRT1 XXX.X °F No Cool Reset Temperature

CRT2 XXX.X °F Full Cool Reset Temperature

DGRC XX.X ∆F Degrees Cool Reset

DMDC X Demand Limit Select

DM20 XXX % Demand Limit at 20 mA

SHNM XXX

SHDL XXX%

SHTM XXX MIN

DLS1 XXX %

DLS2 XXX%

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 configure the DMDC to 0. See

Table 28 . EXTERNALLY POWERED DEMAND LIMIT (4 to

20 mA Controlled) — To configure Demand Limit for 4 to 20 mA control set the Demand Limit Select (DMDC) to 2. Then configure the Demand Limit at 20 mA (DM20) to the maximum loadshed value desired. The control will reduce allowable capacity to this level for the 20 mA signal. See Table 28 and Fig. 23.

DEMAND LIMIT (CCN Loadshed Controlled) — To configure Demand Limit for CCN Loadshed control set the Demand Limit Select (DMDC) to 3. Then configure the Loadshed Group Number (SHNM), Loadshed Demand Delta (SHDL), and Maximum Loadshed Time (SHTM). See Table 28.

The Loadshed Group number is established by the CCN system designer. The MBB 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 MBB will reduce the current stages by the value entered for Loadshed Demand delta. The Maximum Loadshed Time defines the maximum length of time that a loadshed condition is allowed to exist. The control will disable the Redline/ Loadshed command if no Cancel command has been received within the configured maximum loadshed time limit.

Default: 0 0 = None 1 = Switch 2 = 4 to 20 mA Input 3 = CCN Loadshed

Default: 100% Range: 0 to 100

Loadshed Group

Number

Loadshed Demand

Delta

Maximum Loadshed

Time

Demand Limit

Switch 1

Demand Limit

Switch 2

Default: 0 Range: 0 to 99

Default: 0% Range: 0 to 60%

Default: 60 min. Range: 0 to 120 min.

Default: 80% Range: 0 to 100%

Default: 50% Range: 0 to 100%

100

ABLE LOAD (%)

100% CAPACITY AT 4 mA

ALLOW

MAX.

75% CAPACITY AT 12 mA

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

Fig. 23 — 4 to 20 mA Demand Limiting

50% CAPACITY AT 20 mA

16 18

TROUBLESHOOTING

Compressor Protection Control System (CPCS) Board —

trols the compressor and compressor crankcase heater.

The ground current protection is provided by the compres-

sor board.

The large relay located on the board is used to provide a

feedback signal to the Main Base Board.

The operation of the compressor board can be checked using the Service Test procedure. When the Service Test step is turned on, the compressor board is energized. All safeties are continuously monitored. The crankcase heater will be turned off and the compressor contactor will be turned on. The feedback contacts will close and the Main Base Board (MBB) will read the feedback status.

If the board does not perform properly, use standard wiring troubleshooting procedures to check the wiring for open circuits. Refer to Alarms and Alerts section on page 48 for alarm or alert codes for possible causes for failure.

If a compressor short-to-ground exists, the compressor board may detect the short before the circuit breaker trips. If this is suspected, check the compressor for short-to-ground failures with an ohmmeter. The ground current is sensed with a current toroid (coil) around all 3 or 6 wires between the main terminal block and the compressor circuit breaker(s).

The compressor protection board con-

Compressor Ground Current (CGF) Board (30GTN,R and 30GUN,R 130-210, 230A-315A, and 330A/B-420A/B) —

cuit of these units. Each board receives input from up to 4 toroids wired in series, one toroid per compressor. With 24 v supplied at terminals A and B, a current imbalance (compressor ground current) sensed by any toroid causes the NC (normally closed) contacts to open, shutting down the lead compressor in the affected circuit. All other compressors in that circuit shut down as a result. The NC contacts remain open until the circuit is reset by momentarily deenergizing the board using the pushbutton switch.

If the NC contacts open, it is necessary to remove toroids from the T1-T2 circuit to determine which toroid is causing the trip. The chiller circuit can then be put back on line after the circuit breaker of the faulty compressor is opened. The compressor problem can then be diagnosed by normal troubleshooting procedures.

EXV Troubleshooting —

not properly controlling operating suction pressure or superheat, there are a number of checks that can be made using

One board is used for each cir-

If it appears that the EXV is

the quick test and initialization features built into the ComfortLink™ control.

Follow the procedure below to diagnose and correct EXV

problems. STEP 1 — CHECK PROCESSOR EXV OUTPUTS —

Check EXV output signals at the J6 and J7 terminals of the EXV board.

Turn unit power off. Connect the positive lead of the meter to terminal 3 on connector J6 on the EXV board. Set meter for approximately 20 vdc. Turn unit power on. Enter and enable the Service Test mode. Locate the appropriate EXV under ‘OUTS.’ Select the desired percentage and press Enter to move the valve. The valve will overdrive in both directions when either 0% or 100% are entered. During this time, connect the negative test lead to terminals 1, 2, 4, and 5 in succession. The voltage should fluctuate at each pin. If it remains constant at a voltage or at 0 v, replace the EXV board. If the outputs are correct, then check the EXV.

To test Circuit B outputs, follow the same procedure above, except connect the positive lead of the meter to terminal 3 on connector J7 on the EXV board and the negative lead to terminals 1, 2, 4, and 5 in succession.

STEP 2 — CHECK EXV WIRING — Check wiring to EXVs from J6 and J7 connectors on EXV board.

1. Check color coding and wire connections. Make sure that wires are connected to correct terminals at J6 and J7 connectors and EXV plug connections. Check for correct wiring at driver board input and output terminals. See Fig. 2-4.

2. Check for continuity and tight connection at all pin terminals.

3. Check plug connections at J6 and J7 connectors and at EXVs. Be sure EXV connections are not crossed.

STEP 3 — CHECK RESISTANCE OF EXV MOTOR WINDINGS — Remove connector at J6 and/or J7 of EXV board and check resistance between common lead (red wire, terminal D) and remaining leads A, B, C, and E. Resistance should be 25 ohms ± 2 ohms. Check all leads to ground for shorts.

STEP 4 — CHECK THERMISTORS THAT CONTROL EXV — Check thermistors that control processor output voltage pulses to the EXVs. Circuit A thermistor is T7, and circuit B thermistor is T8. Refer to Fig. 9 and 10 for location.

1. Refer to Thermistors section on page 59 for details on checking thermistor calibration.

2. Make sure that thermistor leads are connected to the proper pin terminals at the J5 connector on EXV board and that thermistor probes are located in proper position in the refrigerant circuit.

When these checks have been completed, the actual operation of the EXV can be checked by using the procedures outlined in Step 5 — Check Operation of the EXV section below.

STEP 5 — CHECK OPERATION OF THE EXV — Use the following procedure to check the actual operation of the EXVs. The ENABLE/OFF/REMOTE contact switch must be in the OFF position.

1. Close the liquid line service valve for the circuit to be checked and run through the appropriate service test to pump down the low side of the system. Run lead compressor for at least 30 seconds to ensure all refrigerant has been pumped from the low side and that the EXV has been driven fully open (1500 steps).

NOTE: Do not use the Emergency ON-OFF switch to recycle the control during this step.

2. Turn off the compressor circuit breaker(s) and the control circuit power and then turn the Emergency ON/OFF switch to the OFF position. Close compressor service valves and remove any remaining refrigerant from the low side of the system.

3. Carefully loosen the 2-

/8 in. nut. Do not twist the valve. Remove the motor canister from the valve body using caution to avoid damage to the o-ring seal. If the EXV plug was disconnected during this process reconnect it after the motor canister is removed.

4. Note position of lead screw (see Fig. 15). If valve has responded properly to processor signals in Step 5.1 above, the lead screw should be fully retracted.

5. Recycle the control by turning the Emergency ON-OFF switch to the ON position. This puts the control in initialization mode. During the first 60 seconds of the initialization mode, each valve is driven to the fully closed position (1500 steps) by the processor. Observe the movement of the lead screw. It should be smooth and uniform from the fully retracted (open) to the fully extended (closed) position.

6. When the test has been completed, carefully reassemble expansion valve. Apply a small amount of O-ring grease to the housing seal O-ring before installing the motor canister. Be careful not to damage the O-ring. Tighten the motor nut to 15 to 25 lb-ft (20 to 34 N-m). Evacuate the low side of the open refrigerant circuit. Open compressor service valves and close compressor circuit breakers.

Open liquid line service valve. Check for any refrigerant leaks. Turn the ENABLE/OFF/REMOTE switch back to ENABLE or REMOTE and allow the unit to operate. Verify proper unit operation.

NOTE: The EXV orifice is a screw-in type and may be removed for inspection and cleaning. Once the motor canister is removed the orifice can be removed by using the orifice removal tool (part no. TS429). A slot has been cut in the top of the orifice to facilitate removal. Turn orifice counterclockwise to remove. A large screwdriver may also be used.

When cleaning or reinstalling orifice assembly be careful not to damage orifice assembly seals. The bottom seal acts as a liquid shut-off, replacing a liquid line solenoid valve. If the bottom seal should become damaged it can be replaced. Remove the orifice. Remove the old seal. Using the orifice as a guide, add a small amount of O-ring grease, to the underside of the orifice. Be careful not to plug the vent holes. Carefully set the seal with the O-ring into the orifice. The O-ring grease will hold the seal in place. If the O-ring grease is not used, the seal O-ring will twist and bind when the orifice is screwed into the EXV base. Install the orifice and seal assembly. Remove the orifice to verify that the seal is properly positioned. Clean any O-ring grease from the bottom of the orifice. Reinstall the orifice and tighten to 100 in.-lb (11 N-m). Apply a small amount of O-ring grease to the housing seal O-ring before installing the motor canister. Reinstall the motor canister assembly. Tighten the motor nut to 15 to 25 ft-lb (20 to 34 N-m).

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 29.

Automatic alarms will reset without operator intervention if the condition corrects itself. The following method must be used to reset manual alarms:

Before resetting any alarm, first determine the cause of the alarm and correct it. Enter the Alarms mode indicated by the LED on the side of the Scrolling Marquee Display. Press

ENTER

ALL CURRENT ALARMS” is displayed. Press .

and until the sub-menu item RCRN “RESET

ENTER The control will prompt the user for a password, by displaying PASS and WORD. Press to display the default password, 1111. Press for each character. If the password

ENTER

ENTER has been changed, use the arrow keys to change each individual character. Toggle the display to “YES” and press .

ENTER

The alarms will be reset.

Table 29 — Alarm and Alert Codes

ALARM/

ALERT

CODE

T051 Alert Circuit A, Compressor 1

T052 Alert Circuit A, Compressor 2

T053 Alert Circuit A, Compressor 3

T054 Alert Circuit A, Compressor 4

T055 Alert Circuit B, Compressor 1

T056 Alert Circuit B, Compressor 2

T057 Alert Circuit B, Compressor 3

A060 Alarm Cooler Leaving Fluid

A061 Alarm Cooler Entering Fluid

T064 Alert Circuit A Saturated Con-

T065 Alert Circuit B Saturated Con-

T066 Alert Circuit A Saturated Suction

T067 Alert Circuit B Saturated Suction

T068 Alert Compressor A1 Suction

T069 Alert Compressor B1 Suction

T073 Alert Outside Air Thermistor

T074 Alert Space Temperature

T077 Alert Circuit A Saturated

T078 Alert Circuit B Saturated

T079 Alert Lead/Lag Thermistor Failure Thermistor outside range of

ALARM

ALERT

DESCRIPTION

Failure

Thermistor Failure (T1)

Thermistor Failure (T2)

densing Thermistor Failure (T3)

densing Thermistor Failure (T4)

Thermistor Failure (T5)

Thermistor Failure (T6)

Gas Thermistor Failure (T7)

Gas Thermistor Failure (T8)

Failure (T9)

Thermistor Failure (T10)

Suction Temperature exceeds Cooler Leaving Fluid Temperature

WHY WAS THIS

ALARM

GENERATED?

Compressor feedback signal does not match relay state

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

Saturated suction is greater than leaving fluid temperature for more than 5 minutes

–40 to 245 F (–40 to 118 C)

ACTION TAKEN

BY CONTROL

Circuit A shut down. Manual High-pressure or loss-of-

Circuit A shut down. Circuit restarted in 1 minute. Compressor A2 not used until alarm is reset.

Circuit A shut down. Circuit restarted in 1 minute. Compressor A3 not used until alarm is reset.

Circuit A shut down. Circuit restarted in 1 minute. Compressor A4 not used until alarm is reset.

Circuit B shut down. Manual High-pressure or loss-of-

Circuit B shut down. Circuit restarted in 1 minute. Compressor B2 not used until alarm is reset.

Circuit B shut down. Circuit restarted in 1 minute. Compressor B3 not used until alarm is reset.

Chiller shutdown after pumpdown complete.

Circuit A shutdown after pumpdown complete.

Circuit B shutdown after pumpdown complete.

Circuit A shutdown after pumpdown complete. (EXV only)

Circuit B shutdown after pumpdown complete. (EXV only).

Circuit A shutdown after pumpdown complete. (EXV only).

Circuit B shutdown after pumpdown complete. (EXV only).

Temperature reset disabled. Chiller runs under normal control/set points.

Circuit A shutdown after pumpdown complete.

Circuit B shutdown after pumpdown complete

Lead/lag algorithm runs using Master LWT sensor Master is lead chiller.

RESET

METHOD

Manual High-pressure switch open,

Automatic Thermistor failure, damaged

Automatic Faulty expansion valve or

Automatic Dual chiller LWT thermistor

PROBABLE

CAUSE

charge switch open, faulty control relay or CPCS board, loss of condenser air, liquid valve closed, operation beyond capability.

faulty control relay or CPCS board, loss of condenser air, liquid valve closed, operation beyond capability.

charge switch open, faulty control relay or CPCS board, loss of condenser air, liquid valve closed, operation beyond capability.

faulty control relay or CPCS board, loss of condenser air, liquid valve closed, operation beyond capability.

cable/wire or wiring error.

EXV board, faulty cooler suction thermistor (T5) or leaving fluid thermistor (T1).

EXV board, faulty cooler suction thermistor (T6) or leaving fluid thermistor (T1).

failure, damaged cable/wire or wiring error.

ALARM/

ALERT

CODE

T112

T113

T114

T115

T116

T117

T118

T119

CCN — CPCS — CXB — EMM — EWT — EXV — FSM — LCW — LWT — MBB — MOP — WSM —

Table 29 — Alarm and Alert Codes (cont)

ALARM

ALERT

Alert Circuit A High Suction

Alert Circuit B High Suction

Alert Circuit A Low Suction

Alert Circuit B Low Suction

Alert Circuit A Low Cooler

Alert Circuit B Low Cooler

Alert Circuit A Low Oil

Alert Circuit B Low Oil

Carrier Comfort Network Compressor Protection Control System Compressor Expansion Board Energy Management Module Entering Fluid Temperature Electronic Expansion Valve Flotronic™ System Manager Leaving Chilled Water Leaving Fluid Temperature Main Base Board Maximum Operating Pressure Water System Manager

DESCRIPTION

Superheat

Suction Temperature

Pressure

LEGEND *Freeze is defined as 34° F (1.1 C) for water. For brine fluids, freeze

WHY WAS THIS

ALARM

GENERATED?

If EXV is greater than 98%, suction superheat is greater than 75 F (41.7 C) and saturated suction temperature is less than MOP for 5 minutes

If EXV is greater than 98% suction superheat is greater than 75 F (41.7 C) and saturated suction temperature is less than MOP for 5 minutes

If EXV is greater than 10%, and either suction superheat is less than superheat set point –10 F (5.6 C) or saturated suction temperature is greater than MOP for 5 minutes

1. If the saturated suction temperature is 24 to 29° F (13.3 to 16.1° C) below cooler LWT and is also 2° F (1.1° C) less than freeze*

2. If the saturated suction temperature is 30° F (16.7° C) below cooler LWT and is also 2° F (1.1° C) less than freeze* for 10 minutes

1. If the saturated suction temperature is 24 to 29°F (13.3 to 16.1° C) below cooler LWT and is also 2°F (1.1° C) less than freeze*

2. If the saturated suction temperature is 30° F (16.7° C) below cooler LWT and is also 2° F (1.1° C) less than freeze* for 10 minutes

Oil pressure switch open after 1 minute of continuous operation

ACTION TAKEN

BY CONTROL

Circuit A shutdown after pumpdown complete.

Circuit B shutdown after pumpdown complete.

Circuit A shutdown after pumpdown complete.

Circuit B shutdown after pumpdown complete.

1. Mode 7 initiated. No additional capacity increases. Alert not tripped.

2. Circuit shutdown without going through pumpdown.

1. Mode 8 initiated. No additional capacity increases. Alert not tripped.

2. Circuit shutdown without going through pumpdown.

Circuit shutdown without going through pumpdown.

is CSP.1 –8° F (4.4 C) for single set point and lower of CSP.1 or CSP.2 –8° F (4.4 C) for dual set point configuration.

RESET

METHOD

Manual Faulty expansion

Automatic restart after first daily occurrence. Manual restart thereafter.

1. Automatic reset if corrected.

2. Manual

1. Automatic reset if corrected.

2. Manual

Manual Oil pump failure, low

PROBABLE

valve or EXV board, low refrigerant charge, plugged filter drier, faulty suction gas thermistor (T7) or cooler thermistor (T5).

valve or EXV board, low refrigerant charge, plugged filter drier, faulty suction gas thermistor (T8) or cooler thermistor (T6).

Faulty expansion valve or EXV board, faulty suction gas thermistor (T7) or cooler thermistor (T5).

Faulty expansion valve or EXV board, faulty suction gas thermistor (T8) or cooler thermistor (T6).

Faulty expansion valve or EXV board, low refrigerant charge, plugged filter drier, faulty suction gas thermistor (T7) or cooler thermistor (T5), low cooler fluid flow.

Faulty expansion valve or EXV board, low refrigerant charge, plugged filter drier, faulty suction gas thermistor (T8) or cooler thermistor (T6), low cooler fluid flow.

oil level, switch failure or compressor circuit breaker tripped.

CAUSE

ALARM/

ALERT

CODE

A150

A151

A152

T153

A154

T155

A156

A157

T170

A172

T173

T174

T176

T177

A200

A201

A202

Table 29 — Alarm and Alert Codes (cont)

ALARM

ALERT

Alarm Emergency Stop CCN emergency stop

Alarm Illegal Configuration One or more of the ille-

Alarm Unit Down Due to

Alert Real Time Clock

Alarm Serial EEPROM

Alert Serial EEPROM

Alarm Critical Serial

Alarm A/D Hardware

Alert Loss of Communica-

Alarm Loss of Communica-

Alert Loss of Communica-

Alert 4 to 20 mA Cooling

Alert 4 to 20 mA Tempera-

Alert 4 to 20 mA Demand

Alarm Cooler Pump Inter-

DESCRIPTION

Failure

Hardware Failure

Storage Failure

EEPROM Storage Failure

Failure

tion with CXB

tion with EXV

tion with EMM

Set Point Input Failure

ture Reset Input Failure

Limit Input Failure

lock Failure to Close at Start-Up

lock Opened During Normal Operation

lock Closed When Pump is Off

WHY WAS THIS

ALARM

GENERATED?

command received

gal configurations exists.

Both circuits are down due to alarms/alerts.

Internal clock on MBB fails

Hardware failure with MBB

Configuration/storage failure with MBB

Hardware failure with peripheral device

MBB loses communication with CXB

MBB loses communication with EXV

MBB loses communication with EMM

If configured with EMM and input less than 2 mA or greater than 22 mA

Interlock not closed within 5 minutes after unit is started

Interlock opens during operation

If configured for cooler pump control and interlock closes while cooler pump relay is off

ACTION TAKEN

BY CONTROL

Chiller shutdown without going through pumpdown.

Chiller is not allowed to start.

Chiller is unable to run.

Occupancy schedule will not be used. Chiller defaults to Local On mode.

Chiller is unable to run.

No Action Manual Potential failure of

Chiller is not allowed to run.

Compressors A3, A4 and B3 and unloaders A2/B2 unable to operate.

Chiller shutdown without going through pumpdown.

4 to 20 mA temperature reset disabled. Demand Limit set to 100%. 4 to 20 mA set point disabled.

Set point function disabled. Chiller controls to CSP.1.

Reset function disabled. Chiller returns to normal set point control.

Demand limit function disabled. Chiller returns to 100% demand limit control.

Cooler pump shut off. Chiller shutdown without going through pumpdown.

Chiller is not allowed to start.

RESET

METHOD

Automatic once CCN command for EMSTOP returns to normal

Manual once configuration errors are corrected

Automatic once alarms/alerts are cleared that prevent the chiller from starting.

Automatic when correct clock control restarts.

Manual Main Base Board

Automatic Wiring error, faulty

Automatic Faulty signal gen-

Manual Failure of cooler

PROBABLE

CAUSE

CCN Network command.

Configuration error. See Note on page 52.

Alarm notifies user that chiller is100% down.

Time/Date/Month/ Day/Year not properly set.

failure.

MBB. Download current operating software. Replace MBB if error occurs again.

failure.

wiring or failed CXB module.

wiring or failed EXV module.

wiring or failed Energy Management Module (EMM).

erator, wiring error, or faulty EMM.

pump, flow switch, or interlock.

pump relay or interlock, welded contacts.

Table 29 — Alarm and Alert Codes (cont)

ALARM/

ALERT

CODE

T203

T204

T205

T206

A207

A208

T950

T951

CCN — CPCS — CXB — EMM — EXV — FSM — LCW — LWT — MBB — MOP — WSM —

*Freeze is defined as 34° F (1.1 C) for water. For brine fluids, freeze

is CSP.1 –8° F (4.4 C) for single set point and lower of CSP.1 or CSP.2 –8° F (4.4 C) for dual set point configuration.

ALARM

ALERT

Alert Loss of Communica-

Alert Master and Slave

Alert High Leaving Chilled

Alarm Cooler Freeze

Alarm Low Cooler Fluid Flow Cooler EWT is less

Alert Loss of Communica-

LEGEND

Carrier Comfort Network Compressor Protection Control System Compressor Expansion Board Energy Management Module Electronic Expansion Valve Flotronic™ System Manager Leaving Chilled Water Leaving Fluid Temperature Main Base Board Maximum Operating Pressure Water System Manager

DESCRIPTION

tion with Slave Chiller

tion with Master Chiller

Chiller with Same Address

Water Temperature

Protection

tion with WSM

tion with FSM

WHY WAS THIS

GENERATED?

Master MBB loses communication with Slave MBB

Slave MBB loses communication with Master MBB

Master and slave chiller have the same CCN address (CCN.A)

LWT read is greater than LCW Alert Limit, plus control point and Total capacity is 100% and LWT is greater than LWT reading one minute ago

Cooler EWT or LWT is less than freeze*

than LWT by 3° F (1.7° C) for 1 minute after a circuit is started

No communications have been received by MBB within 5 minutes of last transmission

ALARM

ACTION TAKEN

BY CONTROL

Dual chiller control disabled. Chiller runs as a stand-alone machine.

Dual chiller control disabled. Chiller runs as a stand-alone machine

Dual chiller routine disabled. Master/slave run as stand-alone chillers.

Alert only. No action taken.

Chiller shutdown without going through pumpdown. Cooler pump continues to run (if control enabled).

Chiller shutdown without going through pumpdown. Cooler pump shut off (if control enabled).

WSM forces removed. Chiller runs under own control.

FSM forces removed. Chiller runs under own control.

NOTE: The following table shows illegal configurations:

Unit type = 0.

4 Compressors in a circuit with 2 unloaders.

4 Compressors in a circuit with 1 unloader and hot gas

bypass. 2 Unloaders and hot gas bypass in a circuit.

More than one compressor difference between circuits (e.g., 4

compressors in Ckt A, 2 in Ckt B). Water cooled units with optional thermistors and configured

for head pressure control. Split system chillers with optional thermistors and configured

for head pressure control. Low temperature brine selected for air cooled chillers or split

systems with air cooled head pressure control. Water cooled unit configured for air cooled head pressure

control. Air cooled head pressure control with common fan staging

and different head pressure control methods for each circuit

(EXV controlled vs. set point controlled). Lead/lag enabled, Master selected and Cooling Set Point

select is LWT POT. Water cooled or split units (units types 2, 3, 4) with more than

one compressor on a circuit. Condenser pump interlock enabled on air cooled unit.

Unit type changed.

Low pressure set points out of range.

Cooler fluid type is water and ice mode is enabled.

RES

METHOD

Automatic Wiring error, faulty wir-

Automatic CCN Address for both-

Automatic Building load greater

Automatic for first occurrence of day. Manual reset thereafter.

Manual Faulty cooler pump,

Automatic Failed module, wiring

PROBABLE

CAUSE

ing, failed Slave MBB module, power loss at Slave chiller, wrong slave address.

ing, failed Master MBB module, power loss at Master chiller.

chillers is the same. Must be different. Check CCN.A under the OPT2 sub-mode in configuration at both chillers.

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

Faulty thermistor (T1/ T2), low water flow.

low water flow, plugged fluid strainer.

error, failed transformer, loose connection plug, wrong address.

SERVICE

ELECTRIC SHOCK HAZARD. Turn off all power to unit before servicing.

The ENABLE/OFF/REMOTE CONTACT switch on control panel does not shut off control power; use field disconnect.

Electronic Components

CONTROL COMPONENTS — Unit uses an advanced electronic control system that normally does not require service. For details on controls refer to Operating Data section.

30GTN,R AND 30GUN,R 040-110, AND 230B-315B UNIT CONTROL BOX — When facing compressors, main control box is at left end of unit. All incoming power enters through main box. Control box contains power components and electronic controls.

Outer panels are hinged and latched for easy opening. Remove screws to remove inner panels. Outer panels can be held open for service and inspection by using door retainer on each panel. To use door retainers: remove bottom pin from door retainer assembly, swing retainer out horizontally, and engage pin in one of the retainer ears and the hinge assembly.

30GTN,R AND 30GUN,R 130-210, 230A-315A, AND 330A/B-420A/B UNIT CONTROL AND MAIN POWER BOXES — The main power box is on the cooler side of the unit, and the control box is on the compressor side. Outer panels are hinged and latched for easy opening. Remove screws to remove inner panels.

Compressors —

circuit becomes inoperative for any reason, circuit is locked off and cannot be operated due to features built into the electronic control system. Do not attempt to bypass controls to force com- pressors to run.

COMPRESSOR REMOVAL — Access to the oil pump end of the compressor is from the compressor side of the unit. Access to the motor end of the compressor is from the inside of the unit. All compressors can be removed from the compressor side of the unit.

IMPORTANT: All compressor mounting hardware and

support brackets removed during servicing must be rein-

stalled prior to start-up.

Following the installation of the new compressor:

Tighten discharge valves to —

20 to 25 ft-lb (27 to 34 N-m) 06E250 80 to 90 ft-lb (109 to 122 N-m) 06E265,275,299

Tighten suction valves to —

80 to 90 ft-lb (109 to 122 N-m) 06E250 90 to 120 ft-lb (122 to 163 N-m) 06E265,275,299

Tighten the following fittings to —

120 in.-lb (13.5 N-m) High-Pressure Switch

OIL CHARGE (Refer to Table 30) — All units are factory charged with oil. Acceptable oil level for each compressor is from 1/8 to 3/8-in. of sight glass (see Fig. 35).

When additional oil or a complete charge is required, use only Carrier-approved compressor oil.

30GTN,R approved oils are as follows: Petroleum Specialties, Inc. — Cryol 150 (factory oil charge) Texaco, Inc. — Capella WF-32 Witco Chemical Co. — Suniso 3GS

If lead compressor on either refrigerant

Compressor(s)

30GUN,R approved polyolester (POE) oils are as follows:

• Mobil Artic EAL 68

• Castrol SW68

• ICI Emkarate RL68H

• Lubrizol 29168 (Texaco HFC Capella 68NA)

• CPI Solest 68

Table 30 — Oil Charge

COMPRESSOR

06E250 06E265 06E275 06E299

OIL REQUIRED

Pts L

14 6.6 19 9.0 19 9.0 19 9.0

Do not reuse drained oil or any oil that has been exposed to

atmosphere.

Cooler —

The cooler is easily accessible from the cooler side of the unit. The refrigerant feed components are accessible from the control box end of the unit.

COOLER REMOVAL — Cooler can be removed from the cooler side of the unit as follows:

Open and tag all electrical disconnects before any work begins. Note that cooler is heavy and both fluid-side and refrigerant-side may be under pressure.

1. To ensure the refrigerant is in the condenser, follow this procedure:

a. Open the circuit breakers and close the discharge

valves for the lag compressors in both circuits.

Do not close the discharge valve of an operating compressor. Severe damage to the compressor can result.

b. After the lag compressor discharge service valves

have been closed, close the liquid line service valve for one circuit. Allow the lead compressor to pump down that circuit until it reaches approximately 10 to 15 psig (68.8 to 103.2 kPa).

c. As soon as the system reaches that pressure, shut

down the lead compressor by opening the compressor circuit breaker, then quickly close the discharge service valve for that compressor.

d. Repeat the procedure for the other circuit.

2. Close the shutoff valves, if installed, in the cooler fluid lines. Remove the cooler fluid piping.

3. Cooler may be under pressure. Open the air vent at the top of the cooler, and open the drain on the bottom of the cooler (near the leaving fluid outlet) to drain the cooler. Both the drain and the air vent are located on the leaving fluid end of cooler. See Fig. 24. Remove the cooler waterside strainer.

4. Disconnect the conduit and cooler heater wires, if equipped. Remove all thermistors from the cooler, being sure to label all thermistors as they are removed. Thermistor T1 is a well-type thermistor, and thermistor T2 is immersed directly in the fluid. See Fig. 24.

5. Remove the insulation on the refrigerant connection end of the cooler.

6. Unbolt the suction flanges from the cooler head. Save the bolts.

7. Remove the liquid lines by breaking the silver-soldered joints at the cooler liquid line nozzles.

8. On 30GTN,GTR and 30GUN,R 080-110 and 230B-315B units, remove the vertical support(s) under the condenser coil in front of the cooler. Provide temporary support as needed. Save all screws for reinstallation later.

9. Remove the screws in the cooler feet. Slide the cooler slightly to the left to clear the refrigerant tubing. Save all screws.

Removing the cooler can be accomplished in one of 2 ways, depending on the jobsite. Either continue sliding the cooler toward the end of the unit opposite the tubing and carefully remove, or pivot the cooler and remove it from the cooler side of the unit.

REPLACING COOLER — To replace the cooler:

1. Insert new cooler carefully into place. Reattach the screws into the cooler feet (using saved screws).

On 30GTN,GTR and 30GUN,GUR080-110 and 230B315B units, reattach the 2 vertical supports under the condenser coil in front of the cooler using screws saved.

2. Replace the liquid lines and solder at the cooler liquid line nozzles.

3. Rebolt the suction flanges onto the cooler head using bolts saved during removal. Use new gaskets for the suction line flanges. Use compressor oil to aid in gasket sealing and tighten the suction flange bolts to 70 to 90 ft-lb (94 to 122 N-m).

NOTE: The suction flange has a 4-bolt pattern. See Carrier specified parts for replacement part number, if necessary.

4. Using adhesive, reinstall the cooler insulation on the refrigerant connection end of the cooler.

5. Reinstall the thermistors. Refer to Thermistors section on page 59, and install as follows:

a. Apply pipe sealant to the 1/4-in. NPT threads on

the replacement coupling for the fluid side, and install it in place of the original.

Do not use the packing nut to tighten the coupling. Damage to the ferrules will result.

b. Reinstall thermistor T1 well, and insert thermistor

T1 into well.

c. Install thermistor T2 (entering fluid temperature)

so that it is not touching an internal refrigerant tube, but so that it is close enough to sense a freeze condition. The recommended distance is 1/8 in. (3.2 mm) from the cooler tube. Tighten the packing nut finger tight, and then tighten 11/4 turns more using a back-up wrench.

6. Install the cooler heater and conduit (if equipped), connecting the wires as shown in the unit wiring schematic located on the unit.

7. Close the air vent at the top of the cooler, and close the drain on the bottom of the cooler near the leaving fluid outlet. Both the drain and the air vent are located on the leaving fluid end of the cooler. See Fig. 24.

8. Reconnect the cooler fluid piping and strainer, and open the shutoff valves (if installed). Purge the fluid of all air before starting unit.

9. Open the discharge service valves, close the circuit breakers, and open the liquid line service valves for the compressors.

SERVICING THE COOLER — When cooler heads and partition plates are removed, tube sheets are exposed showing ends of tubes.

Certain tubes in the 10HB coolers cannot be removed. Eight tubes in the bundle are secured inside the cooler to the baffles and cannot be removed. These tubes are marked by a dimple on the tube sheet. See Fig. 25. If any of these

tubes have developed a leak, plug the tube(s) as described under Tube Plugging section on page 55.

Fig. 24 — Cooler Thermistor Locations

LIQUID CONNECTION

SIZES 040-050

SIZES 060,070

SIZES 130,150*

SIZES 170,190*

SIZES 080,090*

*And associated modular units (see Tables 1A and 1B).

SIZES 100,110*

Fig. 25 — Typical Tube Sheets, Cover Off (Non-Removable Tubes)

Tube Plugging

— A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon cooler must be retubed. Tubes plugged in the following locations will affect the performance of the unit: Any tube in the area, particularly the tube that thermistor T2 is adjacent to, will affect unit reliability and performance. Thermistor T2 is used in the freeze protection algorithm for the controller. If several tubes require plugging, check with your local Carrier representative to find out how number and location can affect unit capacity.

Figure 26 shows an Elliott tube plug and a cross-sectional

view of a plug in place.

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

Retubing (See Table 31)

— When retubing is to be done, obtain service of qualified personnel experienced in boiler maintenance and repair. Most standard procedures can be followed when retubing the 10HB coolers. An 8% crush is recommended when rolling replacement tubes into the tubesheet. An 8% 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 Elliott 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.

Fig. 26 — Elliott Tube Plug

SIZE 210*

Table 31 — Plugs

COMPONENTS FOR

For Tubes

For Holes without Tubes

Loctite Locquic

*Order directly from: Elliott Tube Company, Dayton, Ohio. †Can be obtained locally.

PLUGGING

Brass Pin Brass Ring

PART NUMBER

853103-500*

853002-570*

853103-1*

853002-631*

No. 675†

“N”†

Tube information follows:

in. mm

• Tube sheet hole diameter . . . . . . . . . . 0.631 16.03

• Tube OD . . . . . . . . . . . . . . . . . . . . . . 0.625 15.87

• Tube ID after rolling. . . . . . . . . . . . . . . 0.581 14.76

(includes expansion due to to to clearance) 0.588 14.94

NOTE: Tubes next to gasket webs must be flush with tube sheet (both ends).

Tightening Cooler Head Bolts Gasket Preparation — When reassembling cooler heads,

always use new gaskets. Gaskets are neoprene-based and are brushed with a light film of compressor oil. Do not soak gasket or gasket deterioration will result. Use new gaskets within 30 minutes to prevent deterioration. Reassemble cooler nozzle end or plain end cover of the cooler with the gaskets. Torque all cooler bolts to the following specification and sequence:

/8-in. Diameter Perimeter Bolts . . . . . . . . . . . . 150 to 170 ft-lb

(201 to 228 N-m)

/2-in. Diameter Flange Bolts . . . . . . . . . . . . . . . . 70 to 90 ft-lb

(94 to 121 N-m)

1. Install all bolts finger tight.

2. Bolt tightening sequence is outlined in Fig. 27. Follow the numbering or lettering sequence so that pressure is evenly applied to gasket.

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

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

5. After refrigerant is restored to system, check for refrigerant leaks with soap solution or Halide device.

6. Replace cooler insulation.

Condenser Coils

COIL CLEANING — For standard aluminum, copper and pre-coated aluminum fin coils, clean the coils with a vacuum cleaner, fresh water, compressed air, 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.

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

CLEANING E-COATED COILS — Follow the outlined procedure below for proper care, cleaning and maintenance of E-coated aluminum or copper fin coils:

Coil Maintenance and Cleaning Recommendations tine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit.

Remove Surface Loaded Fibers

— Surface loaded fibers or

dirt should be removed with a vacuum cleaner. If a vacuum

— Rou-

cleaner is not available, a soft brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

Periodic Clean Water Rinse

— A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended.

Routine Cleaning of Coil Surfaces

— Monthly cleaning with Enviro-Shield™ Coil cleaner is essential to extend the life of coils. It is recommended that all coils, including standard aluminum, pre-coated, copper/copper or E-coated coils are cleaned with the Enviro-Shield Coil Cleaner as described below. Coil cleaning should be part of the units regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.

Enviro-Shield Coil Cleaner is non-flammable, hypoallergenic, non-bacterial, USDA accepted biodegradable and 100% ecologically safe agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

SIZES 080,090* WITH 14-BOLT HEADS

SIZES 130,150*

*And associated modular units.

Fig. 27 — Cooler Head Bolt Tightening Sequence (Typical Tube Sheet)

SIZES 100,110* WITH 22-BOLT HEADS

SIZES 170,190*

SIZES 080,090* WITH 18-BOLT HEADS

SIZES 100,110* WITH 16-BOLT HEADS

SIZE 210*

Enviro-Shield™

PLASTIC FAN PROPELLER

CLEARANCE OF 0.25 INCHES (6.4 MM)

FAN DECK SURFACE

FAN ORIFICE

NOTE: Fan rotation is clockwise as viewed from top of unit.

Fig. 28A — Condenser Fan Adjustment —

Standard 50 and 60 Hz Units and

60 Hz Low Noise Fan Option Units

DIMENSION

FAN TYPE

Standard

Low Noise 60 Hz Only

(Optional)

0.50” (13 mm) 1.50” (38 mm)

0.88” (22 mm) 1.13” (29 mm)

Fig. 28B — Condenser Fan Adjustment —

50 Hz Low Noise Fan Option Units

NOTE: Dimensions are in millimeters. Dimensions in [ ] are in inches.

Fig. 29 — Condenser Fan Adjustment,

Units with High-Static Fan Operation

Coil Cleaner Application Equipment

• 21/2 Gallon Garden Sprayer

• Water Rinse with Low Velocity Spray Nozzle

Enviro-Shield

Coil Cleaner Application Instructions

• Although Enviro-Shield Coil cleaner is harmless to humans, animals, and marine life, proper eye protection such as safety glasses is recommended during mixing and application.

• Remove all surface loaded fibers and dirt with a vacuum cleaner as described above.

• Thoroughly wet finned surfaces with clean water and a low velocity garden hose being careful not to bend fins.

• Mix Enviro-Shield Coil Cleaner in a 21/2 gallon garden sprayer according to the instructions included with the Enzyme Cleaner. The optimum solution temperature is 100 F.

NOTE: DO NOT USE

water in excess of 130 F as the enzy-

matic activity will be destroyed.

• Thoroughly apply Enviro-Shield Coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers.

• Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage.

• Ensure cleaner thoroughly penetrates deep into finned areas.

• Interior and exterior finned areas must be thoroughly cleaned.

• Finned surfaces should remain wet with cleaning solution for 10 minutes.

• Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved.

• Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.

Harsh Chemical and Acid Cleaners — Harsh chemical, household bleach or acid cleaners should not be used clean outdoor or indoors coils of any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the Enviro-Shield Coil Cleaner as described above.

High Velocity Water or Compressed Air

— High velocity water from a pressure washer, garden hose or compressed air should never be used

to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdown may occur.

IMPORTANT: Check for proper fan rotation (clockwise viewed from above). If necessary, switch any 2 power leads to reverse fan rotation.

Condenser Fans —

wire mount bolted to fan deck and covered with a wire guard.

Each fan is supported by a formed

The exposed end of fan motor shaft is protected from weather by grease. If fan motor must be removed for service or replacement, be sure to regrease fan shaft and reinstall fan guard. For proper performance, fan should be positioned as in Fig. 28A and 28B (standard and low-noise applications). Tighten setscrews to 15 ± 1 ft-lb (20 ± 1.3 N-m).

If the unit is equipped with the high-static fan option, the fan must be set from the top of the fan deck to the plastic ring or center of the fan to a distance of 2.13 in. ± 0.12 in. (54 ± 3 mm). This is different from standard fans, since there is no area available to measure from the top of the orifice ring to the fan hub itself. See Fig. 29.

Refrigerant Feed Components —

Fig. 30 — Electronic Expansion Valve (EXV)

ELECTRONIC EXPANSION VALVES (EXVs)

Fig. 31 — Printed Circuit Board Connector

Each circuit has

all necessary refrigerant controls. ELECTRONIC EXPANSION VALVE (EXV) — A cut-

away view of valve is shown in Fig. 30.

High-pressure liquid refrigerant enters valve through bottom. A series of calibrated slots have been machined in side of orifice assembly. As refrigerant passes through orifice, pressure drops and refrigerant changes to a 2-phase condition (liquid and vapor). To control refrigerant flow for different operating conditions, a sleeve moves up and down over orifice and modulates orifice size. A sleeve is moved by a linear stepper motor. Stepper motor moves in increments and is controlled directly by EXV module. As stepper motor rotates, motion is transferred into linear movement by lead screw. Through stepper motor and lead screw, 1500 discrete steps of motion are obtained. The large number of steps and long stroke results in very accurate control of refrigerant flow. The minimum position for operation is 120 steps.

The EXV module controls the valve. The lead compressor in each circuit has a thermistor located in the suction manifold after the compressor motor and a thermistor located in a well where the refrigerant enters the cooler. The thermistors measure the temperature of the superheated gas entering the compressor cylinders and the temperature of the refrigerant entering the cooler. The difference between the temperature of the superheated gas and the cooler suction temperature is the superheat. The EXV module controls the position of the electronic expansion valve stepper motor to maintain superheat set point.

The superheat leaving cooler is approximately 3° to 5° F (2° to 3° C), or less.

Because EXV status is communicated to the Main Base Board (MBB) and is controlled by the EXV modules (see Fig. 31), it is possible to track the valve position. By this means, head pressure is controlled and unit is protected against loss of charge and a faulty valve. During initial start-up, EXV is fully closed. After initialization period, valve position is tracked by the EXV module by constantly monitoring amount of valve movement.

The EXV is also used to limit cooler saturated suction temperature to 50 F (10 C). This makes it possible for the chiller to start at higher cooler fluid temperatures without overloading the compressor. This is commonly referred to as MOP (maximum operating pressure).

If it appears that EXV is not properly controlling circuit operation to maintain correct superheat, there are a number of checks that can be made using test functions and initialization features built into the microprocessor control. See Service Test section on page 29 to test EXVs.

of O-ring grease to the housing seal O-ring before installing the motor canister. Reinstall the motor canister assembly. Tighten the motor nut to 15 to 25 ft-lb (20 to 34 N-m).

Check EXV operation using test functions described in the

Service Test section on page 29. MOISTURE-LIQUID INDICATOR — Clear flow of liquid

refrigerant indicates sufficient charge in system. Bubbles in the sight glass indicate undercharged system or presence of noncondensables. Moisture in system measured in parts per million (ppm), changes color of indicator:

Green — moisture is below 45 ppm; Yellow-green (chartreuse) — 45 to 130 ppm (caution); Yellow (wet) — above 130 ppm.

Change filter drier at first sign of moisture in system.

IMPORTANT: Unit must be in operation at least 12 hours before moisture indicator can give an accurate reading. With unit running, 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(s). There is one filter drier on each circuit. Refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, for details on servicing filter driers.

LIQUID LINE SOLENOID VALVE — All TXV units have a liquid line solenoid valve to prevent liquid refrigerant migration to low side of system during the off cycle.

LIQUID LINE SERVICE VALVE — This valve is located immediately ahead of filter drier, and has a

/4-in. Schrader connection for field charging. In combination with compressor discharge service valve, each circuit can be pumped down into the high side for servicing.

STEPPER MOTOR (12 VDC)

LEAD SCREW

PISTON SLEEVE

ORIFICE ASSEMBLY (INSIDE PISTON SLEEVE)

PL-EXVB

BRN

WHT

RED

BLK

GRN

PL-EXVA

BRN

WHT

RED

BLK

GRN

EXV-B

EXV-A

Thermistors —

BLU

PNK

TB5

T10

REMOTE SPACE TEMP (ACCESSORY)

COOLER ENTERING FLUID TEMP

OUTDOOR-AIR TEMP

(ACCESSORY) OR

DUAL CHILLER LWT

COOLER LEAVING FLUID TEMP

SATURATED CONDENSING TEMPCIRCUIT B

SATURATED SUCTION TEMPCIRCUIT B*

SATURATED CONDENSING TEMPCIRCUIT A

SATURATED SUCTION TEMPCIRCUIT A*

MAIN BASE BOARD

T1-T6, T9, T10 THERMISTORS

EXV BOARD

10 9

11 10 9

CKTA* CKTB*

COMPRESSOR RETURN GAS TEMP

T7, T8 THERMISTORS

LEGEND

*Not used on units with TXV (Thermostatic Expansion Valve) FIOP (Factory-Installed Option).

Fig. 33 — Thermistor Connections to J5 and J8

Processor Boards

LWT —

Leaving Fluid Temperature

Electronic control uses 4 to 10 thermistors to sense temperatures used to control the operation of chiller.

Thermistors T1-T9 vary in their temperature vs resistance

and voltage drop performance. Thermistor T10 is a 10 kΩ input channel and has a different set of temperature vs resistance and voltage drop performance. Resistances at various temperatures are listed in Tables 32A-33B.

LOCATION — General locations of thermistor sensors are shown in Fig. 7-10. See Table 2 for pin connection points.

Sensor T2 is installed directly in the fluid circuit. Relieve all pressure or drain fluid before removing.

REPLACING THERMISTOR T2

1. Remove and discard original sensor and coupling. Do not disassemble new coupling. Install assembly as received. See Fig. 32.

2. Apply pipe sealant to 1/4-in. NPT threads on replacement coupling, and install in place of original. Do not use the packing nut to tighten coupling. Damage to ferrules will result.

3. Thermistor T2 (entering fluid temperature) should not be touching an internal refrigerant tube, but should be close enough to sense a freeze condition. Recommended distance is 1/8 in. (3.2 mm) from cooler tube. Tighten packing nut finger tight to position ferrules, then tighten 11/ turns more using a back-up wrench. Ferrules are now attached to the sensor, which can be withdrawn from coupling for service.

REPLACING THERMISTORS T1, T5, T6, T7, AND T8 — Add a small amount of thermal conductive grease to thermistor well. Thermistors are friction-fit thermistors, which must be slipped into wells located in the cooler leaving fluid nozzle for T1, in the cooler head for T5 and T6 (EXV units only), and in the compressor pump end for T7 and T8 (EXV units only).

THERMISTORS T3 AND T4 — These thermistors are located on header end of condenser coil. They are clamped on a return bend.

THERMISTOR/TEMPERATURE SENSOR CHECK — A high quality digital volt-ohmmeter is required to perform this check.

1. Connect the digital voltmeter across the appropriate thermistor terminals at the J8 terminal strip on the Main Base Board for thermistors T1-T6, T9, T10; or the J5 terminal strip on the EXV Board for thermistors T7 and T8 (see Fig. 33). Using the voltage reading obtained, read the sensor temperature from

FLUID-SIDE TEMPERATURE SENSOR (T1) AND

REFRIGERANT TEMPERATURE SENSOR (T5, T6, T7, T8)

X = T1,T5,T6 = 3″ (76)

T7,T8 = 4″ (102)

Tables 32A-33B. To check thermistor accuracy, measure temperature at probe location with an accurate thermocouple-type temperature measuring instrument. Insulate thermocouple to avoid ambient temperatures from influencing reading. Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close, ± 5° F (3° C) if care was taken in applying thermocouple and taking readings.

2. If a more accurate check is required, unit must be shut down and thermistor removed and checked at a known temperature (freezing point or boiling point of water) using either voltage drop measured across thermistor at the J8 or J5 terminals, by determining the resistance with chiller shut down and thermistor disconnected from J8 or J5. Compare the values determined with the value read by the control in the Temperatures mode using the Marquee display.

NOTE: Dimensions in ( ) are in millimeters.

FLUID-SIDE TEMPERATURE SENSOR (T2)

Fig. 32 — Thermistors (Temperature Sensors)

TEMP

(F)

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

–9 –8 –7 –6 –5 –4 –3 –2 –1

0 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Table 32A — 5K Thermistor Temperature (F) vs Resistance/Voltage

VOLTAGE

DROP A

3.699 4.538 98,010

3.689 4.523 94,707

3.679 4.508 91,522

3.668 4.493 88,449

3.658 4.476 85,486

3.647 4.460 82,627

3.636 4.444 79,871

3.624 4.427 77,212

3.613 4.409 74,648

3.601 4.391 72,175

3.588 4.373 69,790

3.576 4.354 67,490

3.563 4.335 65,272

3.550 4.316 63,133

3.536 4.296 61,070

3.523 4.276 59,081

3.509 4.255 57,162

3.494 4.234 55,311

3.480 4.213 53,526

3.465 4.191 51,804

3.450 4.169 50,143

3.434 4.146 48,541

3.418 4.123 46,996

3.402 4.100 45,505

3.386 4.076 44,066

3.369 4.052 42,679

3.352 4.027 41,339

3.335 4.002 40,047

3.317 3.976 38,800

3.299 3.951 37,596

3.281 3.924 36,435

3.262 3.898 35,313

3.243 3.871 34,231

3.224 3.844 33,185

3.205 3.816 32,176

3.185 3.788 31,202

3.165 3.760 30,260

3.145 3.731 29,351

3.124 3.702 28,473

3.103 3.673 27,624

3.082 3.643 26,804

3.060 3.613 26,011

3.038 3.583 25,245

3.016 3.552 24,505

2.994 3.522 23,789

2.972 3.490 23,096

2.949 3.459 22,427

2.926 3.428 21,779

2.903 3.396 21,153

2.879 3.364 20,547

2.856 3.331 19,960

2.832 3.299 19,393

2.808 3.266 18,843

2.784 3.234 18,311

2.759 3.201 17,796

2.735 3.168 17,297

2.710 3.134 16,814

2.685 3.101 16,346

2.660 3.068 15,892

2.634 3.034 15,453

2.609 3.000 15,027

2.583 2.966 14,614

2.558 2.933 14,214

2.532 2.899 13,826

2.506 2.865 13,449

2.480 2.831 13,084

2.454 2.797 12,730

2.428 2.764 12,387

2.402 2.730 12,053

2.376 2.696 11,730

2.349 2.662 11,416

2.323 2.628 11,112

2.296 2.594 10,816

2.270 2.561 10,529

2.244 2.527 10,250

2.217 2.494 9,979

2.191 2.461 9,717

2.165 2.427 9,461

2.138 2.395 9,213

2.112 2.362 8,973

2.086 2.329 8,739

2.060 2.296 8,511

2.034 2.264 8,291

2.008 2.232 8,076

(V)

VOLTAGE

DROP B

(V)

RESISTANCE

(Ohms)

VOLTAGE DROP A FOR THERMISTORS T1, T2, T7-T9

VOLTAGE DROP B FOR THERMISTORS T3-T6

TEMP

(F)

59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142

VOLTAGE

DROP A

1.982 2.200 7,686

1.956 2.168 7,665

1.930 2.137 7,468

1.905 2.105 7,277

1.879 2.074 7,091

1.854 2.043 6,911

1.829 2.013 6,735

1.804 1.982 6,564

1.779 1.952 6,399

1.754 1.923 6,238

1.729 1.893 6,081

1.705 1.864 5,929

1.681 1.835 5,781

1.656 1.806 5,637

1.632 1.778 5,497

1.609 1.749 5,361

1.585 1.722 5,229

1.562 1.694 5,101

1.538 1.667 4,976

1.516 1.640 4,855

1.493 1.613 4,737

1.470 1.587 4,622

1.448 1.561 4,511

1.426 1.535 4,403

1.404 1.510 4,298

1.382 1.485 4,196

1.361 1.460 4,096

1.340 1.436 4,000

1.319 1.412 3,906

1.298 1.388 3,814

1.278 1.365 3,726

1.257 1.342 3,640

1.237 1.319 3,556

1.217 1.296 3,474

1.198 1.274 3,395

1.179 1.253 3,318

1.160 1.231 3,243

1.141 1.210 3,170

1.122 1.189 3,099

1.104 1.169 3,031

1.086 1.148 2,964

1.068 1.128 2,898

1.051 1.109 2,835

1.033 1.089 2,773

1.016 1.070 2,713

0.999 1.051 2,655

0.983 1.033 2,597

0.966 1.015 2,542

0.950 0.997 2,488

0.934 0.980 2,436

0.918 0.963 2,385

0.903 0.946 2,335

0.888 0.929 2,286

0.873 0.913 2,239

0.858 0.896 2,192

0.843 0.881 2,147

0.829 0.865 2,103

0.815 0.850 2,060

0.801 0.835 2,018

0.787 0.820 1,977

0.774 0.805 1,937

0.761 0.791 1,898

0.748 0.777 1,860

0.735 0.763 1,822

0.723 0.750 1,786

0.710 0.736 1,750

0.698 0.723 1,715

0.686 0.710 1,680

0.674 0.698 1,647

0.663 0.685 1,614

0.651 0.673 1,582

0.640 0.661 1,550

0.629 0.650 1,519

0.618 0.638 1,489

0.608 0.627 1,459

0.597 0.616 1,430

0.587 0.605 1,401

0.577 0.594 1,373

0.567 0.584 1,345

0.557 0.573 1,318

0.548 0.563 1,291

0.538 0.553 1,265

0.529 0.543 1,240

0.520 0.534 1,214

(V)

VOLTAGE

DROP B

(V)

RESISTANCE

(Ohms)

TEMP

(F)

143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225

VOLTAGE

DROP A

0.511 0.525 1,190

0.502 0.515 1,165

0.494 0.506 1,141

0.485 0.497 1,118

0.477 0.489 1,095

0.469 0.480 1,072

0.461 0.471 1,050

0.453 0.463 1,029

0.445 0.455 1,007

0.438 0.447 986

0.430 0.449 965

0.423 0.432 945

0.416 0.424 925

0.408 0.417 906

0.402 0.410 887

0.395 0.403 868

0.388 0.396 850

0.381 0.389 832

0.375 0.382 815

0.369 0.376 798

0.362 0.369 782

0.356 0.363 765

0.350 0.357 750

0.344 0.351 734

0.339 0.345 719

0.333 0.339 705

0.327 0.333 690

0.322 0.327 677

0.317 0.322 663

0.311 0.316 650

0.306 0.311 638

0.301 0.306 626

0.296 0.301 614

0.291 0.295 602

0.286 0.291 591

0.282 0.286 581

0.277 0.281 570

0.272 0.276 561

0.268 0.272 551

0.264 0.267 542

0.259 0.263 533

0.255 0.258 524

0.251 0.254 516

0.247 0.250 508

0.243 0.246 501

0.239 0.242 494

0.235 0.238 487

0.231 0.234 480

0.228 0.230 473

0.224 0.226 467

0.220 0.223 461

0.217 0.219 456

0.213 0.216 450

0.210 0.212 445

0.206 0.209 439

0.203 0.205 434

0.200 0.202 429

0.197 0.199 424

0.194 0.196 419

0.191 0.192 415

0.188 0.189 410

0.185 0.186 405

0.182 0.183 401

0.179 0.181 396

0.176 0.178 391

0.173 0.175 386

0.171 0.172 382

0.168 0.169 377

0.165 0.167 372

0.163 0.164 367

0.160 0.162 361

0.158 0.159 356

0.155 0.157 350

0.153 0.154 344

0.151 0.152 338

0.148 0.150 332

0.146 0.147 325

0.144 0.145 318

0.142 0.143 311

0.140 0.141 304

0.138 0.138 297

0.135 0.136 289

0.133 0.134 282

(V)

VOLTAGE

DROP B

(V)

RESISTANCE

(Ohms)

TEMP

(C)

–32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10

–9 –8 –7 –6 –5 –4 –3 –2 –1

10 11 12 13 14

Table 32B — 5K Thermistor Temperature (C) vs Resistance/Voltage (cont)

VOLTAGE

DROP A

3.705 4.547 100,260

3.687 4.520 94,165

3.668 4.493 88,480

3.649 4.464 83,170

3.629 4.433 78,125

3.608 4.402 73,580

3.586 4.369 69,250

3.563 4.335 65,205

3.539 4.300 61,420

3.514 4.264 57,875

3.489 4.226 54,555

3.462 4.187 51,450

3.434 4.146 48,536

3.406 4.104 45,807

3.376 4.061 43,247

3.345 4.017 40,845

3.313 3.971 38,592

3.281 3.924 38,476

3.247 3.876 34,489

3.212 3.827 32,621

3.177 3.777 30,866

3.140 3.725 29,216

3.103 3.673 27,633

3.065 3.619 26,202

3.025 3.564 24,827

2.985 3.509 23,532

2.945 3.453 22,313

2.903 3.396 21,163

2.860 3.338 20,079

2.817 3.279 19,058

2.774 3.221 18,094

2.730 3.161 17,184

2.685 3.101 16,325

2.639 3.041 15,515

2.593 2.980 14,749

2.547 2.919 14,026

2.500 2.858 13,342

2.454 2.797 12,696

2.407 2.737 12,085

2.360 2.675 11,506

2.312 2.615 10,959

2.265 2.554 10,441

2.217 2.494 9,949

2.170 2.434 9,485

2.123 2.375 9,044

2.076 2.316 8,627

2.029 2.258 8,231

(V)

VOLTAGE

DROP B

(V)

VOLTAGE DROP A FOR THERMISTORS T1, T2, T7-T9

VOLTAGE DROP B FOR THERMISTORS T3-T6

RESISTANCE

(Ohms)

TEMP

(C)

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

VOLTAGE

DROP A

1.982 2.200 7,855

1.935 2.143 7,499

1.889 2.087 7,161

1.844 2.031 6,840

1.799 1.976 6,536

1.754 1.923 6,246

1.710 1.870 5,971

1.666 1.817 5,710

1.623 1.766 5,461

1.580 1.716 5,225

1.538 1.667 5,000

1.497 1.619 4,786

1.457 1.571 4,583

1.417 1.525 4,389

1.378 1.480 4,204

1.340 1.436 4,028

1.302 1.393 3,861

1.265 1.351 3,701

1.229 1.310 3,549

1.194 1.270 3,404

1.160 1.231 3,266

1.126 1.193 3,134

1.093 1.156 3,008

1.061 1.120 2,888

1.030 1.085 2,773

0.999 1.051 2,663

0.969 1.019 2,559

0.940 0.987 2,459

0.912 0.956 2,363

0.885 0.926 2,272

0.858 0.896 2,184

0.832 0.868 2,101

0.807 0.841 2,021

0.782 0.814 1,944

0.758 0.788 1,871

0.735 0.763 1,801

0.713 0.739 1,734

0.691 0.716 1,670

0.669 0.693 1,609

0.649 0.671 1,550

0.629 0.650 1,493

0.610 0.629 1,439

0.591 0.609 1,387

0.573 0.590 1,337

0.555 0.571 1,290

0.538 0.553 1,244

0.522 0.536 1,200

(V)

VOLTAGE

DROP B

(V)

RESISTANCE

(Ohms)

TEMP

(C)

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

99 100 101 102 103 104 105 106 107

VOLTAGE

DROP A

0.506 0.519 1,158

0.490 0.502 1,118

0.475 0.487 1,079

0.461 0.471 1,041

0.447 0.457 1,006

0.433 0.443 971

0.420 0.429 938

0.407 0.415 906

0.395 0.403 876

0.383 0.390 836

0.371 0.378 805

0.360 0.367 775

0.349 0.355 747

0.339 0.345 719

0.329 0.334 693

0.319 0.324 669

0.309 0.314 645

0.300 0.305 623

0.291 0.295 602

0.283 0.287 583

0.274 0.278 564

0.266 0.270 547

0.258 0.262 531

0.251 0.254 516

0.244 0.247 502

0.237 0.239 489

0.230 0.232 477

0.223 0.226 466

0.217 0.219 456

0.211 0.213 446

0.204 0.207 436

0.199 0.201 427

0.193 0.195 419

0.188 0.189 410

0.182 0.184 402

0.177 0.179 393

0.172 0.174 385

0.168 0.169 376

0.163 0.164 367

0.158 0.160 357

0.154 0.155 346

0.150 0.151 335

0.146 0.147 324

0.142 0.143 312

0.138 0.139 299

0.134 0.135 285

(V)

VOLTAGE

DROP B

(V)

RESISTANCE

(Ohms)

Table 33A — 10K Thermistor Temperatures (°F) vs Resistance/Voltage Drop

(For Thermistor T10)

TEMP

(F)

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

–9 –8 –7 –6 –5 –4 –3 –2 –1

0 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

VOLTAGE DROP (V)

4.758 196,453

4.750 189,692

4.741 183,300

4.733 177,000

4.724 171,079

4.715 165,238

4.705 159,717

4.696 154,344

4.686 149,194

4.676 144,250

4.665 139,443

4.655 134,891

4.644 130,402

4.633 126,183

4.621 122,018

4.609 118,076

4.597 114,236

4.585 110,549

4.572 107,006

4.560 103,558

4.546 100,287

4.533 97,060

4.519 94,020

4.505 91,019

4.490 88,171

4.476 85,396

4.461 82,729

4.445 80,162

4.429 77,662

4.413 75,286

4.397 72,940

4.380 70,727

4.363 68,542

4.346 66,465

4.328 64,439

4.310 62,491

4.292 60,612

4.273 58,781

4.254 57,039

4.235 55,319

4.215 53,693

4.195 52,086

4.174 50,557

4.153 49,065

4.132 47,627

4.111 46,240

4.089 44,888

4.067 43,598

4.044 42,324

4.021 41,118

3.998 39,926

3.975 38,790

3.951 37,681

3.927 36,610

3.903 35,577

3.878 34,569

3.853 33,606

3.828 32,654

3.802 31,752

3.776 30,860

3.750 30,009

3.723 29,177

3.697 28,373

3.670 27,597

3.654 26,838

3.615 26,113

3.587 25,396

3.559 24,715

3.531 24,042

3.503 23,399

3.474 22,770

3.445 22,161

3.416 21,573

3.387 20,998

3.357 20,447

3.328 19,903

3.298 19,386

3.268 18,874

3.238 18,384

3.208 17,904

3.178 17,441

3.147 16,991

3.117 16,552

3.086 16,131

3.056 15,714

3.025 15,317

RESISTANCE

(Ohms)

TEMP

(F)

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146

VOLTAGE DROP (V)

2.994 14,925

2.963 14,549

2.932 14,180

2.901 13,824

2.870 13,478

2.839 13,139

2.808 12,814

2.777 12,493

2.746 12,187

2.715 11,884

2.684 11,593

2.653 11,308

2.622 11,031

2.592 10,764

2.561 10,501

2.530 10,249

2.500 10,000

2.470 9,762

2.439 9,526

2.409 9,300

2.379 9,078

2.349 8,862

2.319 8,653

2.290 8,448

2.260 8,251

2.231 8,056

2.202 7,869

2.173 7,685

2.144 7,507

2.115 7,333

2.087 7,165

2.059 6,999

2.030 6,838

2.003 6,683

1.975 6,530

1.948 6,383

1.921 6,238

1.894 6,098

1.867 5,961

1.841 5,827

1.815 5,698

1.789 5,571

1.763 5,449

1.738 5,327

1.713 5,210

1.688 5,095

1.663 4,984

1.639 4,876

1.615 4,769

1.591 4,666

1.567 4,564

1.544 4,467

1.521 4,370

1.498 4,277

1.475 4.185

1.453 4,096

1.431 4,008

1.409 3,923

1.387 3,840

1.366 3,759

1.345 3,681

1.324 3,603

1.304 3,529

1.284 3,455

1.264 3,383

1.244 3,313

1.225 3,244

1.206 3,178

1.187 3,112

1.168 3,049

1.150 2,986

1.132 2,926

1.114 2,866

1.096 2,809

1.079 2,752

1.062 2,697

1.045 2,643

1.028 2,590

1.012 2,539

0.996 2,488

0.980 2,439

0.965 2,391

0.949 2,343

0.934 2,297

0.919 2,253

0.905 2,209

RESISTANCE

(Ohms)

TEMP

(F)

147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225

VOLTAGE DROP (V)

0.890 2,166

0.876 2,124

0.862 2,083

0.848 2,043

0.835 2,003

0.821 1,966

0.808 1,928

0.795 1,891

0.782 1,855

0.770 1,820

0.758 1,786

0.745 1,752

0.733 1,719

0.722 1,687

0.710 1,656

0.699 1,625

0.687 1,594

0.676 1,565

0.666 1,536

0.655 1,508

0.645 1,480

0.634 1,453

0.624 1,426

0.614 1,400

0.604 1,375

0.595 1,350

0.585 1,326

0.576 1,302

0.567 1,278

0.558 1,255

0.549 1,233

0.540 1,211

0.532 1,190

0.523 1,169

0.515 1,148

0.507 1,128

0.499 1,108

0.491 1,089

0.483 1,070

0.476 1,052

0.468 1,033

0.461 1,016

0.454 998

0.447 981

0.440 964

0.433 947

0.426 931

0.419 915

0.413 900

0.407 885

0.400 870

0.394 855

0.388 841

0.382 827

0.376 814

0.370 800

0.365 787

0.359 774

0.354 762

0.349 749

0.343 737

0.338 725

0.333 714

0.328 702

0.323 691

0.318 680

0.314 670

0.309 659

0.305 649

0.300 639

0.296 629

0.292 620

0.288 610

0.284 601

0.279 592

0.275 583

0.272 574

0.268 566

0.264 557

RESISTANCE

(Ohms)

Table 33B — 10K Thermistor Temperatures (°C) vs Resistance/Voltage Drop

(For Thermistor T10)

TEMP

(C)

–32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10

–9 –8 –7 –6 –5 –4 –3 –2 –1

0 1 2 3 4 5 6 7 8

9 10 11 12 13 14

VOLTAGE DROP (V)

4.762 200,510

4.748 188,340

4.733 177,000

4.716 166,342

4.700 156,404

4.682 147,134

4.663 138,482

4.644 130,402

4.624 122,807

4.602 115,710

4.580 109,075

4.557 102,868

4.533 97,060

4.508 91,588

4.482 86,463

4.455 81,662

4.426 77,162

4.397 72,940

4.367 68,957

4.335 65,219

4.303 61,711

4.269 58,415

4.235 55,319

4.199 52,392

4.162 49,640

4.124 47,052

4.085 44,617

4.044 42,324

4.003 40,153

3.961 38,109

3.917 36,182

3.873 34,367

3.828 32,654

3.781 31,030

3.734 29,498

3.686 28,052

3.637 26,686

3.587 25,396 3,537 24,171

3.485 23,013

3.433 21,918

3.381 20,883

3.328 19,903

3.274 18,972

3.220 18,090

3.165 17,255

3.111 16,474

RESISTANCE

(Ohms)

TEMP

(C)

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

VOLTAGE DROP (V)

3.056 15,714

3.000 15,000

2.944 14,323

2.889 13,681

2.833 13,071

2.777 12,493

2.721 11,942

2.666 11,418

2.610 10,921

2.555 10,449

2.500 10,000

2.445 9,571

2.391 9,164

2.337 8,776

2.284 8,407

2.231 8,056

2.178 7,720

2.127 7,401

2.075 7,096

2.025 6,806

1.975 6,530

1.926 6,266

1.878 6,014

1.830 5,774

1.784 5,546

1.738 5,327

1.692 5,117

1.648 4,918

1.605 4,727

1.562 4,544

1.521 4,370

1.480 4,203

1.439 4,042

1.400 3,889

1.362 3,743

1.324 3,603

1.288 3,469

1.252 3,340

1.217 3,217

1.183 3,099

1.150 2,986

1.117 2,878

1.086 2,774

1.055 2,675

1.025 2,579

0.996 2,488

0.968 2,400

RESISTANCE

(Ohms)

TEMP

(C)

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

99 100 101 102 103 104 105 106 107

VOLTAGE DROP (V)

0.940 2,315

0.913 2,235

0.887 2,157

0.862 2,083

0.837 2,011

0.813 1,943

0.790 1,876

0.767 1,813

0.745 1,752

0.724 1,693

0.703 1,637

0.683 1,582

0.663 1,530

0.645 1,480

0.626 1,431

0.608 1,385

0.591 1,340

0.574 1,297

0.558 1,255

0.542 1,215

0.527 1,177

0.512 1,140

0.497 1,104

0.483 1,070

0.470 1,037

0.457 1,005

0.444 974

0.431 944

0.419 915

0.408 889

0.396 861

0.386 836

0.375 811

0.365 787

0.355 764

0.345 742

0.336 721

0.327 700

0.318 680

0.310 661

0.302 643

0.294 626

0.287 609

0.279 592

0.272 576

0.265 561

RESISTANCE

(Ohms)

Safety Devices —

Chillers contain many safety devices and protection logic built into electronic control. Following is a brief summary of major safeties.

COMPRESSOR PROTECTION Circuit Breaker

— One manual-reset, calibrated-trip magnetic circuit breaker for each compressor protects against overcurrent. Do not bypass or increase size of a breaker to correct problems. Determine cause for trouble and correct before resetting breaker. Circuit breaker must-trip amps (MTA) are listed on individual circuit breakers, and on unit label diagrams.

30GTN,R and 30GUN,R070 (50 Hz), 080-110 and 230B315B Compressor Protection Board (CPCS) — The CPCS is used to control and protect compressors and crankcase heaters. Board provides following features:

• compressor contactor control

• crankcase heater control

• ground current protection

• status communication to processor board

• high-pressure protection

One large relay is located on CPCS that controls crankcase heater and compressor contactor. In addition, this relay provides a set of contacts that the microprocessor monitors to determine operating status of compressor. If the MBB determines that compressor is not operating properly through signal contacts, control locks compressor off.

The CPCS contains logic that can detect if current-toground of any winding exceeds 2.5 amps; if so, compressor shuts down.

A high-pressure switch with a trip pressure of 426 ± 7 psig (2936 ± 48 kPa) is mounted on each compressor; switch setting is shown in Table 34. Switch is wired in series with the CPCS. If switch opens, CPCS relay opens, processor detects it through signal contacts, and compressor locks off. A loss-of-charge switch is also wired in series with the high-pressure switch and CPCS.

If any of these switches opens during operation, the compressor stops and the failure is detected by the MBB when signal contacts open. If lead compressor in either circuit is shut down by high-pressure switch, ground current protector, loss of charge switch, or oil pressure switch, all compressors in the circuit are locked off.

30GTN,R and 30GUN,R 130-210, 230A-315A and 330A/B-420A/B — A control relay in conjunction with a ground fault module replaces the function of the CPCS (above). To reset, press the push-button switch (near the Marquee display).

Table 34 — Pressure Switch Settings,

psig (kPa)

SWITCH CUTOUT CUT-IN

High Pressure

30GTN,R Units

High Pressure

30GUN,R Units

Loss-of-Charge

426 ± 7

(2936 ± 48)

280 ± 10

(1830 ± 69)

7 (48.2) 22 (151.6)

320 ± 20

(2205 ± 138)

180 ± 20

(1240 ± 138)

source is auxiliary control power, independent of main unit power. This assures compressor protection even when main unit power disconnect switch is off.

IMPORTANT: Never open any switch or disconnect that deenergizes crankcase heaters unless unit is being serviced or is to be shut down for a prolonged period. After a prolonged shutdown or service, energize crankcase heaters for 24 hours before starting unit.

COOLER PROTECTION Freeze Protection

— Cooler can be wrapped with heater cables as shown in Fig. 34, which are wired through an ambient temperature switch set at 36 F (2 C). Entire cooler is covered with closed-cell insulation applied over heater cables. Heaters plus insulation protect cooler against low ambient temperature freeze-up to 0° F (–18 C).

IMPORTANT: If unit is installed in an area where ambient temperatures fall below 32 F (0° C), it is recommended that inhibited ethylene glycol or other suitable corrosion-inhibitive antifreeze solution be used in chilled-liquid circuit.

Low Fluid Temperature

— Main Base Board is programmed to shut chiller down if 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. The unit will shut down without a pumpout. When fluid temperature rises to 6° F (3.3° C) above leaving fluid set point, safety resets and chiller restarts. Reset is automatic as long as this is the first occurrence.

Loss of Fluid Flow Protection

— Main Base Board contains internal logic that protects cooler against loss of cooler flow. Entering and leaving fluid temperature sensors in cooler detect a no-flow condition. Leaving sensor is located in leaving fluid nozzle and entering sensor is located in first cooler baffle space in close proximity to cooler tubes, as shown in Fig. 34. When there is no cooler flow and the compressors start, leaving fluid temperature does not change. However, entering fluid temperature drops rapidly as refrigerant enters cooler through EXV. Entering sensor detects this temperature drop and when entering temperature is 3° F (1.6° C) below leaving temperature, unit stops and is locked off.

Loss-of-Charge

— A pressure switch connected to high side of each refrigerant circuit protects against total loss-of-charge. Switch settings are listed in Table 34. If switch is open, unit cannot start; if it opens during operation, unit locks out and cannot restart until switch is closed. Low charge is also monitored by the processor when an EXV is used. The loss-ofcharge switch is wired in series with the high-pressure switch on each circuit’s lead compressor.

LOW OIL PRESSURE PROTECTION — Lead compressor in each circuit is equipped with a switch to detect low oil pressure. Switch is connected directly to processor board. Switch is set to open at approximately 5 psig (35 kPa) and to close at 9 psig (62 kPa) maximum. If switch opens when compressor is running, CR or processor board stops all compressors in circuit. During start-up, switch is bypassed for 2 minutes.

CRANKCASE HEATERS — Each compressor has a 180-w crankcase heater to prevent absorption of liquid refrigerant by oil in crankcase when compressor is not running. Heater power

LEGEND

T —

Thermistor

Fig. 34 — Cooler Heater Cables

Relief Devices —

*Lead compressor only.

Fig. 35 — Compressor Connections

(Lead Compressor Shown)

Fusible plugs are located in each cir-

cuit to protect against damage from excessive pressures. HIGH-SIDE PROTECTION — One device is located

between condenser and filter drier; a second is on filter drier. These are both designed to relieve pressure on a temperature rise to approximately 210 F (99 C).

LOW-SIDE PROTECTION — A device is located on suction line and is designed to relieve pressure on a temperature rise to approximately 170 F (77 C).

PRESSURE RELIEF VALVES (208/230, 460, 575 v; 60 Hz Units Only) — Valves are installed in each circuit (one per circuit). The valves are designed to relieve at 450 psig (3103 kPa). These valves should not be capped. If a valve relieves, it should be replaced. If valve is not replaced, it may relieve at a lower pressure, or leak due to trapped dirt from the system which may prevent resealing.

The pressure relief valves are equipped with a 3/8-in. SAE flare for field connection. Some local building codes require that relieved gases be removed. This connection will allow conformance to this requirement.

Other Safeties —

There are several other safeties that are provided by microprocessor control. For details refer to Alarms and Alerts section on page 48.

PRE-START-UP

IMPORTANT: Before beginning Pre-Start-Up or StartUp, complete Start-Up Checklist for ComfortLink™ Chiller Systems at end of this publication (page CL-1). The Checklist assures proper start-up of a unit, and provides a record of unit condition, application requirements, system information, and operation at initial start-up.

heater has been energized for at least 24 hours. See Oil Charge section on page 53 for Carrier-approved oils.

7. Electrical power source must agree with unit nameplate.

8. Crankcase heaters must be firmly locked into compres- sors, and must be on for 24 hours prior to start-up.

9. Fan motors are 3 phase. Check rotation of fans during the service test. Fan rotation is clockwise as viewed from top of unit. If fan is not turning clockwise, reverse 2 of the power wires. For low noise fan option on 50 Hz chillers, fans rotate counterclockwise as viewed from top of unit. If fan is not turning counterclockwise, reverse 2 of the power wires.

10. Check compressor suspension. Mounting rails must be floating freely on the springs.

11. Perform service test to verify proper settings.

Do not attempt to start the chiller until following checks

have been completed.

System Check

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

2. Backseat (open) compressor suction and discharge shutoff valves. Close valves one turn to allow refrigerant pressure to reach the test gages.

3. Open liquid line service valves.

4. Fill the chiller fluid circuit with clean water (with recommended inhibitor added) or other noncorrosive fluid to be cooled. Bleed all air out of high points of system. An air vent is included with the cooler. If outdoor temperatures are expected to be below 32 F (0° C), sufficient inhibited ethylene glycol or other suitable corrosion-inhibited antifreeze should be added to the chiller water circuit to prevent possible freeze-up.

5. Check tightness of all electrical connections.

6. Oil should be visible in the compressor sight glass. See Fig. 35. An acceptable oil level in the compressor is from

/8 in. to 3/8 in. of sight glass. Adjust the oil level as re-

quired. No oil should be removed unless the crankcase

START-UP AND OPERATION

NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-8.

Actual Start-Up —

Actual start-up should be done only

under supervision of a qualified refrigeration mechanic.

1. Be sure all service valves are open. Units are shipped from factory with suction, discharge, and liquid line service valves closed.

2. Using the Marquee display, set leaving-fluid set point (CSP.1 is Set Point mode under sub-mode COOL). No cooling range adjustment is necessary.

3. If optional control functions or accessories are being used, the unit must be properly configured. Refer to Operating Data section for details.

4. Start chilled fluid pump.

5. Turn ENABLE/OFF/REMOTE CONTACT switch to ENABLE position.

6. Allow unit to operate and confirm that everything is functioning properly. Check to see that leaving fluid temperature agrees with leaving set point (CSP.1 or CSP.2), or if reset is used, with the control point (CTPT) in the Run Status mode under the sub-mode VIEW.

Operating Limitations

TEMPERATURES (See Table 35) — If unit is to be used in an area with high solar radiation, mounted position should be such that control box is not exposed to direct solar radiation. Exposure to direct solar radiation could affect the temperature switch controlling cooler heaters.

Table 35 — Temperature Limits for Standard Units

TEMPERATURE F C Maximum Ambient Temperature Minimum Ambient Temperature Maximum Cooler EWT* Maximum Cooler LWT Minimum Cooler LWT†

LEGEND

EWT — LWT —

*For sustained operation, EWT should not exceed 85 F (29.4 C). †Unit requires modification below this temperature.

Low-Ambient Operation

Entering Fluid (Water) Temperature Leaving Fluid (Water) Temperature

— If operating temperatures below 0° F (–18 C) are expected, refer to separate installation instructions for low-ambient operation using accessory Motormaster® III control. Contact your Carrier representative for details.

NOTE: Wind baffles and brackets must be field-fabricated for all units using accessory Motormaster III controls to ensure proper cooling cycle operation at low-ambient temperatures. See Installation Instructions shipped with the Motormaster III accessory for more details.

Brine duty application (below 38 F [3.3 C] LCWT) for chiller normally requires factory modification. Contact your Carrier representative for applicable LCWT range for standard water-cooled chiller in a specific application.

125 52

0 –18 95 35 70 21 38 3.3

Unbalanced 3-Phase Supply Voltage — Never operate a motor where a phase imbalance between phases is greater than 2%.

To determine percent voltage imbalance:

max voltage deviation

% Voltage Imbalance = 100 x

from avg voltage

average voltage

The maximum voltage deviation is the largest difference between a voltage measurement across 2 legs and the average across all 3 legs.

Example: Supply voltage is 240-3-60. AB = 243 v BC = 236 v AC = 238 v

1. Determine average voltage:

Avera ge voltage =

243 + 236 + 238

717

239

2. Determine maximum deviation from average voltage: (AB) 243 – 239 = 4 v

(BC) 239 – 236 = 3 v (AC) 239 – 238 = 1 v

Maximum deviation is 4 v.

3. Determine percent voltage imbalance:

% Voltage Imbalance = 100 x

239

= 1.7%

This voltage imbalance is satisfactory as it is below the

maximum allowable of 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately. Do not operate unit until imbalance condition is corrected.

Control Circuit Power

— Electronic control includes logic to detect low control circuit voltage. Acceptable voltage ranges are shown in the Installation Instructions.

MINIMUM FLUID LOOP VOLUME — To obtain proper temperature control, loop fluid volume must be at least 3 gallons per ton (3.25 L per kW) of chiller nominal capacity for air conditioning and at least 6 gallons per ton (6.5 L per kW) for process applications or systems that must operate at low ambient temperatures (below 32 F [0° C]). Refer to application information in Product Data literature for details.

FLOW RATE REQUIREMENTS — Standard chillers should be applied with nominal flow rates approximating those listed in Table 36. Higher or lower flow rates are permissible to obtain lower or higher temperature rises. Minimum flow rates must be exceeded to assure turbulent flow and proper heat transfer in the cooler.

VOLTAGE Main Power Supply

— Minimum and maximum acceptable

supply voltages are listed in the Installation Instructions.

Operation below minimum flow rate could subject tubes to frost pinching in tube sheet, resulting in failure of cooler.

Consult application data section in the Product Data literature and job design requirements to determine flow rate requirements for a particular installation.

Table 36 — Nominal and Minimum Cooler

Fluid Flow Rates

K/W).

MINIMUM

FLOW RATE

(See Notes)

UNIT SIZE

30GTN,R

AND 30GUN,R

040 86 5.43 36.8 2.32 045 1016.3737.72.38 050 123 7.7637.72.38 060 151 9.5347.53.00

070 173 10.91 47.5 3.00 080,230B 192 12.11 66.7 4.20 090,245B 216 13.62 59.5 3.75

100,255B,270B 240 15.14 84.1 5.30 110,290B,315B 264 16.65 84.1 5.30

130 30018.9110 6.9

150,230A-255A 34821.9110 6.9

170,270A,330A/B,

360B (50 Hz)

190,290A,360A/B (60 Hz),

360A (50 Hz), 390B

210,315A,390A,420A/B 48030.2148 9.3

LEGEND

ARI — Air Conditioning and Refrigeration Institute Gpm — Gallons per minute (U.S.) L/s — Liters per second N — Liters per kW V — Gallons per ton

*Nominal flow rates required at ARI conditions are 44 F (6.7 C) leaving-fluid

temperature, 54 F (12.2 C) entering-fluid temperature, 95 F(35 C) ambient. Fouling factor is .00001 ft2 ⋅ hr ⋅ F/Btu (.000018 m

NOTES:

1. Minimum flow based on 1.0 fps (0.30 m/s) velocity in cooler without special cooler baffling.

2. Minimum Loop Volumes: Gallons = V x ARI Cap. in tons Liters = N x ARI Cap. in kW

APPLICATION V N Normal Air Conditioning 33.25 Process Type Cooling 6 to 10 6.5 to 10.8 Low Ambient Unit Operation 6 to 10 6.5 to 10.8

Operation Sequence —

NOMINAL

FLOW RATE*

Gpm L/s Gpm L/s

38424.2120 7.5

43227.2120 7.5

⋅

During unit off cycle, crankcase heaters are energized. If ambient temperature is below 36 F (2 C), cooler heaters (if equipped) are energized.

The unit is started by putting the ENABLE/OFF/REMOTE CONTACT switch in ENABLE or REMOTE position. When the unit receives a call for cooling (either from the internal control or CCN network command or remote contact closure), the unit stages up in capacity to maintain the cooler fluid set point. The first compressor starts 11/2 to 3 minutes after the call for cooling.

The lead circuit can be specifically designated or randomly selected by the controls, depending on how the unit is field configured (for 040-070 sizes, Circuit A leads unless an accessory unloader is installed on Circuit B). A field configuration is also available to determine if the unit should stage up both circuits equally or load one circuit completely before bringing on the other.

When the lead circuit compressor starts, the unit starts with a pumpout routine. On units with the electronic expansion valve (EXV), compressor starts and continues to run with the EXV at minimum position for 10 seconds to purge the refrigerant lines and cooler of refrigerant. The EXV then moves to 23% and the compressor superheat control routine takes over, modulating the valve to feed refrigerant into the cooler.

On units with thermostatic expansion valve (TXV) (30GTN,R and 30GUN,R 040,045 units with brine option), head pressure control is based on set point control. When the lead compressor starts, the liquid line solenoid valve (LLSV) is

kept closed for 15 seconds by a time delay relay. The microprocessor stages fans to maintain the set point temperature specified by the controller. There is no pumpout sequence during shutdown of TXV controlled chillers.

On all other units (EXV units), the head pressure is controlled by fan cycling. The desired head pressure set point is entered, and is controlled by EXV position or saturated condensing temperature measurement (T3 and T4). For proper operation, maintain set point of 113 F (45 C) as shipped from factory. The default head pressure control method is set point control. The head pressure control can also be set to EXV control or a combination of the 2 methods between circuits.

For all units, if temperature reset is being used, the unit controls to a higher leaving-fluid temperature as the building load reduces. If demand limit is used, the unit may temporarily be unable to maintain the desired leaving-fluid temperature because of imposed power limitations.

On EXV units, when the occupied period ends, or when the building load drops low enough, the lag compressors shut down. The lead compressors continue to run as the EXV closes, and until the conditions of pumpout are satisfied. If a fault condition is signaled requiring immediate shutdown, pumpout is omitted.

Loading sequence for compressors is shown in Tables 5A and 5B.

Refrigerant Circuit

LEAK TESTING — Units are shipped with complete operating charge of refrigerant R-22 for 30GTN,R and R-134a for 30GUN,R (see Physical Data tables supplied in the chiller’s installation instructions) and should be under sufficient pressure to conduct a leak test. If there is no pressure in the system, introduce enough nitrogen to search for the leak. Repair the leak using good refrigeration practices. After leaks are repaired, system must be evacuated and dehydrated.

REFRIGERANT CHARGE (Refer to Physical Data tables supplied in the chiller’s installation instructions) — Immediately ahead of filter drier in each circuit is a factory-installed liquid line service valve. Each valve has a 1/4-in. Schrader connection for charging liquid refrigerant.

Charging with Unit Off and Evacuated

— Close liquid line service valve before charging. Weigh in charge shown on unit nameplate (also in Physical Data tables supplied in the chiller’s installation instructions). Open liquid line service valve; start unit and allow it to run several minutes fully loaded. Check for a clear sight glass. Be sure clear condition is liquid and not vapor.

Charging with Unit Running

— If charge is to be added while unit is operating, all condenser fans and compressors must be operating. It may be necessary to block condenser coils at low ambient temperatures to raise condensing pressure to approximately 280 psig (1931 kPa) to turn all condenser fans on. Do not totally block a coil to do this. Partially block all coils in uniform pattern. Charge each circuit until sight glass shows clear liquid, then weigh in amount over a clear sight glass as listed in Physical data tables supplied in chiller’s installation instructions.

IMPORTANT: When adjusting refrigerant charge, circulate fluid through cooler continuously to prevent freezing and possible damage to the cooler. Do not overcharge, and never charge liquid into low-pressure side of system.

FIELD WIRING

Field wiring is shown in Fig. 36-41.

ALM — CWFS — CWP — CWPI — CXB — HGBPS — LWT — MBB — OAT — SPT — SW — TB — UL —

LEGEND FOR FIG. 36-41

Alarm Chilled Water Flow Switch Chilled Water Pump Chilled Water Pump Interlock Compressor Expansion Board Hot Gas Bypass Switch Leaving Fluid Temperature Main Base Board Outdoor-Air Temperature Sensor Remote Space Temperature Sensor Switch Terminal Block Unloader Field Supplied Wiring Factory Wiring

MBB,

PLUG J8

BLU

PNK

TB5

SPT ACCESSORY

T10

OAT ACCESSORY OR DUAL CHILLER LWT. (MASTER CHILLER)

Fig. 36 — Accessory Sensor

Control Wiring

MAIN BASE BOARD

PLUG J10A

TB5

CWPI

REMOTE

CONTACT

SW1

ENABLE

RED

OFF

DUAL SETPOINT

CWFS

TB5

RED

TB5

REMOTE

ON-OFF SWITCH

RED

TB5

ORN

RED

GRA

MBB,

PLUG J7

Fig. 37 — Control Wiring (24 V)

K11

GRA

TB5

VIO

BLK

VIO

HGBPS-A

HGBPS-B

Fig. 38 — Hot Gas Bypass Control Wiring (115 V, 230 V)

GRA

TB5

HGBPS-B

TB5

MBB

TB5

ALM

MAX LOAD-75VA SEALED

360VA INRUSH

CWP

MAX LOAD-75VA SEALED

360VA INRUSH

PLUG J10B

BLK

VIO

Fig. 39 — Chilled Water Pump Control Wiring and Remote Alarm 115 V Relay Wiring

EMM, PLUG J6 EMM, PLUG J7

12 111098765432 1 111098765432 1

121110987654321

BRN

TB6

PNK

ORN

VIO

13 12

14131211109876543 21

BLU

RED GRA

BLU RED GRA

TB6

10 9

TB5

4.20 MA SIGNAL

GENERATOR

COOLING

SETPOINT

GENERATOR

TEMPERATURE

4.20 MA SIGNAL

RESET

4.20 MA SIGNAL

GENERATOR

DEMAND

LIMIT

Fig. 40 — Energy Management Module (EMM) Wiring

DEMAND LIMIT STEP 2

DEMAND LIMIT STEP 1

FIELD SUPPLIED

DRY CONTACTS 24V

ICE DONE

GND

BLK

WHT

RED

CXB ACCESSORY

CXB

BOARD

Fig. 41 — Compressor Expansion Board (CXB) Accessory Wiring

CXB ACCESSORY

UL-A2

UL-B2

24V

115V/ 230V

10 11 12 13 14

15 16

APPENDIX A — CCN TABLES

UNIT (Configuration Settings)

DESCRIPTION STATUS DEFAULT UNITS POINT

2 3 4 5 6 7 8 9

Unit Type 1 = Air Cooled

Unit Size 20 to 300 * TONS SIZE Circuit A1% Capacity 0 to 100 * % CAP_A Number Circ A Compressor 1 to 4 * NUMCA Compressor A1 Cylinders 4 or 6 * NUM_CYLA Number Circ B Compressor 1 to 4 * NUMCB Compressor B1 Cylinders 4 or 6 * NUM_CYLB EXV Module Installed No/Yes Yes EXV_BRD EXV Superheat Setpoint 10 to 40 29.0 (30GTN,R)

EXV MOP 40 to 80 50.0 °FMOP_SP EXV Superheat Offset –20 to 20 0.0 ^F SH_OFFST EXV Circ. A Min Position 0 to 100 8.0 % EXVAMINP EXV Circ. B Min Position 0 to 100 8.0 % EXVBMINP Refrigerant 1 = R22

Low Pressure Setpoint 3 to 60 10.0 PSI LOW_PRES Fan Staging Select 1 = 2 Stage indpt.

2 = Water Cooled 3 = Split System 4 = Heat Machine 5 = Air Cooled Heat Reclaim

2 = R134A

2 = 3 Stage indpt. 3 = 2 Stage common 4 = 3 Stage common

1 UNIT_TYP

23.0 (30GUN,R)

1 (30GTN,R) 2 (30GUN,R)

* FAN_TYPE

^F SH_SP

REFRIG_T

2 3

5 6 8 9

11 12 13 14

*Unit size dependent.

OPTIONS1 (Options Configuration)

DESCRIPTION STATUS DEFAULT POINT

Cooler Fluid 1 = Water

Hot Gas Bypass Select No/Yes No HGBV_FLG Head Press. Cont. Method 1 = EXV controlled

Head Press. Control Type 0 = None

Motormaster Select No/Yes No MTR_TYPE Pressure Transducers Off/On Off PRESS_TY Cooler Pump Control Off/On Off CPC Condenser Pump Interlock Off/On Off CND_LOCK Condenser Pump Control 0 = No control

Condenser Fluid Sensors No/Yes No CD_TEMP No. Circuit A Unloaders 0-2 * NUNLA No. Circuit B Unloaders 0-2 * NUNLB EMM Module Installed No/Yes No EMM_BRD

2 = Med. Brine 3 = Low Brine

2 = Setpoint control 3 = Setpoint-A, EXV-B 4 = EXV-A, Setpoint-B

1 = Air Cooled 2 = Water Cooled

1 = On with Mode 2 = On with Compressors

1FLUIDTYP

2HEAD_MET

1HEAD_TYP

0 CNPC

10 11

APPENDIX A — CCN TABLES (cont)

CONFIGURATION SCREEN (TYPE 10)

OPTIONS2 (Options Configuration)

DESCRIPTION STATUS DEFAULT UNITS POINT

6 7 8 9

Control Method 0 = Switch

Loading Sequence Select 1 = Equal loading

Lead/Lag Circuit Select 1 = Automatic

Cooling Setpoint Select 0 = Single

Heating Setpoint Select 0 = Single

Ramp Load Select Enable/Disable Disable RAMP_EBL Heat Cool Select Cool/Heat Cool HEATCOOL High LCW Alert Limit 2 to 60 60.0 ^F LCW_LMT Minutes off time 0 to 15 0 min DELAY Deadband Multiplier 1.0 to 4.0 1.0 Z_GAIN Ice Mode Enable Enable/Disable Disable ICE_CNFG

1 = 7 day sched. 2 = Occupancy 3 = CCN

2 = Staged loading

2 = Circuit A leads 3 = Circuit B leads

1 = Dual, remote switch controlled 2 = Dual, 7-day occupancy 3 = Dual CCN occupancy 4 = 4-20 mA input 5 = External POT

1 = Dual, remote switch controlled 2 = Dual, 7 day occupancy 3 = Dual CCN occupancy 4 = 4-20 mA input

0 CONTROL

1 SEQ_TYPE

*LEAD_TYP

0CLSP_TYP

0HTSP_TYP

1 2 3 4

1 2 3 4 5

*Unit size dependent.

DISPLAY (STDU SETUP)

DESCRIPTION STATUS DEFAULT UNITS POINT

Service Password nnnn 1111 PASSWORD Password Enable Enable/Disable Enable PASS_EBL Metric Display Off/On Off DISPUNIT Language Selection 0 = ENGLISH

1 = FRANCAIS 2 = ESPANOL 3 = PORTUGUES

0LANGUAGE

SCHEDOVR (TIMED OVERRIDE SETUP)

DESCRIPTION STATUS DEFAULT UNITS POINT

Schedule Number 0-99 0 SCHEDNUM Override Time Limit 0-4 0 hours OTL Timed Override Hours 0-4 0 hours OTL_EXT Timed Override Yes/No No TIMEOVER

ALARMDEF (Alarm Definition Table)

DESCRIPTION STATUS DEFAULT UNITS POINT

Alarm Routing Control 00000000 00000000 ALRM_CNT Equipment Priority 0 to 7 4 EQP_TYPE Comm Failure Retry Time 1 to 240 10 min RETRY_TM Re-alarm Time 1 to 255 30 min RE-ALARM Alarm System Name XXXXXXXX Chiller ALRM_NAM

10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28

APPENDIX A — CCN TABLES (cont)

RESETCON (Temperature Reset and Demand Limit)

DESCRIPTION STATUS DEFAULT UNITS POINT 1 2

3 4 5 6 7 8

COOLING RESET

Cooling Reset Type 0 = No Reset

No Cool Reset Temp 0 to 125 125.0 °FCT_NO Full Cool Reset Temp 0 to 125 0.0 °F CT_FULL Degrees Cool Reset –30 to 30 0.0 ^F CT_DEG

HEATING RESET

Heating Reset Type 0 = No Reset

No Heat Reset Temp 0 to 125 0.0 HT_NO Full Heat Reset Temp 0 to 125 125.0 % HT_FULL Degrees Heat Reset –30 to 30 0.0 min HT_DEG

DEMAND LIMIT

Demand Limit Select 0 = None

Demand Limit at 20 mA 0 to 100 100 % DMT20MA Loadshed Group Number 0 to 99 0 SHED_NUM Loadshed Demand Delta 0 to 60 0 % SHED_DEL Maximum Loadshed Time 0 to 120 60 min SHED_TIM Demand Limit Switch 1 0 to 100 80 % DLSWSP1 Demand Limit Switch 2 0 to 100 50 % DLSWSP2

LEAD/LAG

Lead/Lag Chiller Enable Enable/Disable Disable LL_ENA Master/Slave Select Slave/Master Master MS_SEL Slave Address 0 to 239 0 SLV_ADDR Lead/Lag Balance Select Enable/Disable Disable LL_BAL Lead/Lag Balance Delta 40 to 400 168 hours LL_BAL_D Lag Start Delay 0 to 30 5 mins LL_DELAY

1 = 4-20 ma input 2 = External temp-OAT 3 = Return fluid 4 = External temp-SPT

1 = 4-20 ma input 2 = External temp — OAT 3 = Return fluid 4 = External temp — SPT

1 = External switch input 2 = 4-20 ma input 3 = Loadshed

0 CRST_TYP

0 HRST_TYP

0DMD_CTRL

10 11 12 13 14

BRODEFS (Broadcast POC Definition Table)

DESCRIPTION STATUS DEFAULT UNITS POINT 1 2 3 4 5 6 7 8 9

CCN Time/Date Broadcast Yes/No No CCNBC CCN OAT Broadcast Yes/No No OATBC Global Schedule Broadcast Yes/No No GSBC CCN Broadcast Acker Yes/No No CCNBCACK Daylight Savings Start

Month 1 to 12 4 STARTM Week 1 to 5 1 STARTW Day 1 to 7 7 STARTD Minutes to add 0 to 99 60 min MINADD

Daylight Savings Stop

Month 1 to 12 10 STOPM Week 1 to 5 5 STOPW Day 1 to 7 7 STOPD Minutes to subtract 0 to 99 60 min MINSUB

10 11 12 13 14 15

APPENDIX A — CCN TABLES (cont)

A_UNIT (General Unit Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE

2 3 4 5 6 7 8 9

Control Mode 0 = Service

Occupied Yes/No OCC N CCN Chiller Start/Stop CHIL_S_S Y Alarm State Normal ALM N Active Demand Limit 0-100 % DEM_LIM Y Override Modes in Effect Yes/No MODE N Percent Total Capacity 0-100 % CAP_T N Requested Stage nn STAGE N Active Setpoint snnn.n °FSP N Control Point snnn.n °F CTRL_PNT Y Entering Fluid Temp snnn.n °FEWT N Leaving Fluid Temp snnn.n °FLWT N Emergency Stop Enable/Emstop EMSTOP Y Minutes Left for Start nn min MIN_LEFT N Heat Cool Select Heat/Cool HEATCOOL Y

1 = OFF - local 2 = OFF-CCN 3 = OFF-time 4 = Emergency 5 = ON-local 6 = ON-CCN 7 = ON-time

STAT N

10 11 12 13 14 15 16 17

CIRCA_AN (Circuit A Analog Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE 1 2 3 4 5 6 7 8 9

Circuit A Analog Values Percent Total Capacity 0-100 % CAPA_T N Percent Available Cap 0-100 % CAPA_A N Discharge Pressure nnn.n PSI DP_A N Suction Pressure nnn.n PSI SP_A N Saturated Condensing Tmp snnn.n °FTMP_SCTA N Saturated Suction Temp snnn.n °FTMP_SSTA N Compressor Suction Temp snnn.n °FCTA_TMP N Suction Superheat Temp snnn.n ^F SH_A N EXV % Open 0-100.0 % EXV_A N

CIRCA_DIO (Circuit A Discrete Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE 1 2 3 4 5 6 7 8 9

CIRC. A DISCRETE OUTPUTS

Compressor A1 Relay ON/OFF K_A1_RLY N Compressor A2 Relay ON/OFF K_A2_RLY N Compressor A3 Relay ON/OFF K_A3_RLY N Compressor A4 Relay ON/OFF K_A4_RLY N Unloader A1 Relay ON/OFF UNL_A1 N Unloader A2 Relay ON/OFF UNL_A2 N Liq. Line Solenoid Valve OPEN/CLOSE LLSV_A N Hot Gas Bypass Relay ON/OFF HGB N

CIRC. A DISCRETE INPUTS

Compressor A1 Feeback ON/OFF K_A1_FBK N Compressor A2 Feedback ON/OFF K_A2_FBK N Compressor A3 Feedback ON/OFF K_A3_FBK N Compressor A4 Feedback ON/OFF K_A4_FBK N Oil Pressure Switch A OPEN/CLOSE OILSW_A N Low Pressure Switch A OPEN/CLOSE LPS_A N

10 11 12 13 14 15 16 17

APPENDIX A — CCN TABLES (cont)

CIRCB_AN (Circuit B Analog Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

Circuit B Analog Values Percent Total Capacity 0-100 % CAPB_T N Percent Available Cap 0-100 % CAPB_A N Discharge Pressure nnn.n PSI DP_B N Suction Pressure nnn.n PSI SP_B N Saturated Condensing Tmp snnn.n °FTMP_SCTB N Saturated Suction Temp snnn.n °FTMP_SSTB N Compressor Suction Temp snnn.n °FCTB_TMP N Suction Superheat Temp snnn.n ^F SH_B N EXV % Open 0-100.0 % EXV_B N

CIRCBDIO (Circuit B Discrete Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE

CIRC. B DISCRETE OUTPUTS

Compressor B1 Relay ON/OFF K_B1_RLY N Compressor B2 Relay ON/OFF K_B2_RLY N Compressor B3 Relay ON/OFF K_B3_RLY N Compressor B4 Relay ON/OFF K_B4_RLY N Unloader B1 Relay ON/OFF UNL_B1 N Unloader B2 Relay ON/OFF UNL_B2 N Liq. Line Solenoid Valve ON/OFF LLSV_B N Hot Gas Bypass Relay ON/OFF HGB N

CIRC. B DISCRETE INPUTS

Compressor B1 Feedback ON/OFF K_B1_FBK N Compressor B2 Feedback ON/OFF K_B2_FBK N Compressor B3 Feedback ON/OFF K_B3_FBK N Compressor B4 Feedback ON/OFF K_B4_FBK N Oil Pressure Switch B OPEN/CLOSE OILSW_B N Low Pressure Switch B OPEN/CLOSE LPS_B N

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32 33 34

APPENDIX A — CCN TABLES (cont)

OPTIONS (Unit Parameters)

DESCRIPTION STATUS UNITS POINT FORCEABLE 1 2 3 4 5 6 7 8 9

FANS

Fan 1 Relay ON/OFF FAN_1 N Fan 2 Relay ON/OFF FAN_2 N Fan 3 Relay ON/OFF FAN_3 N Fan 4 Relay ON/OFF FAN_4 N

UNIT ANALOG VALUES

Cooler Entering Fluid snnn.n °F COOL_EWT N Cooler Leaving Fluid snnn.n °F COOL_LWT N Condensing Entering Fluid snnn.n °F COND_EWT N Condenser Leaving Fluid snnn.n °F COND_LWT N Lead/Lag Leaving Fluid snnn.n °F DUAL_LWT N

TEMPERATURE RESET

4-20 mA Reset Signal nn.n mA RST_MA N Outside Air Temperature snnn.n °FOAT Y Space Temperature snnn.n °FSPT Y

DEMAND LIMIT

4-20 mA Demand Signal n.nn LMT_MA N Demand Limit Switch 1 ON/OFF DMD_SW1 N Demand Limit Switch 2 ON/OFF DMD_SW2 N CCN Loadshed Signal 0 = Normal

PUMPS

Cooler Pump Relay ON/OFF COOL_PMP Condenser Pump Relay ON/OFF COND_PMP N

MISCELLANEOUS

Dual Setpoint Switch ON/OFF DUAL_IN N Cooler LWT Setpoint snn.n °FLWR_SP N Cooler Flow Switch ON/OFF COOLFLOW N Condenser Flow Switch ON/OFF CONDFLOW N Ice Done ON/OFF ICE N

1 = Redline 2 = Shed

OL_STAT N

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

APPENDIX A — CCN TABLES (cont)

STRTHOUR

DESCRIPTION STATUS UNITS POINT 1 2 3 4 5 6 7 8 9

Machine Operating Hours nnnnn hours HR_MACH Machine Starts nnnnn CY_MACH

Circuit A Run Hours nnnnn hours HR_CIRA

Compressor A1 Hours nnnnn hours HR_A1 Compressor A2 Hours nnnnn hours HR_A2 Compressor A3 Hours nnnnn hours HR_A3 Compressor A4 Hours nnnnn hours HR_A4

Circuit B Run Hours nnnnn hours HR_CIRB

Compressor B1 Hours nnnnn hours HR_B1 Compressor B2 Hours nnnnn hours HR_B2 Compressor B3 Hours nnnnn hours HR_B3 Compressor B4 Hours nnnnn hours HR_B4

Circuit A Starts nnnnn CY_CIRA

Compressor A1 Starts nnnnn CY_A1 Compressor A2 Starts nnnnn CY_A2 Compressor A3 Starts nnnnn CY_A3 Compressor A4 Starts nnnnn CY_A4

Circuit B Starts nnnnn CY_CIRB

Compressor B1 Starts nnnnn CY_B1 Compressor B2 Starts nnnnn CY_B2 Compressor B3 Starts nnnnn CY_B3 Compressor B4 Starts nnnnn CY_B4

DESCRIPTION STATUS UNITS POINT 1 2 3 4 5 6 7 8 9

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

NOTE: Alerts will displayed as Txxx.

Active Alarm #1 Axxx or Txxx ALARM01C

Active Alarm #2 Axxx or Txxx ALARM02C

Active Alarm #3 Axxx or Txxx ALARM03C

Active Alarm #4 Axxx or Txxx ALARM04C

Active Alarm #5 Axxx or Txxx ALARM05C

Active Alarm #6 Axxx or Txxx ALARM06C

Active Alarm #7 Axxx or Txxx ALARM07C

Active Alarm #8 Axxx or Txxx ALARM08C

Active Alarm #9 Axxx or Txxx ALARM09C

Active Alarm #10 Axxx or Txxx ALARM10C Active Alarm #11 Axxx or Txxx ALARM11C Active Alarm #12 Axxx or Txxx ALARM12C Active Alarm #13 Axxx or Txxx ALARM13C Active Alarm #14 Axxx or Txxx ALARM14C Active Alarm #15 Axxx or Txxx ALARM15C Active Alarm #16 Axxx or Txxx ALARM16C Active Alarm #17 Axxx or Txxx ALARM17C Active Alarm #18 Axxx or Txxx ALARM18C Active Alarm #19 Axxx or Txxx ALARM19C Active Alarm #20 Axxx or Txxx ALARM20C Active Alarm #21 Axxx or Txxx ALARM21C Active Alarm #22 Axxx or Txxx ALARM22C Active Alarm #23 Axxx or Txxx ALARM23C Active Alarm #24 Axxx or Txxx ALARM24C Active Alarm #25 Axxx or Txxx ALARM25C

ALARMS

10 11 12 13 14 15 16 17 18 19 20 21 22

APPENDIX A — CCN TABLES (cont)

CURRMODS

DESCRIPTION STATUS UNITS POINT 1 2 3 4 5 6 7 8 9

FSM controlling chiller ON/OFF MODE_1 WSM controlling chiller ON/OFF MODE_2 Master/Slave control ON/OFF MODE_3 Low source protection ON/OFF MODE_4 Ramp Load Limited ON/OFF MODE_5 Timed Override in effect ON/OFF MODE_6 Low Cooler Suction TempA ON/OFF MODE_7 Low Cooler Suction TempB ON/OFF MODE_8 Slow Change Override ON/OFF MODE_9 Minimum OFF Time ON/OFF MODE_10 Low Suction Superheat A ON/OFF MODE_11 Low Suction Superheat B ON/OFF MODE_12 Dual Setpoint ON/OFF MODE_13 Temperature Reset ON/OFF MODE_14 Demand Limit in effect ON/OFF MODE_15 Cooler Freeze Prevention ON/OFF MODE_16 Lo Tmp Cool/Hi Tmp Heat ON/OFF MODE_17 Hi Tmp Cool/Lo Tmp Heat ON/OFF MODE_18 Making Ice ON/OFF MODE_19 Storing Ice ON/OFF MODE_20 High SCT Circuit A ON/OFF MODE_21 High SCT Circuit B ON/OFF MODE_22

10 11 12 13 14 15 16

SETPOINT

DESCRIPTION STATUS UNITS POINT DEFAULTS 1 2 3 4 5 6 7 8 9

COOLING

Cool Setpoint 1 –20 to 70 °FCSP1 44 Cool Setpoint 2 –20 to 70 °FCSP2 44 Ice Setpoint –20 to 32 °FCSP3 32

HEATING

Heat Setpoint 1 80 to 140 °F HSP1 100 Heat Setpoint 2 80 to 140 °F HSP2 100

RAMP LOADING

Cooling Ramp Loading 0.2 to 2.0 °F/min CRAMP 1.0 Heating Ramp Loading 0.2 to 2.0 °F/min HRAMP 1.0

HEAD PRESSURE

Head Pressure Setpoint A 80 to 140 °F HSP_A 113 Head Pressure Setpoint B 80 to 140 °F HSP_B 113

LOADFACT

DESCRIPTION STATUS UNITS POINT 1 2 3 4

CAPACITY CONTROL

Load/Unload Factor snnn.n % SMZ Control Point snnn.n °F CTRL_PNT Leaving Water Temp snnn.n °FLWT

VERSIONS

DESCRIPTION STATUS UNITS POINT 1 2 3 4 5 6

MBB CESR-131170 nn-nn EXV CESR-131172 nn-nn CXB CESR131173- nn-nn EMM CESR131174- nn-nn MARQ CESR131171- nn-nn NAV CESR131227- nn-nn

APPENDIX A — CCN TABLES (cont)

CSM/FSM EQUIPMENT TABLE (Type 621H, Block 2)

LINE DESCRIPTION POINT

2 3 4 5 6 7 8 9

Chiller Status 0 = Chiller is off 1 = Valid run state in CCN mode 2 = Recycle active 3 = Chiller is in Local Mode 4 = Power Fail Restart in Progress 5 = Shutdown due to fault 6 = Communication Failure

Lag Status LAGSTAT Percent Total Capacity Running CAP_T Service Runtime HR_MACH unused unused unused Power Fail Auto Restart ASTART Percent Available Capacity On CAP_A

WSM EQUIPMENT PART COOL SOURCE MAINTENANCE TABLE

SUPERVISOR MAINTENANCE TABLE

DESCRIPTION STATUS POINT WSM Active? Chilled water temp Equipment status Commanded state CHW setpoint reset value Current CHW setpoint

Yes WSMSTAT snn.n °F CHWTEMP On CHLRST Enable/Disable/None CHLRENA nn.n^F CHWRVAL snn.n °F CHWSTPT

CHILSTAT

OCCUPANCY MAINTENANCE TABLE

OCCUPANCY SUPERVISORY

DESCRIPTION STATUS POINT Current Mode (1=Occup.) Current Occup. Period # Timed-Override in Effect Time-Override Duration Current Occupied Time Current Unoccupied Time Next Occupied Day Next Occupied Time Next Unoccupied Day Next Unoccupied Time Previous Unoccupied Day Previous Unoccupied Time

0,1 MODE 0-8 PER-NO Yes/No OVERLAST 0-4 hours OVR_HRS hh:mm STRTTIME hh:mm ENDTIME

hh:mm NXTOCTIM

hh:mm NXTUNTIM

hh:mm PRVUNTIM

NXTOCDAY

NXTUNDAY

APPENDIX B — FLUID DROP PRESSURE CURVES

Cooler Fluid Pressure Drop Curves — 30GUN,GUR040-110

ENGLISH AND SI

LEGEND

040

—



045,050

—



NOTE: Ft of water = 2.31 x change in psig.

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GUN,GUR130-210

ENGLISH

COOLER PRESSURE DROP KEY

— 30GUN,GUR130,150

— 30GUN,GUR170,190

— 30GUN,GUR210

NOTE: Ft of water = 2.31 x change in psig.

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GUN,GUR230A-255A, 270A/B-420A/B

ENGLISH

COOLER PRESSURE DROP KEY

Module B — 30GUN,GUR270

Module A — 30GUN,GUR230-255

Module A — 30GUN,GUR270,330

Module B — 30GUN,GUR330,360 (50 Hz)

Module A — 30GUN,GUR290,315,360 (50 or 60 Hz), 390, and 420

Module B — 30GUN,GUR360 (60 Hz), 390, and 420

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GUN,GUR230B-315B

ENGLISH AND SI

COOLER PRESSURE DROP KEY

Module B — 30GUN,GUR230,245

Module B — 30GUN,GUR255,290,315

NOTE: Ft of water = 2.31 x change in psig.

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GTN,GTR040-110

ENGLISH AND SI

LEGEND

040

—



045,050

—



NOTE: Ft of water = 2.31 x change in psig.

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GTN,GTR130-210

ENGLISH

COOLER PRESSURE DROP KEY

— 30GTN,GTR130,150

— 30GTN,GTR170,190

— 30GTN,GTR210

NOTE: Ft of water = 2.31 x change in psig.

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GTN,GTR230A-420A, 270B, 330B-420B

ENGLISH

COOLER PRESSURE DROP KEY

Module B — 30GTN,GTR270

Module A — 30GTN,GTR230-255

Module A — 30GTN,GTR270,330

Module B — 30GTN,GTR330,360 (50 Hz)

Module A — 30GTN,GTR290,315,360 (50 or 60 Hz), 390, and 420

Module B — 30GTN,GTR360 (60 Hz), 390, and 420

APPENDIX B — FLUID DROP PRESSURE CURVES (cont)

Cooler Fluid Pressure Drop Curves — 30GTN,GTR230B, 245B, 255B, 290B, 315B

ENGLISH AND SI

COOLER PRESSURE DROP KEY

Module B — 30GTN,GTR230,245

Module B — 30GTN,GTR255,290,315

NOTE: Ft of water = 2.31 x change in psig.

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • 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 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 Ta b 5 c

PC 903 Catalog No. 563-025 Printed in U.S.A. Form 30GTN-3T Pg 88 3-00 Replaces: 30GTN-2T

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

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

Book 2 Ta b 5c

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

START-UP CHECKLIST FOR

COMFORT

LINK™ CHILLER SYSTEMS

(Remove and use for job file)

A. Preliminary Information

JOB NAME _______________________________________________________________________________

LOCATION _______________________________________________________________________________

INSTALLING CONTRACTOR _________________________________________________________________

DISTRIBUTOR ____________________________________________________________________________

START-UP PERFORMED BY _________________________________________________________________

EQUIPMENT: Chiller:

MODEL NO.

SERIAL NO.

COMPRESSORS:

COOLER:

MODEL NO.

MANUFACTURED BY

SERIAL NO. DATE

TYPE OF EXPANSION VALVES (check one): EXV TXV

AIR-HANDLING EQUIPMENT:

MANUFACTURER

MODEL NO. SERIAL NO.

ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES

CIRCUIT A CIRCUIT B

1) MODEL NO. 1) MODEL NO.

SERIAL NO. SERIAL NO.

MTR NO. MTR NO.

2) MODEL NO. 2) MODEL NO.

SERIAL NO. SERIAL NO.

MTR NO. MTR NO.

3) MODEL NO. 3) MODEL NO.

SERIAL NO. SERIAL NO.

MTR NO. MTR NO.

4) MODEL NO.

SERIAL NO.

MTR NO.

B. Preliminary Equipment Check

(

)

Check box if complete

IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE

_________________________________________________________________________________________

WILL THIS DAMAGE PREVENT UNIT START-UP?



HAVE COMPRESSOR BASE RAIL ISOLATORS ALL BEEN PROPERLY ADJUSTED?



CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?



HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)



ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)



HAS THE GROUND WIRE BEEN CONNECTED?



ARE ALL TERMINALS TIGHT?

CHECK AIR SYSTEMS



ALL AIR HANDLERS OPERATING? (refer to air-handling equipment Installation and Start-Up Instructions)



ALL CHILLED FLUID VALVES OPEN?



ALL FLUID PIPING CONNECTED PROPERLY?



ALL AIR BEEN VENTED FROM THE COOLER LOOP?



CHILLED WATER (FLUID) PUMP (CWP) OPERATING WITH THE CORRECT ROTATION?

CWP MOTOR AMPERAGE: Rated

(Check box if complete)

Actual

PUMP PRESSURE: Inlet Outlet

C. Unit Start-Up



CHILLER HAS BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CHILLED

(insert check mark as each item is completed)

FLUID PUMP STARTER.



UNIT IS SUPPLIED WITH CORRECT CONTROL VOLTAGE POWER (115 V FOR 208/230, 460, AND 575 V UNITS; 230 V FOR 380 AND 380/415 UNITS)



CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF



COMPRESSOR OIL LEVEL IS CORRECT.



BOTH LIQUID LINE SERVICE VALVES ARE BACKSEATED.

24 HOURS

PRIOR TO START-UP.



ALL

COMPRESSOR DISCHARGE SERVICE VALVES ARE BACKSEATED.



ALL

COMPRESSOR SUCTION SERVICE VALVES ARE BACKSEATED.



LOOSEN COMPRESSOR SHIPPING HOLDDOWN BOLTS.



LEAK CHECK

THOROUGHLY

: CHECK ALL COMPRESSORS, CONDENSER MANIFOLDS AND HEADERS, EXVs, TXVs, SOLENOID VALVES, FILTER DRIERS, FUSIBLE PLUGS, THERMISTORS, AND COOLER HEADS, WITH ELECTRONIC LEAK DETECTOR.

LOCATE, REPAIR, AND REPORT ANY REFRIGERANT LEAKS.

CL-2

CL-3

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

C. Unit Start-Up (cont)



CHECK VOLTAGE IMBALANCE: AB

AC BC

AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = V

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER!

CALL LOCAL POWER COMPANY FOR ASSISTANCE.



INCOMING POWER VOLTAGE TO CHILLER MODULES IS WITHIN RATED UNIT VOLTAGE

RANGE.

SYSTEM FLUID VOLUME IN LOOP:

TYPE SYSTEM:

AIR CONDITIONING — MINIMUM 3 GAL PER NOMINAL TON (3.25 L PER kW) =

GAL (L)

PROCESS COOLING — MINIMUM 6 GAL PER NOMINAL TON (6.50 L PER kW) =

GAL (L)

CHECK PRESSURE DROP ACROSS COOLER.

FLUID ENTERING COOLER:

PSIG (kPa)

FLUID LEAVING COOLER:

PSIG (kPa)

(PSIG DIFFERENCE) x 2.31 = FT OF FLUID PRESSURE DROP =

PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (LOCATED IN PRODUCT DATA

LITERATURE) TO DETERMINE TOTAL GPM (L/s).

TOTAL GPM (L/s) =

UNIT’S RATED MIN GPM (L/s) =

GPM (L/s) PER TON = UNIT’S RATED MIN PRESSURE DROP =

(Refer to product data literature.)

JOB’S SPECIFIED GPM (L/s) (if available):

NOTE: IF UNIT HAS LOW FLUID FLOW, FIND SOURCE OF PROBLEM: CHECK FLUID PIPING, IN-LINE FLUID STRAINER, SHUT-OFF VALVES, CWP ROTATION, ETC.

COOLER LOOP FREEZE PROTECTION IF REQUIRED:

GALLONS (LITERS) ADDED:

PIPING INCLUDES ELECTRIC TAPE HEATERS (Y/N):

VISUALLY CHECK MAIN BASE BOARD AND EXV BOARD FOR THE FOLLOWING:



INSPECT ALL THERMISTORS AND EXV CABLES FOR POSSIBLE CROSSED WIRES.



CHECK TO BE SURE ALL WELL-TYPE THERMISTORS ARE FULLY INSERTED INTO THEIR

RESPECTIVE WELLS.



ALL CABLES AND PIN CONNECTORS TIGHT?



ALL EXV, EMM, AND CXB BOARDS (IF INSTALLED) AND DISPLAY CONNECTIONS TIGHT?

VOLTAGE IMBALANCE =

(MAX. DEVIATION)

x 100 =

% VOLTAGE IMBALANCE

AVERAGE VOLTAGE

C. Unit Start-Up (cont)

UNIT (Configuration Settings)

ITEM DESCRIPTION STATUS UNITS VALUE

TYPE

TONS CAP.A CMP.A CYL.A CMP.B CYL.B EXV SH.SP SH.OF REFG FAN.S

PRESS ESCAPE KEY TO DISPLAY ‘UNIT’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT1’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW:

Unit Type 1 = Air Cooled

Unit Size 15 to 300 TONS Circuit A1% Capacity 0 to 100 % Number Circ A Compressor 1 to 4 Compressor A1 Cylinders 4 or 6 Number Circ B Compressor 1 to 4 Compressor B1 Cylinders 4 or 6 EXV Module Installed No/Yes EXV Superheat Setpoint 10 to 40 ^F EXV Superheat Offset –20 to 20 ^F Refrigerant 1 = R22 2 = R134A Fan Staging Select 1 = 2 Stage indpt.

2 = Water Cooled 3 = Split System 4 = Heat Machine 5 = Air Cooled Heat Reclaim

2 = 3 Stage indpt. 3 = 2 Stage common 4 = 3 Stage common

OPTIONS1 (Options Configuration)

ITEM DESCRIPTION STATUS VALUE

FLUD

HGB.S HPCM

HPCT

MMR.S PRTS PMP.I CPC CNP.I CNPC

CWT.S CA.UN CB.UN EMM

Cooler Fluid 1 = Water

Hot Gas Bypass Select No/Yes Head Press. Cont. Method 1 = EXV controlled

Head Press. Control Type 0 = None

Motormaster Select No/Yes Pressure Transducer No/Yes Cooler Pump Interlock Off/On Cooler Pump Control Off/On Condenser Pump Interlock Off/On Condenser Pump Control 0 = No Control

Condenser Fluid Sensors No/Yes No. Circuit A Unloaders 0-2 No. Circuit B Unloaders 0-2 EMM Module Installed No/Yes

2 = Med. Brine 3 = Low Brine

2 = Setpoint controlled 3 = Setpoint-A, EXV-B 4 = EXV-A, Setpoint-B

1 = Air Cooled 2 = Water Cooled

1 = On with Mode 2 = On with Compressor(s)

CL-4

CL-5

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

C. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY ‘OPT1’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT2’. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW:

OPTIONS2 (Options Configuration)

PRESS ESCAPE KEY TO DISPLAY ‘OPT2’. PRESS DOWN ARROW KEY TO DISPLAY ‘RSET’. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW:

RESETCON (Temperature Reset and Demand Limit)

ITEM DESCRIPTION STATUS UNITS VALUE

CTRL

Control Method 0 = Switch

1 = 7 day sched. 2 = Occupancy 3 = CCN

CCNA

CCN Address 1 to 239

CCNB

CCN Bus Number 0 to 239

BAUD

CCN Baud Rate 1 = 240

2 = 480 3 = 9600 4 = 19,200 5 = 38,400

LOAD

Loading Sequence Select 1 = Equal loading

2 = Staged loading

LLCS

Lead/Lag Circuit Select 1 = Automatic

2 = Circuit A leads 3 = Circuit B leads

LCWT

High LCW Alert Limit 2 to 60 ^F

DELY

Minutes off time 0 to 15 min.

ICE.M

Ice Mode Enable Enable/Disable

ITEM DESCRIPTION STATUS UNITS VALUE

COOLING RESET

CRST

Cooling Reset Type 0 = No Reset

1 = 4-20 mA input 2 = External temp-OAT 3 = Return fluid 4 = External temp-SPT

CRT1

No Cool Reset Temp 0 to 125 °F

CRT2

Full Cool Reset Temp 0 to 125 °F

DGRC

Degrees Cool Reset –30 to 30 ^F

HRST

Heating Reset Type 0 = No Reset

1 = 4-20 mA input 2 = External temp-OAT 3 = Return fluid 4 = External temp-SPT

HRT1

No Heat Reset Temp Not Supported °F

HRT2

Full Heat Reset Temp Not Supported °F

DGRH

Degrees Heat Reset –30 to 30 ^F

DEMAND LIMIT

DMDC

Demand Limit Select 0 = None

1 = External switch input 2 = 4-20 ma input 3 = Loadshed

DM20

Demand Limit at 20mA 0 to 100 %

SHNM

Loadshed Group Number 0 to 99

SHDL

Loadshed Demand Delta 0 to 60 %

SHTM

Maximum Loadshed Time 0 to 120 min

DLS1

Demand Limit Switch 1 0 to 100 %

DLS2

Demand Limit Switch 2 0 to 100 %

LEAD/LAG

LLEN

Lead/Lag Chiller Enable Enable/Disable

MSSL

Master/Slave Select Slave/Master

SLVA

Slave Address 0 to 239

LLBL

Lead/Lag Balance Select Enable/Disable

LLBD

Lead/Lag Balance Delta 40 to 400 hours

LLDY

Lag Start Delay 0 to 30 min

C. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY ‘RSET’. PRESS DOWN ARROW KEY TO DISPLAY ‘SLCT’. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW:

SLCT (Heating Cooling Setpoint Select)

ITEM DESCRIPTION STATUS UNITS VALUE

CLSP

HTSP

RL.S CRMP HRMP HCSW Z.GN

PRESS ESCAPE KEY SEVERAL TIMES TO GET TO THE MODE LEVEL (BLANK DISPLAY). USE THE ARROW KEYS TO SCROLL TO THE SET POINT LED. PRESS ENTER TO DISPLAY SETPOINTS. RECORD CONFIGURATION INFORMATION BELOW:

Cooling Setpoint Select 0 = Single

Heating Setpoint Select 0 = Single

Ramp Load Select Enable/Disable Cooling Ramp Loading 0.2 to 2.0 Heating Ramp Loading 0.2 to 2.0 Heat Cool Select Cool/Heat Deadband Multiplier 1.0 to 4.0

1 = Dual Switch 2 = Dual Clock 3 = 4 to 20 mA Input 4 = 4-20 mA Input 5 = External Setpoint Potentiometer

1 = Dual Switch 2 = Dual 7 day schedule 3 = Dual CCN occupancy 4 = 4-20 mA Input 5 = Setpoint Potentiometer

SETPOINT

SUB-MODE ITEM DESCRIPTION STATUS UNITS VALUE

COOL

HEAT

HEAD

CSP.1 Cooling Setpoint 1 –20 to 70 °F CSP.2 Cooling Setpoint 2 –20 to 70 °F CSP.3 Cooling Setpoint 3 –20 to 32 °F HSP.1 Heating Setpoint 1 80 to 140 °F HSP.2 Heating Setpoint 2 80 to 140 °F HD.P.A Head Pressure Setpoint A 80 to 140 °F HD.P.B Head Pressure Setpoint B 80 to 140 °F

USE ARROW/ESCAPE KEYS TO ILLUMINATE TEMPERATURES LED. PRESS ENTER TO DISPLAY ‘UNIT’. PRESS ENTER AND USE THE ARROW KEYS TO RECORD TEMPERATURES FOR T1 AND T2 BELOW. RECORD T9 AND T10 IF INSTALLED. RECORD CONDENSER ENTERING AND LEAVING FLUID TEMPERATURES IF INSTALLED. PRESS ESCAPE TO DISPLAY ‘UNIT’ AGAIN AND PRESS THE DOWN ARROW KEY TO DISPLAY ‘CIR.A’. PRESS ENTER AND USE THE ARROW KEYS TO RECORD TEMPERATURE FOR T3 (30GTN,R ONLY). USING A DC VOLTMETER, MEASURE AND RECORD THE VOLTAGE FOR EACH THERMISTOR AT THE LOCATION SHOWN. FOR MODELS WITH QUICKSET, RECORD THE TEMPERATURES ACCORDING TO THE DC VOLTAGES USING TABLES 32A-33B.

TEMPERATURE VDC BOARD LOCATION

T1 (CLWT) MBB, J8 PINS 13,14

T2 (CEWT) MBB, J8 PINS 11,12

T3 (SCT.A) MBB, J8 PINS 21,22

T9 (OAT) MBB, J8 PINS 7,8

T10 (SPT) MBB, J8 PINS 5,6

(CNDE) MBB, J8 PINS 1,2

(CNDL) MBB, J8 PINS 3,4

CL-6

CL-7

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

C. Unit Start-Up (cont)

USE ESCAPE/ARROW KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER TO DISPLAY ‘DISP’. PRESS ENTER AGAIN TO DISPLAY ‘TEST’ FOLLOWED BY ‘OFF’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ DISPLAY FLASHES. ‘PA SS ’ AND ‘WORD’ WILL FLASH IF PASSWORD NEEDS TO BE ENTERED. PRESS ENTER TO DISPLAY PASSWORD FIELD AND USE THE ENTER KEY FOR EACH OF THE FOUR PASSWORD DIGITS. USE ARROW KEYS IF PASSWORD IS OTHER THAN STANDARD. AT FLASHING ‘OFF’ DISPLAY, PRESS THE UP ARROW KEY TO DISPLAY ’ON’ AND PRESS ENTER. ALL LED SEGMENTS AND MODE LEDS WILL LIGHT UP. PRESS ESCAPE TO STOP THE TEST. PRESS ESCAPE TO RETURN TO THE ‘DISP’ DISPLAY. PRESS THE ESCAPE KEY AGAIN AND USE THE ARROW KEYS TO ILLUMINATE THE SERVICE TEST LED. PRESS ENTER TO DISPLAY ‘TEST’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ FLASHES. PRESS THE UP ARROW KEY AND ENTER TO ENABLE THE MANUAL MODE. PRESS ESCAPE AND DISPLAY NOW SAYS ‘TEST’ ‘ON’.

PRESS THE DOWN ARROW TO DISPLAY ‘OUTS’. PRESS THE ENTER KEY TO DISPLAY ‘LLS.A’. PRESS THE ENTER KEY TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ FLASHES. PRESS THE UP ARROW KEY AND ENTER TO TURN THE OUTPUT ON. PRESS ENTER SO THE ‘ON’ DISPLAY FLASHES, PRESS THE DOWN ARROW KEY AND THEN ENTER TO TURN THE OUTPUT OFF. OUTPUTS WILL ALSO BE TURNED OFF OR SENT TO 0% WHEN ANOTHER OUTPUT IS TURNED ON. CHECK OFF THE FOLLOWING THAT APPLY AFTER BEING TESTED:

USE ESCAPE KEY TO RETURN TO ‘OUTS’ DISPLAY. PRESS DOWN ARROW TO DISPLAY ‘COMP’. PRESS ENTER KEY TO DISPLAY ‘CC.A1’. NOTE THAT UNLOADERS AND HOT GAS BYPASS SOLENOIDS CAN BE TESTED BOTH WITH AND WITHOUT COMPRESSOR(S) RUNNING. MAKE SURE ALL SERVICE VALVES ARE OPEN AND COOLER/CONDENSER PUMPS HAVE BEEN TURNED ON BEFORE STARTING COMPRESSORS. CHECK OFF EACH ITEM AFTER SUCCESSFUL TEST. THE CONTROL WILL ONLY START ONE COMPRESSOR PER MINUTE. WHEN AT THE DESIRED ITEM, PRESS THE ENTER KEY TWICE TO MAKE THE ‘OFF’ FLASH. PRESS THE UP ARROW KEY AND ENTER TO TURN THE OUTPUT ON.

CHECK AND ADJUST SUPERHEAT AS REQUIRED.

LLS.A N/A EXV.A

LLS.B N/A EXV.B

FAN1 FAN2

FAN3 FAN4

CLR.P (TB5 — 10,12) CND.P N/A

RMT.A (TB5 — 11,12)

CC.A1 CC.A2

CC.A3 CC.A4

UL.A1 UL.A2

HGBP

CC.B1 CC.B2

CC.B3 CC.B4

UL.B1 UL.B2

All Units:

MEASURE THE FOLLOWING (MEASURE WHILE MACHINE IS IN STABLE OPERATING CONDITION):

CIRCUIT A CIRCUIT B DISCHARGE PRESSURE SUCTION PRESSURE OIL PRESSURE DISCHARGE LINE TEMP SUCTION LINE TEMP SATURATED COND TEMP (T3/T4) SATURATED SUCT TEMP (T5/T6) SUCTION GAS TEMP (T7/T8) COOLER ENT FLUID (T2) COOLER LVG FLUID (T1)

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

Book 2 Ta b 5c

PC 903 Catalog No. 563-025 Printed in U.S.A. Form 30GTN-3T Pg CL-8 3-00 Replaces: 30GTN-2T

Carrier Air Conditioner Operation And Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual