• 040-110, 130 (60 Hz) UNITS
(And Associated Modular Units)
• 130 (50 Hz), 150-210 UNITS
(And Associated Modular Units)
FIELD WIRING .............................69,70
REPLACING DEFECTIVE PROCESSOR
MODULE (PSIO) ..........................70
Installation .................................70
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903Catalog No. 563-079Printed in U.S.A.Form 30GN-3TPg 17-95Replaces: 30G-1T
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can
be hazardous due to system pressures, electrical components, and equipment location (roof, elevatedstructures,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 ontags, stickers, and labelsattached 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.
GENERAL
IMPORTANT: This publication contains controls, operation and troubleshooting data for 30GN040-420
Flotronic™ II chillers.
Circuits are identified as circuitsAand B, and compressors are identified as A1,A2, etc. in circuit A, and
B1, B2, etc. in circuit B.
Use this guide in conjunction with separate Installation Instructions booklet packaged with the unit.
The 30G Series standard Flotronic II chillers feature
microprocessor-based electronic controls and an electronic
expansion valve (EXV) in each refrigeration circuit.
NOTE: The 30GN040 and 045 chillers with a factoryinstalled brine option have thermal expansion valves (TXV)
instead of the EXV.
Unit sizes 230-420 are modular units which are shipped
as separate sections (modulesAand B). Installation instructions specific to these units are shipped inside the individual
modules. See Table 1 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.
The Flotronic II control system cycles compressor unloaders and/or compressors to maintain the selected leaving
fluid temperature set point. It automatically positions theEXV
to maintain the specified refrigerant superheat entering the
compressor cylinders. It also cycles condenser fans on and
off to maintain suitable head pressure for each circuit. Safeties are continuously monitored to prevent the unit from operating under unsafe conditions. A scheduling function, programmed by the user, controls the unit occupied/unoccupied
schedule. The control also operates a test program that allows the operator to check output signals and ensure components are operable.
The control system consists ofaprocessor module (PSIO),
a low-voltage relay module (DSIO-LV), 2 EXVs, an EXV
driver module (DSIO-EXV), a 6-pack relay board, a keypad
and display module (also called HSIO or LID), thermistors,
and transducers to provide inputs to the microprocessor. A
standard options module (SIO) is used to provide additional
functions. See Fig. 1 for a typical 30GN Control Panel.
MAJOR SYSTEM COMPONENTS
Processor Module —
ating software and controls the operation of the machine. It
continuously monitors information received from the various transducers and thermistors and communicates with the
relay modules and 6-pack relay board to increase or decrease the active stages of capacity. The processor module
This module contains the oper-
2
COMM 3 PWR
POINT NUMBER
OF
FIRST CHANNEL
COMM 1
PWR
COMM 3
S1
S2
XX
XX
STAT EXPN
HIST CLR SCHD
SRVCSET
TESTENTR
STATUS
COMM
J4J4
789
456
123
–
0•
STATUS
J5
COMM
LVEXV
FUSE 1
S
U
E
F
F
E
U
S
S
U
E
F
FUSE 2
GFI - CO
( 5 AMP MAX )
LOCAL/
ENABLE
STOP
CCN
CB5
CB6
12
3+
5VDC
HK35AA002
Potter & Brumfield
CZ770
SW1
FUSE 3
30GT510568 –
4-
EQUIP GND
99NA505322 D
LEGEND
CCN — Carrier Comfort Network
TB— Terminal Block
Fig. 1 — 30GN Control Panel (040-110 Unit Shown)
3
also controls the EXV driver module (as appropriate), commanding it to open or close each EXV in order to maintain
the proper superheat entering thecylinders of each lead compressor.Information istransmittedbetweentheprocessormodule and relay module, the EXV driver module, and the keypad and display module through a 3-wire communications
bus. The options module is also connected to the communications bus.
For the Flotronic™ II chillers,the processor monitors system pressure by means of 6 transducers, 3 in each lead compressor.Compressorsuctionpressure, discharge pressure, and
oil pressure are sensed. If the processor senses high discharge pressure or low suction pressure,it immediately shuts
down all compressors in the affected circuit. During operation, if low oil pressure is sensed for longer than one minute,
all compressors in the affected circuit are shut down. At startup, the oil pressure signal is ignored for 2 minutes. If shutdown occurs due to any of these pressure faults, the circuit
is locked out and the appropriate fault code is displayed.
Low-Voltage Relay Module — This module closes
contacts to energize compressor unloaders and/or compressors. It also senses the status of the safeties for all compressors and transmits this information to the processor.
Electronic Expansion Valve Module (If So
Equipped)—
cessor and operates the electronic expansion valves.
This module receives signals fromthe pro-
Options Module — This module allows the use of Flo-
tronic II features such as dual set point, remote reset, demand limit, hot gas bypass, and accessory unloaders. The
options module also allows for reset and demand limit to be
activated from a remote 4-20 mA signal. The options module is installed at the factory.
Keypad andDisplay Module (Also Called HSIO
or LID) —
tion keys, 5 operative keys, 12 numeric keys, and an alphanumeric 8-character LCD (liquid crystal display). Key usage is explained in Accessing Functions and Subfunctions
section on page 24.
This device consists of a keypad with 6 func-
Control Switch — Control of the chiller is defined by
the position of the LOCAL/ENABLE-STOP-CCN switch.
This is a 3-position manual switch that allows the chiller to
be put under the control of its own FlotronicIIcontrols,manually stopped, or put under the control of a Carrier Comfort
Network (CCN). Switch allows unit operation as shown in
Table 2.
In the LOCAL/ENABLE position, the chiller is under local control and responds to the scheduling configuration and
set point data input at its own local interface device (keypad
and display module).
Table 2 — LOCAL/ENABLE-STOP-CCN
Switch Positions and Operation
SWITCH
POSITION
STOPUnit Cannot Run Read/WriteRead Only
LOCAL/ENABLE Unit Can RunRead/Limited Write Read Only
CCN Stop —Unit Cannot Run Read OnlyRead/Write
Run —Unit Can RunRead Only
UNIT
OPERATION
CONFIGURATION AND
SET POINT CONTROL
Keypad ControlCCN Control
Read/Limited
Write
In the CCN position, the chiller is under remote control
and responds only to CCN network commands. The occupied/
unoccupied conditions are defined by the network. All keypad and display functions can be read at the chiller regardless of position of the switch.
CCN run or stop condition is established by a command
from the CCN network. It is not possible to force outputs
from the CCN network, except that an emergency stop command shuts down the chiller immediately and causes ‘ ‘ALARM
52’’ to be displayed.
Electronic Expansion Valve (EXV) — The micro-
processor controls the EXV (if so equipped) throughtheEXV
driver module. Inside the expansion valve is a linear actuator stepper motor.
The lead compressor in each circuit has a thermistor and
a pressure transducer located in the suction manifold after
the compressor motor. The thermistor measures the temperature of the superheated gas entering the compressor cylinders.Thepressuretransducermeasurestherefrigerant pressure
in the suction manifold. The microprocessor converts the pressure reading to a saturated temperature. The difference between the temperature of the superheated gas and the saturation temperature is the superheat.Themicroprocessorcontrols
the position of the electronic expansion valve stepper motor
to maintain 30 F (17 C) superheat.
At initial unit start-up, the EXV position is at zero. After
that, the microprocessor keeps accurate track of the valve
position in order to usethis information as input for theother
control functions. The control monitors the superheat and
the rate of change of superheat to control the position of the
valve. The valve stroke is very large, which results in very
accurate control of the superheat.
Thermostatic Expansion Valves(TXV) — Model
30GN040 and 045 units with factory-installed brine option
are equipped with conventional thermostatic expansion valves
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.
4
The TXV is set at the factory to maintain approximately
8 to 12° F (4.4to6.7° C) suction superheat leaving thecooler
by monitoring the proper amount of refrigerant intothecooler.
All TXVs are adjustable, but should not be adjusted unlessabsolutely necessary.When TXVis used,thermistorsT7 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.
Sensors— The Flotronic™ II chillercontrolsystemgath-
ers information from sensors to control the operation of the
chiller. The units use 6 standard pressure transducers and
4 standard thermistors to monitor system pressures and temperatures at various points within the chiller. Sensors are listed
in Table 3.
Table 3 — Thermistor and Transducer Locations
Fig. 2 — Compressor Protection Control Module
SensorLocation
T1Cooler Leaving Fluid Temp
T2Cooler Entering Fluid Temp
T7Compressor Suction Gas Temp Circuit A
T8Compressor Suction Gas Temp Circuit B
T10Remote Temperature Sensor (Accessory)
110, and 230B-315B, has its own CPCS as standard equipment. See Fig. 2. All 30GN040-060 and 070 (60 Hz) units
feature the CPCS as an accessory, and CR (control relay) as
standard equipment. The 30GN130-210 and associated modular units havea CR as standard equipment. The CPCS or CR
is used tocontrol and protect the compressors and crankcase
heaters. The CPCS provides the following functions:
• compressor contactor control
• crankcase heater control
• compressor ground current protection
• status communication to processor board
• high-pressure protection
The CR provides all of the same functions as the CPCS
with the exception of compressor ground current protection.
Ground current protection is accomplished by using a CGF
(compressor ground fault module) in conjunction with the
CR. The CGF (See Fig. 3) provides the same ground fault
function as the CPCS for units where the CPCS is not
utilized.
One large relay is located on the CPCS board. This relay
(or CR) controls the crankcase heater and compressor
contactor. The CPCS 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 notoperatingproperly 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-
Fig. 3 — Compressor Ground Fault Module
ground of any compressor winding exceeds 2.5 amps. If this
condition occurs, the CPCS module shuts down the
compressor.
A high-pressure switch with a trip pressure of 426
± 7 psig (2936 ± 48 kPa), is wired in series with the CPCS.
If this switch opens during operation, the compressor stops
and the failure is detected by the processor when the signal
contacts open. The compressor islocked off. If the leadcompressor in either circuit is shut down by the high-pressure
switch or ground current protector, all compressors in the
circuit are locked off.
OPERATION DATA
Capacity Control —
compressor to give capacity control steps as shown in
Tables 4A-4C. The unit controls leaving chilled fluid temperature. Entering fluid temperature is used by the microprocessor in determining the optimum time to add or subtract steps of capacity, but is not a control set point.
The chilled fluid temperature set point can be automatically reset by the return temperature reset or space and
outdoor-air temperature reset features. It can also be reset
from an external 4 to 20 mA signal, or from a network
signal.
The operating sequences shown are some of many possible loading sequences for the control of the leaving fluid
temperature. If a circuit has more unloaders than another,
that circuit will always be the lead circuit.