Carrier Flotronic II 30GN040 Operating And Troubleshooting Manual Download

Page: 1 / 72

Controls, Operation, and

Troubleshooting

with Microprocessor Controls and Electronic Expansion Valves

CONTENTS

Page

SAFETY CONSIDERATIONS

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

GENERAL

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

MAJOR SYSTEM COMPONENTS

. . . . . . . . . . . . 2-5

Processor Module

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

Low-Voltage Relay Module

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

Electronic Expansion Valve Module

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

Options Module

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

Keypad and Display Module

(Also Called HSIO or LID)

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

Control Switch

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

Electronic Expansion Valve (EXV)

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

Thermostatic Expansion Valves (TXV)

. . . . . . . . 4

Sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Compressor Protection Control

Module (CPCS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATION DATA

. . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Capacity Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Head Pressure Control

. . . . . . . . . . . . . . . . . . . . . . 24

• EXV UNITS
• TXV UNITS

Pumpout

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

• EXV UNITS
• TXV UNITS

Keypad and Display Module

(Also Called HSIO or LID)

. . . . . . . . . . . . . . . . . 24

• ACCESSING FUNCTIONS AND SUBFUNCTIONS
• AUTOMATIC DEFAULT DISPLAY
• AUTOMATIC DISPLAY OPERATION/DEFAULT

DISPLAY

• KEYPAD OPERATING INSTRUCTIONS
• STATUS FUNCTION
• TEST FUNCTION
• HISTORY FUNCTION
• SET POINT FUNCTION
• SERVICE FUNCTION
• SCHEDULE FUNCTION

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . 47-64

Checking Display Codes

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

Page

Unit Shutoff

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

Complete Unit Stoppage

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

Single Circuit Stoppage

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

Lag Compressor Stoppage

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

Restart Procedure

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

• POWER FAILURE EXTERNAL TO THE UNIT

Alarms and Alerts

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

Compressor Alarm/Alert Circuit

. . . . . . . . . . . . . 50

Electronic Expansion Valve (EXV)

. . . . . . . . . . . 55

• EXV OPERATION
• CHECKOUT PROCEDURE

Thermostatic Expansion Valve (TXV)

. . . . . . . . . 57

Thermistors

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

• LOCATION
• THERMISTOR REPLACEMENT (T1, T2, T7, T8)

Pressure Transducers

. . . . . . . . . . . . . . . . . . . . . . 60

• TROUBLESHOOTING
• TRANSDUCER REPLACEMENT

Control Modules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

• PROCESSOR MODULE (PSIO), 4IN/4OUT

MODULE (SIO), LOW-VOLTAGE RELAY
MODULE (DSIO-LV), AND EXV DRIVER
MODULE (DSIO-EXV)

• RED LED
• GREEN LED
• PROCESSOR MODULE (PSIO)
• LOW-VOLTAGE RELAY MODULE (DSIO)
• 4IN/4OUT MODULE (SIO)

ACCESSORY UNLOADER INSTALLATION

. . . 64-68

Installation

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

• 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

30GN040-420

Flotronic™ II Reciprocating Liquid Chillers

50/60 Hz

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

Book 2
Tab

PC 903

Catalog No. 563-079

Printed in U.S.A.

Form 30GN-3T

Pg 1

7-95

Replaces: 30G-1T

Summary of Contents for Flotronic II 30GN040

Page 1: ...toppage 48 Single Circuit Stoppage 48 Lag Compressor Stoppage 48 Restart Procedure 48 POWER FAILURE EXTERNAL TO THE UNIT Alarms and Alerts 48 Compressor Alarm Alert Circuit 50 Electronic Expansion Valve EXV 55 EXV OPERATION CHECKOUT PROCEDURE Thermostatic Expansion Valve TXV 57 Thermistors 57 LOCATION THERMISTOR REPLACEMENT T1 T2 T7 T8 Pressure Transducers 60 TROUBLESHOOTING TRANSDUCER REPLACEMENT...

Page 2: ... Installation instruc tions 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 remain ing modules follow instructions for unit sizes 130 210 Table 1 Unit Sizes and Modular Combinations UNIT MODEL 30GN NOMINAL TONS SECTION A UN...

Page 3: ...E F U S E CB5 CB6 EQUIP GND 99NA505322 D COMM 1 COMM 3 PWR X X S1 S2 X X POINT NUMBER OF FIRST CHANNEL COMM 3 PWR LV EXV STATUS COMM STATUS COMM 1 2 3 4 HK35AA002 Potter Brumfield CZ770 5VDC GFI CO 5 AMP MAX 30GT510568 J5 J4 J4 LEGEND CCN Carrier Comfort Network TB Terminal Block Fig 1 30GN Control Panel 040 110 Unit Shown 3 ...

Page 4: ... ENABLE position the chiller is under lo cal 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 UNIT OPERATION CONFIGURATION AND SET POINT CONTROL Keypad Control CCN Control STOP Unit Cannot Run Read Write Read Only LOCAL ENABLE Unit Ca...

Page 5: ...ith 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...

Page 6: ...1 5 100 A1 B1 100 A1 B1 040 50 Hz 045 60 Hz A1 B1 1 21 B1 2 37 B1 3 53 B1 4 68 A1 B1 5 84 A1 B1 6 100 A1 B1 045 50 Hz 050 60 Hz A1 B1 1 31 A1 2 44 A1 3 87 A1 B1 4 100 A1 B1 045 50 Hz 050 60 Hz A1 B1 1 31 A1 38 B1 2 44 A1 56 B1 3 69 A1 B1 69 A1 B1 4 87 A1 B1 82 A1 B1 5 100 A1 B1 100 A1 B1 045 50 Hz 050 60 Hz A1 B1 1 18 A1 2 31 A1 3 73 A1 B1 4 87 A1 B1 5 100 A1 B1 045 50 Hz 050 60 Hz A1 B1 1 18 A1 2...

Page 7: ... 3 42 A1 4 53 A1 B1 5 73 A1 B1 6 87 A1 B1 7 100 A1 B1 050 50 Hz 060 60 Hz A1 B1 1 18 B1 2 38 B1 3 58 B1 4 60 A1 B1 5 80 A1 B1 6 100 A1 B1 050 50 Hz 060 60 Hz A1 B1 1 15 A1 18 B1 2 28 A1 38 B1 3 42 A1 58 B1 4 53 A1 B1 60 A1 B1 5 73 A1 B1 80 A1 B1 6 87 A1 B1 100 A1 B1 7 100 A1 B1 060 50 Hz 070 60 Hz A1 B1 1 33 A1 2 50 A1 3 83 A1 B1 4 100 A1 B1 060 50 Hz 070 60 Hz A1 B1 1 33 A1 33 B1 2 50 A1 50 B1 3 ...

Page 8: ... 92 A1 A2 B1 84 A1 A2 B1 8 100 A1 A2 B1 100 A1 A2 B1 070 50 Hz A1 B1 1 11 A1 2 19 A1 3 57 A1 B1 4 65 A1 B1 5 73 A1 B1 6 84 A1 A2 B1 7 92 A1 A2 B1 8 100 A1 A2 B1 070 50 Hz A1 B1 1 11 A1 2 19 A1 3 27 A1 4 41 A1 B1 5 57 A1 B1 6 65 A1 B1 7 73 A1 B1 8 84 A1 A2 B1 9 92 A1 A2 B1 10 100 A1 A2 B1 070 50 Hz A1 B1 1 15 B1 2 31 B1 3 47 B1 4 57 A1 B1 5 73 A1 B1 6 84 A1 A2 B1 7 100 A1 A2 B1 070 50 Hz A1 B1 1 11...

Page 9: ...A2 B1 8 89 A1 A2 B1 100 A1 A2 B1 9 100 A1 A2 B1 080 230B 50 Hz A1 B1 1 17 A1 25 B1 2 25 A1 38 B1 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 080 230B 50 Hz A1 B1 1 8 A1 2 17 A1 3 25 A1 4 33 A1 B1 5 46 A1 B1 6 54 A1 B1 7 62 A1 B1 8 71 A1 A2 B1 9 84 A1 A2 B1 10 92 A1 A2 B1 11 100 A1 A2 B1 080 230B 50 Hz A...

Page 10: ... A2 B1 B2 12 100 A1 A2 B1 B2 090 245B 60 Hz A1 B1 1 9 A1 9 B1 2 18 A1 18 B1 3 27 A1 27 B1 4 35 A1 B1 35 A1 B1 5 44 A1 B1 44 A1 B1 6 53 A1 B1 53 A1 B1 7 56 A1 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 090 245B 50 Hz A1 B1 1 14 A1 14 B1 2 21 A1 21 B1 3 29 A1 B1 29 A1 B1 4 ...

Page 11: ... A1 A2 B1 B2 15 100 A1 A2 B1 B2 100 A1 A2 B1 B2 100 255B 270B 60 Hz A1 B1 1 16 A1 16 A1 2 23 A1 23 A1 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 100 255B 270B 60 Hz A1 B1 1 8 A1 2 16 A1 3 23 A1 4 31 A1 B1 ...

Page 12: ...A1 A2 B1 B2 100 255B 270B 50 Hz A1 B1 1 7 A1 2 13 A1 3 20 A1 4 26 A1 B1 5 33 A1 B1 6 40 A1 B1 7 50 A1 A2 B1 8 57 A1 A2 B1 9 63 A1 A2 B1 10 70 A1 A2 B1 11 80 A1 A2 B1 B2 12 87 A1 A2 B1 B2 13 93 A1 A2 B1 B2 14 100 A1 A2 B1 B2 100 255B 270B 50 Hz A1 B1 1 7 B1 2 13 B1 3 20 B1 4 26 A1 B1 5 33 A1 B1 6 40 A1 B1 7 50 A1 B1 B2 8 57 A1 B1 B2 9 63 A1 B1 B2 10 70 A1 B1 B2 11 80 A1 A2 B1 B2 12 87 A1 A2 B1 B2 1...

Page 13: ... B1 B2 8 53 A1 B1 B2 9 60 A1 B1 B2 10 67 A1 B1 B2 11 79 A1 A2 B1 B2 12 86 A1 A2 B1 B2 13 93 A1 A2 B1 B2 14 100 A1 A2 B1 B2 110 290B 315B 60 Hz A1 B1 1 7 A1 7 B1 2 14 A1 14 B1 3 21 A1 21 B1 4 29 A1 B1 29 A1 B1 5 36 A1 B1 36 A1 B1 6 43 A1 B1 43 A1 B1 7 47 A1 A2 B1 46 A1 B1 B2 8 54 A1 A2 B1 53 A1 B1 B2 9 61 A1 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 B...

Page 14: ...5 B1 4 33 A1 B1 5 42 A1 B1 6 50 A1 B1 7 58 A1 B1 B2 8 67 A1 B1 B2 9 75 A1 B1 B2 10 83 A1 A2 B1 B2 11 92 A1 A2 B1 B2 12 100 A1 A2 B1 B2 110 290B 315B 50 Hz A1 B1 1 8 A1 8 B1 2 17 A1 17 B1 3 25 A1 25 B1 4 33 A1 B1 33 A1 B1 5 42 A1 B1 42 A1 B1 6 50 A1 B1 50 A1 B1 7 58 A1 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 B...

Page 15: ... B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 130 60 Hz A1 B1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 8 14 21 22 28 35 42 44 51 58 64 71 73 80 87 93 100 A1 A1 A1 A1 B1 A1 B1 A1 B1 A1 B1 A1 A2 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 8 14 21 22 28 35 42 44 51 58 64 71 73 80 87 93 100 B1 B1 B1 A1 B1 A1 B1 A1 B1 A1 B1 A1 B1 B2 A1 B1 B2 A1 B1 B2...

Page 16: ... 14 22 31 35 39 40 49 53 57 65 74 78 82 83 91 96 100 A1 A1 A1 A1 B1 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 8 16 25 31 39 43 47 56 64 65 74 82 83 91 100 B1 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...

Page 17: ... 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 9 18 27 33 42 46 51 60 69 75 86 91 100 B1 B1 B1 A1 B1 A1 kB1 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 150 230A 245A 255A 50 Hz A1 B1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13 20 26 33 40 46 53 60 66 73 80 86 93 100 A1 A1 A1 B1 A1 B1 A1 B1 A1 A2 B1 A1 A2 B1 A1 A2 B1 A1 A2 ...

Page 18: ... 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 11 17 23 28 33 39 45 50 56 61 67 73 78 83 89 95 100 A1 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 11 17 23 28 33 39 45 50 56 61 67 73 78 83 89 95 100 B1 B1 A1 B1 A1 B1 A1 B1 A1 B1 B2 A1 B1 B2 A1 B1 B2 A1 A2 B1 B2 A1 A2 B1...

Page 19: ...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 6 11 17 17 23 28 33 34 39 45 50 51 56 61 67 67 73 78 83 84 89 95 100 B1 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 1...

Page 20: ...2 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 170 270A 330A B 360B 50 Hz A1 B1 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 5 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 A1 A1 A1 A1 B1 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 ...

Page 21: ...11 12 13 14 15 16 17 9 13 18 21 25 33 37 41 49 53 56 71 74 78 93 96 100 A1 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 9 13 18 21 25 33 37 41 49 53 56 71 74 78 93 96 100 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 A...

Page 22: ... 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 210 315A 390A 420A B 60 Hz A1 B1 1 2 3 4 5 6 7 11 25 36 56 67 86 100 A1 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 14 25 44 56 75 86 100 B1 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 210 315A 390A 420A B 60 Hz A1 B1 1 2 3 4 5 6 7 8 9 10...

Page 23: ...4 5 6 7 8 9 10 11 12 13 14 6 9 23 26 32 35 48 51 65 67 81 84 97 100 A1 A1 A1 B1 A1 B1 A1 A2 B1 A1 A2 B1 A1 A2 B1 B2 A1 A2 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 A4 B1 B2 B3 A1 A2 A3 A4 B1 B2 B3 210 315A 390A 420A B 50 Hz A1 B1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11 16 20 26 36 42 46 51 62 67 78 84 94 100 B1 B1 A1 B1 A1 B1 A1 B1 B2 A1 B1 B2 A1 A2 B1 B2 A1 A2 B...

Page 24: ...em perature is 10 F 5 6 C below the saturated suction tem perature at start up is 10 F 5 6 C below the cooler leav ing fluid temperature or reaches a saturated suction temperature of 15 F 26 C No pumpout is necessary if the saturated suction temperature is below 15 F 26 C At this point the EXV starts to open and continues to open gradually to provide a controlled start up to prevent liquid flood b...

Page 25: ...mpressor A1 6 8 FC B1 Compressor B1 3 9 FC A2 First Stage Microprocessor 4 10 FC B2 1 3 9 FC A2 FC A3 Second Stage Microprocessor 2 4 10 FC B2 FC B3 190 210 and associated modular units 5 7 FC A1 Compressor A1 6 8 FC B1 Compressor B1 3 9 FC A2 First Stage Microprocessor 4 10 FC B2 1 3 9 11 FC A2 FC A3 Second Stage Microprocessor 2 4 10 12 FC B2 FC B3 See Table 1 Control box AUTOMATIC DISPLAY OPERA...

Page 26: ...subfunction 4 At any time another subfunction may be entered by press ing the subfunction number then the function key 5 Prior to starting unit check leaving fluid set point for cor rect setting Refer to Set Point Function section on page 38 6 Depending on system configuration all displays may not be shown All displays are shown unless marked with the following symbol Must be configured For additi...

Page 27: ...isplay through all subfunctions within a function and then back to the first DEMAND DEMAND LIMIT SETPOINTS TIME CURRENT TIME AND DAY OF WEEK SETPOINT UNIT SETPOINTS To move to another function either depress function name key for desired function display shows the first subfunction X ALARMS THERE ARE n ALARMS or Access a specific sub STAGE CAPACITY STAGING INFORMATION function by using the sub fun...

Page 28: ...set F TW X Actual Control Temperature F 6 TEMPERATURE TEMPS Temperature Information F EWT X Cooler Entering Fluid Temperature F LWT X Cooler Leaving Fluid Temperature F SCTA X Circuit A Saturated Condenser Temperature F SSTA X Circuit A Saturated Suction Temperature F CTA X Compressor A1 Suction Temperature F SHA X Circuit A Suction Superheat F SCTB X Circuit B Saturated Condenser Temperature F SS...

Page 29: ...PUT Status of Switch Inputs SPW X Dual Set Point Switch open closed DL1 X Demand Limit Switch 1 open closed DL2 X Demand Limit Switch 2 open closed 10 OUTPUTS OUTPUTS Status of Outputs ALMR X Alarm Relay K3 on off FRA1 X Fan Relay K1 on off FRA2 X Fan Relay K2 on off FRB1 X Fan Relay K4 on off FRB2 X Fan Relay K5 on off CHWP X Cooler Water Pump Relay K6 on off ULA1 X Unloader A1 on off ULA2 X Unlo...

Page 30: ...B1 K4 on off FRB2 X Energize Fan Relay B2 K5 on off CHWP X Energize Cooler Water Pump K6 on off LSVA X Energize Liquid Line Solenoid A on off LSVB X Energize Liquid Line Solenoid B on off EXVA X Enter Desired EXVA Position percent EXVB X Enter Desired EXVB Position percent HGBA X Energize Hot Gas Bypass Relay A on off HGBB X Energize Hot Gas Bypass Relay B on off MMA X Enter Desired Motormaster A ...

Page 31: ...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 subfunctions except override SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 OVERRIDE OVRD X Number of Override Hrs 0 4 Hrs For example to extend current occupied mode for 3 hrs press OVRD ...

Page 32: ...ns the password must be entered under the log on subfunction SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 LOG ON AND LOG OFF PASSWORD Enter Password Disable Password Protection LOGGEDON Logged On At this time configurations may be modified When finished viewing and or modifying configurations log out as follows LOGGEDON LOG OFF Disable Password Protection EXIT LOG Logged Off Enable Password Protecti...

Page 33: ...Cooling Reset Control Select ERTYP X External Reset Sensor Select OATSEL X Outdoor Air Sensor Select LSTYP X Demand Limit Control Select RAMP X Ramp Load Select enable disable LOCK X Cooler Pump Interlock Select CPC X Cooler Pump Control Select REMA X Remote Alarm Option Select yes no ALRST X Allow Local Stop CCN Reset of Alarms yes no To toggle between inputs Yes No Press no or yes 5 SERVICE CONF...

Page 34: ...rom Stage 0 to Stage 1 CYA X Circuit A Starts CYB X Circuit B Starts CA1 X Circuit A Comp A1 Starts CA2 X Circuit A Comp A2 Starts CA3 X Circuit A Comp A3 Starts CA4 X Circuit A Comp A4 Starts CB1 X Circuit B Comp B1 Starts CB2 X Circuit B Comp B2 Starts CB3 X Circuit B Comp B3 Starts CB4 X Circuit B Comp B4 Starts 3 ALARM ALERT HISTORY ALRMHIST Last 10 Alarms Alerts ALARM X Alarm Alert Descriptio...

Page 35: ...Fluid DT at Full Reset F CRT3D X Total Degrees of Reset F 3 DEMAND SET POINTS DEMAND Demand Set Points DLS1 X Demand Switch 1 Set Point percent DLS2 X Demand Switch 2 Set Point percent DL20 X Demand Limit at 20 mA percent DLGN X Loadshed Group Number LSDD X Loadshed Demand percent TIME X Minimum Loadshed Time minutes 4 DATE AND TIME DATE TIME Date Time and Day of Week DOW HR MIN Day 1 Mon 2 Tues 7...

Page 36: ...lay module To reset alarms alerts using keypad and display module KEYPAD ENTRY DISPLAY RESPONSE COMMENTS RSAL DSB Reset all alarms alerts function disabled RSAL ENB Reset all alarms alerts function enabled Modes The operating mode codes are dis played to indicate the operating status of the unit at a given time See Table 10 To enter the MODES subfunction press and press the key to determine if mor...

Page 37: ...g the chiller MODE 16 Slow change override is in effect MODE 17 X minute off to on delay is in effect MODE 18 Low suction superheat protection is in effect CCN Carrier Comfort Network Set Point This subfunction displays leaving fluid temperature and leaving chilled fluid set point If unit is programmed for dual set point the chilled fluid set point currently in effect either occupied or unoccupied...

Page 38: ...l unit starts the total starts for each circuit and total starts for each com pressor Pressing and displays the last 10 alarms along with a description of each alarm SET POINT FUNCTION Set points are entered through the keypad Set points can be changed within the upper and lower limits which are fixed The ranges are listed below Chilled Fluid Set Point Water 38 to 86 F 3 3 to 30 C Medium Brine 14 ...

Page 39: ...n is enabled first This is done as a field configuration Select one of the 4 choices for type of reset Return Fluid Reset External Temperature Reset 4 20 mA External Signal Reset or 4 20 mA Internal Signal Reset If dual set point control is enabled see Field Wiring sec tion on page 69 the amount of reset is applied to whichever set point is in effect at the time Examples 5A 5C demonstrate how to a...

Page 40: ...is re quires a thermistor T10 Part No 30GB660002 located in the space or outdoor air and wired to terminals as follows also see Field Wiring section on page 69 and Fig 6 4 in 4 out Module J7 15 and J7 16 At the field configuration step enter set points as de scribed in Examples 5A 5C on pages 39 and 40 Then select external temperature reset by entering when CRTYP 0 appears See Fig 7 Temperature Re...

Page 41: ...g External Temperature Reset LEGEND COMM Communications Bus PWR Power SW Switch NOTE For specific connection points see Fig 25 29 Fig 7 4 IN 4 OUT Options Module Wiring for Reset Demand Limit and Dual Set Point 41 ...

Page 42: ...tage that is set to the lowest demand takes priority if both demand limit inputs are closed The demand limit function must be enabled in order to function and may be turned off when its operation is not de sired The demand limit relays can in off condition remain connected without affecting machine operation Table 12 Service Functions To view and modify configurations the password must be entered ...

Page 43: ...h defines the percent of the load to be removed when a loadshed command is in effect The third set point is maximum loadshed time which de fines the maximum length of time that a loadshed condition is allowed to exist The allowable range for this entry is zero to 120 minutes Subfunction displays date time and day of the week Reading and Changing Time Display Time is entered and displayed in 24 hou...

Page 44: ...that are downloaded at the factory If processor module is replaced in the field the 2 groups of configuration codes must be entered through the keypad and display module The 2 groups of configuration codes groups 8 and 9 that apply to the unit being serviced can be found on a label diagram inside the control box cover See Table 13 for keystroke in formation to enter configuration codes 8 and 9 The...

Page 45: ...address Entered by CCN Technician 001 001 CCN Bus Number Entered by CCN Technician 000 000 CCN Baud Rate Entered by CCN Technician 9600 9600 Cooler Fluid Select 1 Water 38 to 70 F 3 3 to 21 C Set Point 2 Medium Brine 15 to 70 F 9 to 21 C Set Point 1 Standard Models 2 Brine Models 1 Display Unit Select 0 English 1 Metric SI 0 0 Delay at Power Up 0 0 No Circuit A Unloaders 0 No Unloaders 1 One Unloa...

Page 46: ...at 3 00 a m MON NO Monday is now flagged no for period 1 To put period 1 into effect on Monday Monday must be flagged yes MON YES Monday is now flagged for period 1 to be in effect TUE YES For this example period 1 is to be in effect on Monday only All other days must be checked to be sure that they are flagged no If any day is flagged yes change to no TUE NO Tuesday is now flagged no for period 1...

Page 47: ...tures to aid the technicians in troubleshooting a Flotronic II Chiller By us ing the keypad and display module and the status function actual operating conditions of the chiller are displayed while unit is running Test function allows proper operation of com pressors compressor unloaders fans EXVs and other com ponents to be checked while chiller is stopped Service func tion displays how configura...

Page 48: ...as a result of any of the above safety devices determine and correct the cause before attempting another restart Restart Procedure After cause for stoppage has been corrected restart is either automatic or manual depending on fault Manual reset requires that LOCAL ENABLE STOP CCN switch be moved to STOP position then back to original operating position Some typical fault conditions are described i...

Page 49: ... circuit B Circuit B shut down No Manual Faulty expansion valve transducer or thermistor 40 Alert Low oil pressure circuit A Circuit A shut down No Manual Low oil level circuit breaker trip faulty expansion valve crankcase heater or pressure transducer 41 Low oil pressure circuit B Circuit B shut down No Manual Low oil level circuit breaker trip faulty expansion valve crankcase heater or pressure ...

Page 50: ... as sociated modular units will cause a trip 6 Checkout Procedure Shut off main power to unit Turn on control power then step through subfunc tion to proper compressor number i e failure code 5 is compressor B1 Next energize the step If step works correctly then failure code is caused by HPS high pressure switch open Misplaced feedback wire from J4 and J5 terminals Ground wire and 24 v feeds rever...

Page 51: ... affected circuit shuts down without going through pum pout process Alerts 24 27 Other circuit continues to run Reset is automatic if output voltage returns to the acceptable range and circuit start up follows normal sequence The cause of this fault is usually a bad transducer or a wiring error Code 28 Low transducer supply voltage alarm If transducer supply voltage is less than 4 5 v or greater t...

Page 52: ...oss of communication can be attributed to a grounded transformer with a secondary voltage of 21 vac supplying the PSIO DSIO LV or 4 IN 4 OUT modules the 12 5 vac transformer supplying the DSIO EXV module or the 24 vac transformer supplying PS1 for the transformers These transformers should not be grounded or serious damage to controls can result Check to be sure the transformers are not grounded N...

Page 53: ... chillers and 12 psig for brine chillers Possible causes of fault are low refrigerant charge faulty EXV plugged filter drier or faulty transducer Code 38 Failure to pump out Circuit A alert Code 39 Failure to pump out Circuit B alert The pumpout process is terminated when saturated suc tion temperature is 10 F 5 6 C below temperature at be ginning of pumpout or 10 F 5 6 C below leaving water tempe...

Page 54: ...uction superheat is less than 10 F 5 5 C or saturated evaporator temperature is greater than MOP maximum operating pressure for more than 5 minutes affected circuit shuts down after going through pumpout process Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence Possible causes of fault are faulty expansion valve or thermistor Code 50 Illegal configuration alarm...

Page 55: ...upon successful calibration of the transducer Code 63 Complete unit shutdown due to failure alarm This alarm alerts the user that the unit is totally shut down due to one or more fault conditions Reset is automatic when all alarms causing complete unit shutdown are reset Code 64 Loss of charge circuit A alert Code 65 Loss of charge circuit B alert If the unit uses suction and discharge transducers...

Page 56: ...ip on EXV driver See Fig 13 a Check color coding and wire connections Make sure they are connected to correct terminals at driver and EXV plug connections b Check for continuity and tight connection at all pin terminals c Check plug connections at driver and at EXVs to be sure EXV cables are not crossed 3 Check resistance of EXV motor windings Remove plug at J4 terminal strip and check resistance ...

Page 57: ...t connections between processor board terminals and EXV plug Recheck all wiring connections and voltage signals Other possible causes of improper refrigerant flow con trol could be restrictions in liquid line Check for plugged filter drier s or restricted metering slots in the EXV For mation of ice or frost on lower body of electronic ex pansion valve is one symptom of restricted metering slots Ho...

Page 58: ... 2 766 4403 83 2 738 4298 84 2 708 4196 85 2 679 4096 86 2 650 4000 87 2 622 3906 88 2 593 3814 89 2 563 3726 90 2 533 3640 91 2 505 3556 92 2 476 3474 93 2 447 3395 94 2 417 3318 95 2 388 3243 96 2 360 3170 97 2 332 3099 98 2 305 3031 99 2 277 2964 100 2 251 2898 101 2 217 2835 102 2 189 2773 103 2 162 2713 104 2 136 2655 105 2 107 2597 106 2 080 2542 107 2 053 2488 108 2 028 2436 109 2 001 2385 ...

Page 59: ...1 3 129 5 971 22 3 076 5 710 23 3 023 5 461 24 2 970 5 225 25 2 917 5 000 26 2 864 4 786 27 2 810 4 583 28 2 757 4 389 29 2 704 4 204 30 2 651 4 028 31 2 598 3 861 32 2 545 3 701 33 2 493 3 549 34 2 441 3 404 35 2 389 3 266 36 2 337 3 134 37 2 286 3 008 38 2 236 2 888 39 2 186 2 773 40 2 137 2 663 41 2 087 2 559 42 2 039 2 459 43 1 991 2 363 TEMPERATURE VOLTAGE RESISTANCE C DROP V Ohms 44 1 944 2 ...

Page 60: ... range and will not calibrate 4 Press on the HSIO keypad This automatically ap plies the proper correction factor to all future inputs from the transducer Three pressure transducers are mounted on each lead com pressor 2 low pressure transducers to monitor compressor suction pressure and oil pressure and a high pressure trans ducer to monitor compressor discharge pressure see Fig 17 for exact loca...

Page 61: ...ns Circuits A and B Lead Compressor Only FLUID SIDE TEMPERATURE THERMISTOR T2 ALL UNITS COMPRESSOR SUCTION GAS TEMPERATURE THERMISTORS T7 AND T8 ALL UNITS AND FLUID SIDE TEMPERATURE THERMISTOR T1 ALL UNITS Fig 16 Thermistors 61 ...

Page 62: ...er by pulling up on locking tab while pulling weathertight connection plug from end of transducer Do not pull on transducer wires 3 Unscrew transducer from 1 4 in male flare fitting When installing new pressure transducer do not use thread sealer Thread sealer can plug transducer and render it inoperative 4 Insert weathertight wiring plug into end of transducer un til locking tab snaps in place 5 ...

Page 63: ...Driver Module 31 SIO 4 In 4 Out Module 59 If all modules indicate communication failure check COMM plug on PSIO module for proper seating If a good connec tion is assured and condition persists replace PSIO module If only DSIO or SIO module indicates communication fail ure check COMM plug on that mode for proper seating If a good connection is assured and condition persists replace DSIO or SIO mod...

Page 64: ...r or space temperature A remote thermistor Part No 30GB660002 is also re quired NOTE This accessory is not required for return water temperature reset 2 Temperature Reset by remote 4 to 20 mA signal 3 Demand Limit by remote 2 stage switch 4 Demand Limit by remote 4 to 20 mA signal 5 Dual Set Point by remote switch The options module is standard Remember to reconfig ure the chiller for each feature...

Page 65: ...ontrol side Open the left side control box door and remove inner panel Using the holes provided and field supplied screws install field supplied transformer above the DSIO LV on the control panel Wire the primary side of the transformer in parallel with TRAN4 See Fig 23 This supplies transformer with proper line voltage Be sure to connect proper tap of the trans former to ensure supply of proper s...

Page 66: ...doors and windows closed Inefficient compressor Check valves Replace if necessary SYSTEM NOISES Piping vibration Support piping as required Expansion valve hissing Add refrigerant Check for plugged liquid line filter drier Compressor noisy Check valve plates for valve noise Replace compressor worn bearings Check for loose compressor holddown bolts COMPRESSOR LOSES OIL Leak in system Repair leak Me...

Page 67: ...ct UB between TB3 6 and TB3 8 Check all of the electrical connections for proper location and tightness and replace and secure the electrical box of the compressor 4 Configure the microprocessor Once the relays are mounted in the control box the microprocessor must be config ured for the unloader option To do so a Be sure the LOCAL ENABLE STOP CCN switch is in the STOP position b Log into the proc...

Page 68: ...y U Unloader Or HGBPR A Or HGBPR B LEGEND COM Communications Bus TB Terminal Block HGBPR Hot Gas Bypass Relay TRAN Transformer NO Normally Open U Unloader SNB Snubber Fig 24 Flotronic II 115 230 V Unloader Wiring 130 50 Hz 150 210 and Associated Modular Units See Table 1 Fig 23 Accessory Unloader Control Wiring All Units 68 ...

Page 69: ...imit 4 20 mA Signal Internally Powered Fig 28 Remote Reset from Space or Outdoor Air Temperature Fig 29 Remote Reset from 4 20 mA Signal Externally Powered Fig 30 Remote Reset from 4 20 mA Signal Internally Powered TB Terminal Block NOTE Contacts must be rated for dry circuit application capable of reliably switching a 5 vdc 1 mA to 20 mA load Fig 31 Remote On Off Fig 32 Remote Dual Set Point Cont...

Page 70: ...before restoring power 10 Verify the LOCAL ENABLE STOP CCN switch is in STOP position 11 Restore control power Verify the red and green lights on top of PSIO and front of each DSIO module respond as described in Control Modules section on page 63 The keypad and display module should also begin its rotat ing display 12 Using the keypad and display module press to verify that the software version nu...

Page 71: ......

Page 72: ...nufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 Tab 5c PC 903 Catalog No 563 079 Printed in U S A Form 30GN 3T Pg 72 7 95 Replaces 30G 1T ...

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Carrier Flotronic II 30GN040, Operating And Troubleshooting Manual

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