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Carrier 040-420, Installation And Service Manual

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Carrier 040-420 Installation And Service Manual Download Page 59

A I R
VENT

LEAVING

W A T E R / B R I N E
THERMISTOR 

C O O L E R

ENTERING

F L U I D

W A T E R / B R I N E

B A F F L E

C O N N E C T I O N

SUCTION

C O N N E C T I O N

C O N N E C T I O N

D R A I N

L E A V I N G

W A T E R / B R I N E

C O N N E C T I O N

C O O L E R
TUBE
(TYPICAL)

ENTERING

W A T E R / B R I N E
T H E R M I S T O R

Fig. 14 

Thermistor Locations

(Circuits A and B, Lead Compressor Only)

COUPLING
A C C E S S O R Y

F E R R U L E S
INSIDE

JACKETED

JACKETED

S E N S O R

T H E R M I S T O R

C A B L E

TUBE

W E L L

I

NOTE: BEND 

FOR INSERTION

(76)

 6)

 (4 8) DIA

 (6.4)

OD COUPLING

INTO WELL

WATER-SIDE TEMPERATURE SENSOR (Tl, T2, 

 ALL UNITS),

(T7, T8   225, 250, 280)

REFRIGERANT TEMPERATURE SENSOR (T7, T8   040-210 AND

ASSOCIATED MODULAR UNITS)

Fig. 15 

Thermistors

59

Summary of Contents for 040-420

Page 1: ...ing all electrical components Page Restart Procedure 48 l POWER FAILURE EXTERNAL TO THE UNIT Alarm Codes 49 Compressor Alarm Circuit e 50 Electronic Expansion Valve 56 l EXV OPERATION l CHECKOUT PROCEDURE Thermistors 60 a LOCATION l THERMISTOR REPLACEMENT Tl T2 T7 T8 Compressor and Cooler Pressure Transducers 60 l TROUBLESHOOTING l TRANSDUCER REPLACEMENT Control Modules 64 l PROCESSOR MODULE PSIO ...

Page 2: ...led accessory on the 30GT Flo tronic II units See Fig 1 MAJOR SYSTEM COMPONENTS Processor Module This module contains the oper ating software and controls the operation of the machine It continuously monitors information received from the vari ous transducers and thermistors and communicates with the relay modules and pack relay board to increase or de crease the active stages of capacity The proc...

Page 3: ...ier Comfort Network TB 1 erminal Block ELECTRONIC EXPANSION VALVES DRIVER MODULE DSIO EXV L O W V O L T A G E R E L A Y M O D U L E DsroiLv d TB 7 g PACK I RELAY BOARD B rt EFUCER SOURCE PSI C O O L E R I RELAY B TB 3 FIELD ZEol CONNECl iEA1 rlON ER Fig 1 30GN Control Panel 040 110 240B 270B Unit Shown ...

Page 4: ...ous points within the chiller Sensors are listed in Table 3 Table 3 Thermistor and Transducer Locations Sensor T Ti TIO Sensor D P T A S P T A O P T A DPT I3 S P T B O P T B THERMISTORS Location Cooler Leaving Water Temp Cooler Entering Water Temp Compressor Suction Gas Temp Circuit A Compressor Suction Gas Temp Circuit B Remote Temperature Sensor Accessory PFIESSURETRANSDUCERS Location Compressor...

Page 5: ...temperature If a circuit has more unloaders than another that circuit will always be the lead circuit Table 4A Capacity Control Steps 040 070 Compressors LOADING SEQUENCE B Displacement tAppro 2 5 5 0 1 Bl AIBlil Al Bl 4 Al Bl El 5 1 Al Bl 1 0 0 1 040 50 Hz o y y 5 3 4 i i 1 0 0 045 50 Hz 1 050f Hz i A l Al 1 Al Bl 4 Al Bl Bl A l Al sl Al Bl UNIT 3 0 G N ft Hr y yy 040 60 Hz 045 60 Hz AIt 040 50 H...

Page 6: ...0fc Hz 060 50 Hz 07Odpto Hz 060 50 Hz oypg Unloaded compressor j Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded Compressors Displacement tApw0 Compressors Al Al B1 Al k Al A l Al Bl Al Bl A t Vg B l Al l Al sl Al Bl Al sl yi A p 1 8 Bs lt t Al Bl z A t g 8600 d i t Al sl 1 0 0 Al Bi Al Al Bl Al i31 Al Bl Al zi Al Bl 6 6 Al 8 3 Al i31 Al I 1 0 0 Ai Bl A AV ...

Page 7: ...2 6 5 i 1 0 0 Compressors Al 61 1 0 0 GHz Al A FBI Al k Al l A2 Bl Al A2 B1 Al B l Al Al sl Al Bl Al A2 Bl Al A2 B1 Al l oy ya Al fB1 Al Bl Al A2 Bl Al A2 Bl Al A2 Bl Ai A2 Bl 1 5 5 7 ii ylf t Al l Al Bt Al A2 Bl Al A2 B1 A Al Bl Al A2 Bl Al A2 Bl 070 50 Hz Al t Bl Unloaded compressor tCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded ...

Page 8: ...l A2 Bl Al t t Ai Al yBl Al Bl Al Bl Al Bl Al A2 B1 080 60 Hz Aly Blv Al k2 Bl A l Al Al 1 Al Bl Al A2 Bl Al A2 Bl Al A2 Bl Al t t A l Al Bl AWtSg Bl A Al Bl Al Bl Al A2 Bi Al A2 Bl Al A2 B1 08Aqy y Al Bl Al A2 Bl l A4l pi Al A2 Bl B1 t t Bl AIB l Ai 61 Al A2 Bl A A Wt Ai A Bl y f AIBlk Ai Bl Al A2 B1 d A B lt t Ai Ai Bi A Al Bl AJ t Al Bl Al A2 Bl AAit bA l Al A2 Bl 080 SO Hz Aif 6if Unloaded com...

Page 9: ... Al tT A2 i31 B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl Al A2 Bl Al tt A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 A l Al 1 Al Bl Al Bi Al A2 Bl Al A2 Bl Al A2 Bl Al A2 Bl B2 Al A2 B1 B2 Al k2 Bi B2 A Al Bl Al Bl Al Bl Al tt A2 81 l Al tt AP Bl Al A2 61 Al A2 Bl Altt A2 Bl B2 Al tt A2 Bi B2 Al A2 Bl B2 Al A2 61 B2 LOADING 1 Displacement Approx ii 2 r3 1 0 0 8 0 8 2 9 1 QUENCE B Compressors Bl Al Al Bl Al Bl Al Bl ...

Page 10: ...A2 Bl B2 Al A2 Bl B2 090 50 Hz Alt Bly A Al Bl Al I Al Bl Al tt AZBl tt Altt A2 Bl AlTT A2 Bl Al A2 Bl Al A2 Bl Al tt A2 Bl B2 Al TT A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al Al Al 61 Al Bl Al A2 Bl J p Al A2 B2 Al A2 Bl B2 Al A2 Bl B2 Alt AltAt Bl Al Al Bl Al Tt A2 Bl Al Tt A2 Bl Al A2 61 Al A2 Bt Al tt A2 Bl B2 Al Tt A2 Bl B2 Al A2 B1 B2 090 50 Hz Al t Bl t 100 2408 100 24OB 270B 60 Hz Alt Blt Al A2 i...

Page 11: ...i 32 Al A2 B1 B2 Al A l Al Bl A1 Bl Al A2 Bl Al A2 Bl Al A2 Bl Al A2 Bl B2 Al A2 81 B2 Al A2 1 82 Al t t A l Unloaded compressor tCompressor unloader standard Compressor unloader accessory tfTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing LOADING SEQUENCE A r LOADING Displacement Apex 8 i A 20 7 E 100 EQUENCE B Compressors Bitt Bl Al B tt Ai ...

Page 12: ... Al Bl Al Bl Al A2 Bl Al l A2 Bl Al A2 61 Al A2 Bl B2 Al A2 Bl B2 Al A2Bl B2 Unloaded compressor TCompressor unloader standard Compressor unloader accessory TtTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing r LOADING SEQUENCE B Displacement Amrox 100 A Ai Bl B2 Compressors 81 Al51 Al Bl Al Bl gg Ai Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 1 ...

Page 13: ... compressor TCompressor unloader standard Compressor unloader accessory TTTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing SEQUENCE A Compressors A2 p l Al Bl A tkA2 i3BI AleA2 Bl Al tf A2 Bl B2 Al A2 Bl B2 Al AZ Bi B2 T LOADING Displacement Arwox a QUENCE B Compressors Be lt t F t Al Bl A W 3 Ai Bi B2 Al A2 Bl tt B2 Al A2 Bf 82 Al A2 Bl B2 B ...

Page 14: ...A2 Bl Al A2 Bl Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bi B2 r LOAD11 Displacement VVwr ox i z 2 K 100 EQUENCE B Compressors Bl Al Al k Al Bl Al l Bl l B2 Al Bi B2 Al Bl B2 Al A2 Bl B2 Al A2 Bf B2 Al A2 Bl B2 BJ fJ y Ai Bi Al Bl Al Bl tt B2 A B t 2 Al Bl k2 Al A2 Bl tt B2 Al A2 Bl tt B2 Al A2 Bl B2 Al A2 Bl B2 BB Al Al Bl Al t t 41 tt B2 Al Bl tt B2 A BB 2 Al Bl ...

Page 15: ...Al l A2 Bl Al A2 Bi Al A2 Bil B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 81 B2 Al A2 A3 Bl B2 Unloaded compressor tCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing T LOADING SEQUENCE B Displacement Awrox Compressors Bitt Bi AIB Al Bl Al Bl tt B2 Al Bl tt B2 Al Bl B2 Al Bl B2 ...

Page 16: ... Bl B2 y Al Bl Al tt Bl Al Bi Al Bl Al tt A2 Bl Al A2 Bl Al A2 81 Al tt A2 Bl B2 Al tt A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Altt A2 A3 Bi B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Ai A l Al Bl Al Bl Ai A2 Bl Al A2 Bl Al A2 Bl Ai A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 B1 B2 150 60 Hz Aly Blt B l Al q Al sl Al Bl Al Bl B2 Al Bl B2 Al Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A...

Page 17: ...l Bl B2 Al Bl B2 Al Bl B2 Al A2 Bil B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 83 Al A2 Bl B2 B3 Al A2 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 83 Al Bl Al A2 Bl Al A2 Bl Al A2 Bl Al A2 Bl B2 Al A2 Bi B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 83 170 270A 300B 330 fTt Hz Al Ai A Bl 82 83 Al A2 A3 Bl B2 B3 A AltyBl A tttt Al kl Al tt A2 Bl y t3g Al i2 ...

Page 18: ...loader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing r LOADING SEQUENCE B 6 Compressors yp q Ai Bi Al Bl Al BItt B2 Ai B lttb 2 Al Bl BP Al A2 Bi tt B2 Al A2 Bl tt B2 Al A2 Bl l B2 Al A2 Bl B2 Al A2 Bi ft B2 B3 Al A2 Bltt B2 B3 Al A2 Bl B2 B3 Al A2 Bl B2 B3 Al A2 A3 Bl tt B2 B3 Al A2 A3 Bl tt B2 63 A...

Page 19: ... A2 A3 Bl B2 Al A2 A3 Bl B2 Altt A2 A3 Bltt B2 B3 Altt A2 A3 Bl B2 B3 Al tt A2 A3 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 Bi BZ B3 Unloaded compressor j Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 1 9 r LOAD11 Displacement APP x i SEQUENCE B Compressors I31 Al Bltt i Al Bl Al BlTj B...

Page 20: ... A2 B2 Al A2 Bl B2 Al l A2 A3 Bi B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 B3 A1B Bl Al I B2 Al A2 Bl B2 Al A2 B1 B2 B3 Al A2 d3 2 B3 190 36OA B 39oEpt Hz I 190 36OA B 39 jfj Bl AIBf Ai Bl Al Bl B2 Al Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 B3 Al A2 Bl B2 B3 Al A2 A3 Bl B2 83 Al A2 A3 Bl B2 B3 Bl Al l Al i31 Al Bl Al Bl B2 Al Bl B2 Al Bl B2 Al A2 Bi B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl l...

Page 21: ...B2 B3 Al A2 A3 A4 Bl B2 B3 Bl AIBt Ai Bl Al Bl B2 Al Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 B3 Al A2 Bl B2 B3 Al A A Bi l 82 83 Al A2 A3 Bl B2 B3 Bl A Al i31 Al Bl Al l Bl B2 BB g Al i2 B B2 Al A2 Bi B2 Al A2 Bi B2 Al A2 Bl B2 83 Al A2 Bl B2 B3 AI A2 Bl B2 B3 Al A2 A3 Bl B2 B3 AI A2 A3 Bl B2 B3 190 36OA 39 8514w 100 190 36OA J 8 1 y 1 4 AK1 Al 1 B2 Al A2 Bl B2 Al A2 Bl B2 B3 Al A2 A3 Bl B2 B3 A...

Page 22: ...l A2 Bl Al A2 Bl Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 B3 Al A2 A3 Bi B2 83 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 210 390A 420 U f 5 Hz 210 390A 42Ofy w Bl AIB Al Bl Al Bl B2 Al Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 B3 Al A2 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 A4 B1 B2 B3 Al A2 A3 A4 Bl B2 B3 B l Al Al Bl 210 390A 42Of gw Al Al Al Bl Al Bl A...

Page 23: ...3 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bi B2 B3 84 Al Ali Bl Al Bl Al A2 Bl Al A2 Bl At A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 B4 Al A2 A3 A4 Bl B2 B3 84 Unloaded compressor TCompressor unloader standard Compressor unloader accessory TtTwo unloaders both unloaded NOTE These capacity ...

Page 24: ...A4 Bl B2 B3 B4 A l Al Al bl l Al Bl Al A2 Bl Al A2 01 Al A2 Bl Al l A2 Bl B2 Al A2 Bl B2 Al A2 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 Al A2 A3 Bl B2 B3 Al A2 A3 Bl B2 63 Al A2 A3 Bl B2 83 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 B3 B4 Al A2 A3 A4 Bl B2 B3 B4 Al A2 A3 A4 Bl B2 63 84 l LOAC 4G SEQUENCE B Compressors Bl Al B Al Bl Al Bl Al A2 Bl Al ...

Page 25: ...2 B3 Al A2 A3 Bi B2 B3 Al A2 A3 Bl B2 83 Al A2 A3 A4 Bl B2 B3 Al A2 A3 A4 Bl B2 83 Al A2 A3 A4 Bl B2 B3 Ai A2 A3 A4 Bl B2 B3 B4 Ai A2 A3 A4 Bl B2 B3 B4 Ai A2 A3 A4 Bl B2 B3 B4 Unloaded compressor Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing r LOADING SEQUENCE B Compressors AK1 Al...

Page 26: ... 95 F 35 C to prevent excessive discharge pressure during pulldown See Table 5 for condenser fan sequence of operation Table 5 Condenser Fan Sequence FAN ARRANGEMENT FAN NUMBER S FAN CONTACTOR WI CONTROLLED BY 30GN040 050 I I 1 FC Al 2 FC Bi 3 FC A2 Compressor Al Compressor Bl First Stage Microprocessor 4 FGB2 I Second Stage MicrODrOceSSOr 30GN060 070 I FC Al I Compressor Al Compressor Bi First St...

Page 27: ...FC 7 Microprocessor i Control box k tPower box w Pumpout When the lead compressor in each circuit saturated suction temperature is below 15 F 26 C At is started or stopped that circuit goes through a pumpout this point the EXV starts to open and continues to open cycle to purge the cooler and refrigerant suction lines of gradually to provide a controlled start up to prevent liquid refrigerant floo...

Page 28: ...s alarms 0 SRVC SERVICE For entering specific unit configura tion information El EST TEST For checking inputs and outputs for proper operation El CHD SCHEDULE For entering occupied unoccupied schedules for unit operation q S E T SET POINT For entering operating set points and day time information OPERATIVE K E Y S USE El EXPN EXPAND For displaying a non abbreviated ex pansion of the display El CLA...

Page 29: ... E S E T function oup To move to other elements scroll up or down using arrow keys NOTE These displays do not show if control is not configured for reset El 4 CRST2xx c l CREF2xx l i l CRSTi xx I cl 4 CREFlxx When the last element in a subfunction has been dis played the first element is repeated c l R E S E T c l CRST2xx To move to next subfunction it is not necessary to use subfunction number Pr...

Page 30: ...s Tripped Alarms Number of Modes in Effect Displays Mode in Effect Capacity Staging Information Number of Requested Stages Percent of Total Capacity Percent Circuit A Capacity Percent Circuit 6 Capacity Demand Limit Set Point Load Limit Set Point Circuit A Compressor Relay Status Circuit B Compressor Relay Status Load Unload Factor for Compressors Factor 1 Unloader Factor 0 6 6 Fluid Set Point Inf...

Page 31: ...Saturated Suction Temperature Compressor Bl Suction Temperature Circuit B Suction Superheat Reset Temperature Refrigerant System Pressure psig Circuit A Discharge Pressure Circuit A Suction Pressure Circuit A Discharge Suction Circuit A Oil Pressure Differential Circuit B Discharge Pressure Circuit 8 Suction Pressure Circuit B Discharge Suction Circuit B Oil Pressure Differential Status of Analog ...

Page 32: ... Percent To use Test function LOCAL ENABLE STOP CCN switch must be in STOP position To operate a test scroll to desired test Then press m to start test Press m to stop test SUBFUNCTION KEYPAD ENTRY 1 OUTPUTS DISPLAY OUTPUTS 8 8 8 8 8 8 8 8 ALMR X FRAI X FRA2 X FRBl X FRl32 X CHWP X EXVA X E X V B X HGBRA X HGBRB X M M A X M M B X COMMENT Test Outputs Display Check Energize Alarm Relay K3 Energize ...

Page 33: ...Energize Unloader A2T Energize Unloader Bl t Energize Unloader B2t The Schedule function key El CHD is used to configure the occupancy schedule The clock select subfunction can be used for unoccupied shutdown or unoccupied setback depending on the cooling set point control configuration The Schedule function described is for clock 1 which is the internal clock Password required for all subfunction...

Page 34: ...days Holiday Date 1 DAT MM DD NN Holiday Date 30 For example To enter July 4th holiday press 07 04 01 q Display shows Jul 04 For further information on the Schedule function and its operation refer to Schedule Function section on page 45 SERVICE To view and modify configurations the password must be entered under the log on subfunction SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 LOG ON AND LOG OFF ...

Page 35: ...de 5 Configuration Code 6 FLD CFG EN0 X B U S X BAUD X FLUID X UNITS X LANG X NULA X NULB X HGB X S E Q T X SEQF X OPS x HEADM X M M X CSPTYP X CRTYP X E R T Y P X L S T Y P X RAMP X LOCK X CPC x Adjustable Field Configuration CCN Element Address CCN Bus Number CCN Baud Rate Cooler Fluid Select Display Unit Select Display Language Select No Circuit A Unloaders No Circuit B Unloaders Hot Gas Bypass...

Page 36: ...CSPl x CSP2 x H S P A X H S P B X CRAMP X R E S E T CRST2 X CREF2 X CRSTI X CREFI X DEMAND DLSl X DLS2 X DMAX X RMAX X DMIN X RMIN X SHED X DATE TIME DAY HR MIN MM DD YR Jnit Set Point 1 SET POINTS Chiller Fluid Set Point 1 Chiller Fluid Set Point 2 Head Pressure Set Point Circuit A Head Pressure Set Point Circuit B Pulldown Limit t Reset Set Points Cooling Max Reset Max Reset Occurs at X mA or De...

Page 37: ...water outdoor air temperature or space temperature M O D E 7 Demand limit is in effect This indicates that ca pacity of unit is being limited by demand limit con trol option Because of this limitation unit may not be able to produce the desired leaving water temperature Load limit is in effect This indicates that capacity of a system of units is being limited by a CCN load shed command Due to this...

Page 38: ...able 9 for the order of readouts flH Pressure This subfunction displays suction discharge and net oil pressure at lead compressor of each circuit of unit m H Analog Inputs This subfunction displays analog inputs if any Enter m Fi then use the q The transducer supply voltage 4 20 mA reset signal can be dis played This is useful for problem diagnosis prior to using the test function m bi I n p u t s...

Page 39: ...d in the schedule function then when q is pressed the display shows the modified chilled water set point c The final value displayed when the q is pressed is the cooling ramp loading rate This is the maxi mum rate at which the leaving chilled water is al lowed to drop and can be field set from 0 2 to 2 0 F 11 to 1 1 C minute This value is not displayed unless the function is enabled see Adjustable...

Page 40: ...e based on return water temperature the desired reset range is to be 2 to 10 F 1 to 5 5 C and full load is a 10 F 5 5 C drop across the cooler See Fig 4 Activating reset based on external temperature or 4 20 mA signal is done the same way except the reference set point range is 20 to 125 F 6 6 to 5 1 6 C or 4 to 20 mA depending on which method was selected at the field configuration step IO 9 18 8...

Page 41: ...accept demand limit signals from a build ing load shedding control The demand limit function pro vides for 2 capacity steps The keypad is used to set the 2 demand limit set points which range from 100 to 0 of capacity Capacity steps are controlled by 2 field supplied relay contacts connected to the designated chiller terminals See Field Wiring section on page 7 1 and Fig 6 10 Y 8 2 I O Example 6 C...

Page 42: ... first stage demand limit contact puts unit on the first demand limit level that is the unit does not exceed the percentage of capacity entered as demand limit stage 1 Closing con tacts on second stage demand limit relay prevents unit from exceeding capacity entered as demand limit stage 2 The demand limit stage that is set to the lowest demand takes priority if both demand limit inputs are closed...

Page 43: ...SPONSE COMMENTS FLD CFG Field configuration sub function of servicefunction E R T Y P 0 I Scroll past other elements in the subfunction L S T Y P 1 LSTYP 0 Loadshed is enabled for 2 stage switch control Loadshed is now disabled KEYPAD ENTRY ppiq 0 t Cl q n ENTR MH DISPLAY RESPONSE FLD CFG E R T Y P 0 LSTYP 0 LSTYP 2 DEMAND D M A X 1 0 0 D M A X 9 0 RMAX 20 R M A X 1 5 DMIN 0 DMIN 20 RMIN 4 RMlN 6 ...

Page 44: ...COMMENTS Time display sub function of set point function Current setting is Monday 4 00 p m New setting of Tuesday I 05 p m is entered and displayed Current date is Jan 1 1990 New setting April 15 1990 is entered and displayed Factorv Configuration Codes mF allows entry into the factory configuration subfunction Under this subfunc tion there are 6 groups of configuration codes that are down loaded...

Page 45: ...rs do not run until remote chilled water pump interlock contacts are between TB6 1 and TB4 2 on 30GN040 210 and associated modular units or between TB5 1 and TB5 2 on 3OGT225 250 and 280 Flotronic units are closed and leaving chilled water temperature is above set point If a remote chilled water pump interlock is not used the first compressor starts upon a call for cooling approximately one minute...

Page 46: ...ng on a single set point schedule The sched ule is based on building occupancy with a 3 hour off peak cool down period from midnight to 3 a m following the weekend shutdown To learn how this sample schedule would be programmed see Example 9 NOTE This schedule was designed to illustrate the pro gramming of the schedule function and is not intended as a recommended schedule for chiller operation Exa...

Page 47: ...sday is now flagged yes for period 3 Check to be sure that all other days are flagged no Period 4 and 5 can be programmed in the same manner flagging Thursday and Friday yes for period 4 and Saturday yes for period 5 aFor this example periods 6 7 and 8 are not used they should be programmed OCC 00 00 UN0 00 00 NOTE When a day is flagged yes for 2 overlapping peri ods occupied time will take preced...

Page 48: ...pen contacts in any auxiliary interlock Terminals that are jumpered from factory are in series with control switch Opening the circuit between these terminals places unit in stop mode similar to moving the control switch to STOP position Unit cannot start if these contacts are open If they open while unit is running unit pumps down and stops 48 13 Cooler entering or leaving fluid thermistor failur...

Page 49: ... inoperative 4 20 mA reset input failure Normal set point used 4 20 mA demand limit failure Demand limit ignored Loss of communication with DSIO LV Unit shut down A u t o A u t o Auto Loss of communication with DSIO EXV Unit shut down Loss of communication with 4 In 4 Out module Unit shut down N o Yes No No A u t o A u t o Not used I Low refrigerant pressure circuit A Low refrigerant pressure circ...

Page 50: ...through a normal pumpout Other circuit continues to run Reset is automatic if temperature returns to the acceptable range and circuit start up follows normal sequence Cause of this fault is usually a bad thermistor wiring error or loose connection On units with transducers if the saturated suction tem perature is greater than the leaving water temperature plus 10 F 5 5 C for more than 5 minutes th...

Page 51: ... The pumpout process is terminated when saturated suc tion temperature is 10 F 5 5 C below temperature at be 51 ginning of pumpout or 10 F 5 5 C below leaving water temperature or reaches a saturated suction temperature of 15 F 26 C If appropriate saturated suction temperature is not met within 3 minutes on 2 consecutive tries circuit shuts down without pumpout Reset is manual with LOCAL ENABLE ST...

Page 52: ... 8 groups of S digit numbers that must be entered The first 4 groups must be entered under 17a s u b f u n c t i o n G r o u p s 7 and 8 must be entered under MH s u b f u n c t i o n Enter each group then press the H key Use the down arrow 0 after each group to bring up the next empty screen Unit should start after factory and field con figurations are correctly entered The usual cause of this fa...

Page 53: ...PWR GLN U LEGEND Contactor Communications Bus Compressor Protection Control Module Discharge Gas Thermostat Optional Relay Module Low Voltage l tigh Pressure Switch Low Voltage Plug Power Terminal Block Transformer Unloader Fig 1OB 24 V Safety Circuit Wiring 080 110 and Associated Modular Units TE 53 ...

Page 54: ...d Fault Module Communications Bus Compressor Contactor Relay Relay Module Low Voltage High Pressure Switch Low Voltage Plug Snubber Terminal Block Transformer Unloader Fig IOC 24 V Safety Circuit Wiring 130 210 and Associated Modular Units 54 ...

Page 55: ...Ground Fault Module C o m m o n Control Relay Discharge Gas Thermostat Optional Relay Module Low Voltage Electronic Expansion Valve High Pressure Switch Low Volta 8 e Normally losed Plug Reset Button Terminal Board Fig IOD 24 V Safety Circuit Wiring 225 250 and 280 Units 5 5 ...

Page 56: ...s to operate with up to 95 F 35 C entering water temperatures during start up and subsequent pull down O R I F I C E ASSEMBLY INSIDE PISTON SLEEVE Fig 11 Electronil c Expansion Valve EXV STEPPER DC CHECKOUT PROCEDURE Follow steps below to di agnose and correct EXV problems 1 Check EXV driver outputs Check EXV output signals at appropriate terminals on EXV driver module see Fig 12 as follows Connec...

Page 57: ...essor discharge service valves and remove any re maining refrigerant from low side of system c Remove screws holding top cover of EXV Carefully remove top cover If EXV plug was disconnected dur ing this process reconnect it after cover is removed When removing top cover be careful to avoid dam aging motor leads d Enter appropriate EXV test step for EXVA or EXVB in the outputs subfunction of the te...

Page 58: ...O R S CIRCUIT B r CIRCUIT A J FILTER I I c D R I E R LEGEND D P T Discharge Pressure Transducer ppTT Oil Pressure Transducer Suction Pressure Transducer T Thermistor Number Fig 13 Thermistor and Pressure Transducer Locations 58 ...

Page 59: ...AL ENTERING W A T E R B R I N E THERMISTOR Fig 14 Thermistor Locations Circuits A and B Lead Compressor Only COUPLING A C C E S S O R Y F E R R U L E S INSIDE JACKETED JACKETED S E N S O R THERMISTOR C A B L E TUBE WELL poi i I I AY f 1 NOTE BEND SLIGHTLY FOR INSERTION 76 4 6 3 16 4 8 DIA 114 6 4 OD COUPLING INTO WELL WATER SIDE TEMPERATURE SENSOR Tl T2 ALL UNITS T7 T8 225 250 280 REFRIGERANT TEMP...

Page 60: ...vicing To replace thermistors T7 and T8 040 210 and associated modular units Add a small amount of thermal conductive grease to ther mistor well Thermistors are friction fit thermistors which must be slipped into receiver located in the compressor pump end Pressure Transducers TWO tvpes of pressure trans ducers are used on 30G Flotronic Ii chille a low pres sure transducer and a high pressure tran...

Page 61: ... 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 146 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 VOLTAGE D R O P V 3 0 9 3 3 064 3034 3005 2977 2 947 2 917 2884 2857 2 827 2797 2766 2738 2708 2679 2 650 2622 2593 2563 2533 2505 2 476 2447 2417 2388 2360 2332 2 305 2277 2 251 2217 2189 2 162 2136 2107 2080 2053 2028 2 001 1 973 1 946 1 919 1897 1870 1 846...

Page 62: ...5 807 43 247 40 845 38 592 38 476 34 489 32 621 30 866 29 216 27 633 26 202 24 827 23 532 22313 21 163 20 079 19 058 18 094 17184 16 325 15515 14749 14026 13 342 12 696 12085 II 506 IO 959 10441 9 949 9485 9 044 8 627 8 231 7 855 7 499 7 161 6 840 6 536 6 246 5 971 5 710 5 461 5 225 5 000 4 786 4 583 4389 4 204 4 028 3 861 3 701 3 549 3 404 3 266 3134 3 008 2 888 2 773 2 663 2 559 2 459 2 363 46 4...

Page 63: ...GE ENTERING TEMPERATURE PRESSURE CYLINDERS TRANSDUCER EQUALIZER LINE OIL PRESSURE TRANSDUCER SUCTION PRESSURE TRANSDUCER SIGHT GLASS EACH COMPRESSOR Lead compressor only Fig 17 Lead Compressor Transducer and Thermistor Locations 6 3 ...

Page 64: ... SIO 4 In 4 Out Module 59 If all modules indicate communication failure check COMM plug on PSI0 module for proper seating If a good connec tion is assured and condition persists replace PSI0 module If only DSIO or SIO module indicates communication failure check COMM plug on that mode for proper seat ing If a good connection is assured and condition persists replace DSIO or SIO module All system o...

Page 65: ...ORWARD S E N S O R B U S C O N N E C T O R J8 Fig 20 Processor Module PSIO 6 5 LOW VOLTAGE RELAY MODULE DSIO Fig 21 Inputs Inputs on strip 53 are discrete inputs ON OFF When 24vat power is applied across the 2 terminals in a channel it reads as on signal Zero v reads as an off signal Outputs Terminal strips J4 and JS are internal relays whose coils are powered up and powered off by a signal from m...

Page 66: ...switch The options module is standard on 30GN040 210 and associated modular chillers and is available as a field installed accessory on 3OGT225 250 and 280 Flotronic T II chillers Remember to reconfigure the chiller for each feature se lected see Table 13 For temperature reset demand limit and dual set point desired set points must be entered through keypad and display module see Set Point Functio...

Page 67: ...alve body spring Miswired solenoid Defective capacity control valve Plugged strainer high side Stuck or damaged unloader piston or piston ring s REMEDY Reset circuit breaker Check control circuit for ground or short Replace fuse Move LOCAL ENABLE STOP CCN switch to STOP position then back to RUN or CCN position Check the controls Find cause of trip and reset breaker Check connections Check wiring ...

Page 68: ...0 0 And associated modular units Installation 1 1 1 1 1 2 3 4 1 0 4 1 Be sure all electrical disconnects are open and tagged before any work begins Inspect the package contents for any damage during shipping File a claim with the shipper if damage has occurred For ease of installation factory supplied wiring for the additional unloader is provided in the compressor harness Install the additional u...

Page 69: ... 6 y 0 0 0 0 r 1 IDS00 LWl 1 9RA 1 VI0 I I I I I I 1 I L a RED 080 110 SO SO Hz and 130 60 Hz L E G E N D ERCS Contactor Compressor Protection Control System k z ther Control Relay Terminal Block Rela Module u TL Transformer Low oltage U Unloader Fig 23 Accessory Unloader Control Wiring 69 ...

Page 70: ...so a Be sure the LOCAL ENABLE STOP CCN switch is in the STOP position b Log into the processor and enter the service func tion using the keypad and display module Type r I E The keypad LCD will display PASSWORD Enter 1 and the keypad LCD will display LOGGEDON COM HGBPR KB 1 5 C d To change the configuration type 14 H and the keypad LCD will display FLD CFG Press m until either NULA 0 or NULA I is ...

Page 71: ... 4368 k367 4 IN 4 OUT MODULE i t 1 J7 2 STAGE 1 1 L v w _ B B 0 57 3 i i I m w fl 57 6 STAGE2 1 L u J7 7 NOTE Contacts must be rated for dry circuit application capable of reliably switching a 5 vdc 1 mA to 20 mA load Fig 26A Demand Limit Two External Switch Inputs 30GN040 210 and Associated Modular Units l I I cl 4 T B 7 STAGE 1 1 L cl 5 T B 7 r e m H cl I T B 7 STAGE2 1 L m _ cl 2 T B 7 TB Termi...

Page 72: ...emperature EXTERNAL POWER FIELD SUPPLIED LOOP ISOLATOR J7 13 37 14 30GN040 210 AND ASSOCIATED MODULAR UNlTS FIELD SUPPLIED u 3 I I I I B11 LOOP ISOLATOR El 4 l E 11 30GT225 250 280 FLOTRONIC II UNITS TB Terminal Block NOTE The 30GT225 250 280 Flotronic II units require the acces sory options module package for this feature Fig 30 Remote Reset from 4 20 mA Signal Externally Powered a3 73 t 4 2omA S...

Page 73: ...r corner post The proper software and unit configuration data is factory installed by Carrier in the replacement mod ule Therefore when ordering a replacement processor mod ule PSIO specify complete replacement part number full unit model number and serial number If these numbers are not provided the replacement module order is config ured instead as a generic Flotronic 11 replacement mod ule This...

Page 74: ...splay becomes blank and reconfigures itself after pressing the H key while displaying CODE 6 The display returns in ap proximately 15 seconds NOTE Codes with leading zeros in the configuration will be displayed starting with the first number greater than zero 14 Press nn 4 sRvc to verify each item is configured as needed for this particular installation Table 9 shows the fac tory configuration cod...

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Page 76: ...r reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 I PC 903 Catalog No 563 015 Printed in U S A Form 30GN 2T Pg 76 l 94 Replaces 30GEl GT 1 T T a b 5c 30GN 1T ...

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