Carrier 30GTR Specifications

30GTN,GTR040-420
Air-Cooled Reciprocating Liquid Chillers
with ComfortLink™ Controls
50/60 Hz
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 and condenser 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.
DO NOT attempt to unbraze factory joints when servicing this equipment. Compressor oil is flammable and
there is no way to detect how much oil may be in any
of the refrigerant lines. Cut lines with a tubing cutter as
required when performing service. Use a pan to catch
any oil that may come out of the lines and as a gage for
how much oil to add to system. DO NOT re-use compressor oil.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 3-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . 3
Expansion Valve (EXV) Board . . . . . . . . . . . . . . . . . 3
Compressor Expansion Board (CXB) . . . . . . . . . . 3
Scrolling Marquee Display . . . . . . . . . . . . . . . . . . . . 3
Energy Management Module (EMM) . . . . . . . . . . . 3
Enable/Off/Remote Contact Switch . . . . . . . . . . . . 3
Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . 3
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Board Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Module Communication . . . . . . . . . . . . . . 3
Carrier Comfort Network Interface . . . . . . . . . . . . 3
OPERATING DATA . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• 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) . . . . . . . . 15
Compressor Protection Control System
(CPCS) or Control Relay (CR) . . . . . . . . . . . . . . 15
Compressor Current Protection Board
(CGF) and Control Relay (CR) . . . . . . . . . . . . . . 15
Electronic Expansion Valve (EXV) . . . . . . . . . . . . 16
Energy Management Module . . . . . . . . . . . . . . . . . 16
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
• MINUTES LEFT FOR START
• MINUTES OFF TIME
• LOADING SEQUENCE
• LEAD/LAG DETERMINATION
• CAPACITY SEQUENCE DETERMINATION
• CAPACITY CONTROL OVERRIDES
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 533-099
Printed in U.S.A.
Form 30GTN-1T
Pg 1
5-99
Replaces: New
Tab 5c
Page
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . 65
• TEMPERATURES
• VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . 66
APPENDIX A — CCN TABLES . . . . . . . . . . . . . . 67-74
START-UP CHECKLIST . . . . . . . . . . . . . . CL-1 to CL-8
CONTENTS (cont)
Page
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 27
• COMFORTLINK™ UNITS (With EXV)
• UNITS WITH TXV
Pumpout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
• EXV UNITS
• TXV UNITS
Marquee Display Usage . . . . . . . . . . . . . . . . . . . . . 29
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Configuring and Operating Dual Chiller
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• DEMAND LIMIT (2-Stage Switch Controlled)
• EXTERNALLY POWERED DEMAND LIMIT
(4 to 20 mA Controlled)
• DEMAND LIMIT (CCN Loadshed Controlled)
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 46-51
Compressor Protection Control System
(CPCS) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Ground Current (CGC) Board
(30GTN,R130-210, 230A-315A, and
330A/B-420A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
EXV Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 46
• 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-64
Electronic Components . . . . . . . . . . . . . . . . . . . . . 52
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
• COMPRESSOR REMOVAL
• OIL CHARGE
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
• COOLER REMOVAL
• REPLACING COOLER
• SERVICING THE COOLER
Condenser Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Refrigerant Feed Components . . . . . . . . . . . . . . . 56
• ELECTRONIC EXPANSION VALVE (EXV)
• MOISTURE-LIQUID INDICATOR
• FILTER DRIER
• LIQUID LINE SOLENOID VALVE
• LIQUID LINE SERVICE VALVE
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• LOCATION
• REPLACING THERMISTOR T2
• REPLACING THERMISTORS T1,T5,T6,T7, AND T8
• THERMISTORS T3 AND T4
• THERMISTOR/TEMPERATURE SENSOR CHECK
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• COMPRESSOR PROTECTION
• LOW OIL PRESSURE PROTECTION
• CRANKCASE HEATERS
• COOLER PROTECTION
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• HIGH-SIDE PROTECTION
• LOW-SIDE PROTECTION
• PRESSURE RELIEF VALVES
Other Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
START-UP AND OPERATION . . . . . . . . . . . . . . . 65,66
Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
GENERAL
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 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.
INTRODUCTION
This publication contains Start-Up, Service, Controls, Operation, and Troubleshooting information for the 30GTN,R040420 liquid chillers with ComfortLink controls.
The 30GTN,R chillers are equipped with electronic expansion valves (EXVs) or, on size 040-110 FIOP (factoryinstalled 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.
This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short
out or bypass components or otherwise depart from
recommended procedures. Any short-to-ground of the
control board or accompanying wiring may destroy the
board or electrical component.
Table 1 — Unit Sizes and Modular Combinations
UNIT MODEL
30GTN,R
40
45
50
60
70
80
90
100
110
130
150
170
190
210
230
245
255
270
290
315
330
360
390
420
NOMINAL
TONS
40
45
50
60
70
80
90
100
110
125
145
160
180
200
220
230
240
260
280
300
325
350
380
400
*60 Hz units/50 Hz units.
2
SECTION A
UNIT 30GTN,R
—
—
—
—
—
—
—
—
—
—
—
—
—
—
150
150
150
170
190
210
170
190
210
210
SECTION B
UNIT 30GTN,R
—
—
—
—
—
—
—
—
—
—
—
—
—
—
080
090
100
100
110
110
170
190/170*
190
210
MAJOR SYSTEM COMPONENTS
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.
General — The 30GTN,R air-cooled reciprocating 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) — See Fig. 5. The MBB is
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 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.
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 board 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.
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 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. The CXB board can also be
used as an accessory to control up to two field-installed accessory unloaders on 080-110, 130 (60 Hz), and 230B-315B
sizes.
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.
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.
Energy Management Module (EMM) — The EMM
module is available as a factory-installed option or as a fieldinstalled 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 5 vdc, 1 to
20 mA 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.
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.
3
Table 2 — Thermistor Designations
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).
PIN
THERMISTOR CONNECTION
THERMISTOR INPUT
NO.
POINT
T1
J8-13,14 (MBB) Cooler Leaving Fluid
T2
J8-11,12 (MBB) Cooler Entering Fluid
Saturated Condensing
T3
J8-21,22 (MBB) Temperature, Ckt A
Condensing
T4
J8-15,16 (MBB) Saturated
Temperature, Ckt B
Suction Temperature,
T5
J8-24,25 (MBB) Cooler
Ckt A (EXV Only)
T6
J8-18,19 (MBB) Cooler Suction Temperature,
Ckt B (EXV Only)
Suction Gas
T7
J5-11,12 (EXV) Compressor
Temperature, Ckt A (EXV Only)
Compressor Suction Gas
T8
J5-9,10 (EXV) Temperature, Ckt B (EXV Only)
T9
J8-7,8 (MBB) Outdoor-Air Temperature Sensor
(Accessory)
Space Temperature
T10
J8-5,6 (MBB) Remote
Sensor (Accessory)
LEGEND
EXV — Electronic Expansion Valve
MBB — Main Base Board
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 3 — Status Switches
PIN
(50 Hz)
CONNECTION 040-060
040-070 (60 Hz)
POINT
Oil Pressure, Ckt B J7-1, 2 (MBB)
Not Used*
Oil Pressure, Ckt A J7-3, 4 (MBB)
Not Used*
Remote On/Off
TB5-13, 14
Compressor Fault
J5-8, 12 (CXB)
Not Used
Signal, B3
Compressor Fault J9-2, 12 (MBB)
Not Used
Signal, B2
Compressor Fault J9-8, 12 (MBB) CR/CPCS-B1†
Signal, B1
Compressor Fault J5-5, 12 (CXB)
Not Used
Signal, A4
Compressor Fault
J5-11, 12 (CXB)
Not Used
Signal, A3
Compressor Fault J9-5, 12 (MBB)
Not Used
Signal, A2
Compressor Fault J9-11, 12 (MBB) CR/CPCS-A1†
Signal, A1
STATUS SWITCH
070
170,190,
090-110,
130
130 (50 Hz)
210, 315A,
(50 Hz) 245B-315B
(60 Hz) 150, 230A-255A 270A,290A,330A/B, 390A, 420A/B
080, 230B
360A/B, 390B
OPSB
OPSB
OPSB
OPSB
OPSB
OPSB
OPSA
OPSA
OPSA
OPSA
OPSA
OPSA
Field-Installed Relay Closure
Not Used
Not Used
Not Used
Not Used
CR-B3
CR-B3
Not Used
CPCS-B2
CR-B2
CR-B2
CR-B2
CR-B2
CPCS-B1
CPCS-B1
CR-B1
CR-B1
CR-B1
CR-B1
Not Used
Not Used
Not Used
Not Used
Not Used
CR-A4
Not Used
Not Used
Not Used
CR-A3
CR-A3
CR-A3
CPCS-A2
CPCS-A2
CR-A2
CR-A2
CR-A2
CR-A2
CPCS-A1
CPCS-A1
CR-A1
CR-A1
CR-A1
CR-A1
LEGEND
CPCS — Compressor Protection Control System
CR
— Control Relay
CXB — Compressor Expansion Board
MBB — Main Base Board
OPS — Oil Pressure Switch, Circuit A or B
*The OPS can also be added as an accessory.
†The CPCS can be added as an accessory.
4
Table 4 — Output Relay
LEGEND FOR FIG. 1-4
C
— Compressor Contactor
CB
— Circuit Breaker
CCN
— Carrier Comfort Network
CGF
— Compressor Ground Fault
CHT
— Cooler Heater Thermostat
CKT
— Circuit
CLHR
— Cooler Heater Relay
CPCS
— Compressor Protection and Control System
CWF
— Chilled Water Flow Switch
CWP
— Chilled Water Pump
CR
— Control Relay
CXB
— Compressor Expansion Board
EQUIP GND — Equipment Ground
FB
— Fuse Block
FC
— Fan Contactor
FCB
— Fan Circuit Breaker
FIOP
— Factory-Installed Option Package
EMM
— Energy Management Module
EXV
— Electronic Expansion Valve
FCB
— Fan Circuit Breaker
HPS
— High-Pressure Switch
LCS
— Loss-of-Charge Switch
MBB
— Main Base Board
NEC
— National Electrical Code
OAT
— Outdoor-Air Temperature
OPS
— Oil Pressure Switch
PL
— Plug
PW
— Part Wind
SN
— Sensor (Toroid)
SPT
— Space Temperature
TRAN
— Transformer
SW
— Switch
TB
— Terminal Block
TDR
— Time Delay Relay
TXV
— Thermostatic Expansion Valve
UL
— Unloader
XL
— Across-the-Line
RELAY NO.
DESCRIPTION
Energize Compressor A1 and OFM1 (040-110*)
Liquid Line Solenoid Valve for Ckt A (if used)
K0 (MBB) Energize
(040-110*)
Energize Compressor A1, OFM5, and OFM7 (130-210*)
Energize Compressor B1 and OFM2 (040-110*)
Liquid Line Solenoid Valve for Ckt B (if used)
K1 (MBB) Energize
(040-110*)
Energize Compressor B1, OFM6, and OFM8 (130-210*)
Unloader A1 (040-170*)
K2 (MBB) Energize
No Action (190-210*)
K3 (MBB) Energize Unloader B1 (040-070†, 080-170*)
No Action (190,210*)
Action (040-060, 50 Hz; 040-070, 60 Hz)
K4 (MBB) No
Energize Compressor A2 (070, 50 Hz; 080-210*)
K5 (MBB) No Action (040-080*)
Energize Compressor B2 (090-210*)
K6 (MBB) Alarm
K7 (MBB) Cooler Pump
Energize First Stage of Condenser Fans:
040-050 — OFM3
060-110* — OFM3, OFM4
K8 (MBB)
130 (60 Hz) — OFM1,OFM2
Energize First Stage of Ckt A Condenser Fans:
130 (50 Hz), 150,170* — OFM1
190,210* — OFM1,OFM11
Energize First Stage of Condenser Fans:
040-050 — OFM4
060-090* — OFM5, OFM6
100,110* — OFM5,OFM6,OFM7,OFM8
K9 (MBB)
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
K10 (MBB) Hot Gas Bypass
No Action (040-110*; 130, 60 Hz)
K1 (CXB) Energize Compressor A3 (130, 50 Hz; 150-210*)
Action (040-150*)
K2 (CXB) No
Energize Compressor B3 (170-210*)
Compressor A4 (210*)
K3 (CXB) Energize
Energize Accessory Unloader A2 (080-110*)
K4 (CXB) Energize Accessory Unloader B2 (080-110*)
Second Stage of Ckt A Condenser Fans:
K5 (CXB) Energize
130 (50 Hz), 150-210* — OFM3,OFM9
Second Stage of Ckt B Condenser Fans:
K6 (CXB) Energize
130 (50 Hz), 150-210* — OFM4,OFM10
LEGEND
OFM — Outdoor-Fan Motor
*And associated modular units.
†Field-installed accessory unloader.
5
6
Fig. 1 — Typical Control Box (080-110 and Associated Modular Units Shown)
Fig. 2 — 24 V Control Schematic, Unit Sizes 040-070
7
Fig. 3 — 24 V Control Schematic, Unit Sizes 080-110, 230B-315B
8
Fig. 4 — 24 V Control Schematic, Unit Sizes 130-210, 230A-315A, 330A/B-420A/B
9
RED LED - STATUS
GREEN LED LEN (LOCAL EQUIPMENT NETWORK)
YELLOW LED CCN (CARRIER COMFORT NETWORK)
CEPL130346-01
J1
J4
STATUS
J2
J10
LEN
J3
CCN
J5
J6
J7
J9
J8
Fig. 5 — Main Base Board
EMERGENCY ON/OFF
SWITCH
ENABLE/OFF/REMOTE
CONTACT SWITCH
RESET BUTTON
(30GTN,R130-210 AND
ASSOCIATED MODULES ONLY)
GFI-CONVENIENCE
OUTLET ACCESSORY
ON 208/230V 460 AND
575V ONLY
Fig. 6 — Enable/Off/Remote Contact Switch, Emergency On/Off Switch,
and Reset Button Locations
10
T5, T6 — COOLER SUCTION TEMPERATURE SENSORS — These thermistors are located next to the refrigerant inlet in the cooler head, and are inserted into a frictionfit 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.
OPERATING DATA
Sensors — The electronic control uses 4 to 10 thermistors 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 kV at 25 C (77 F) and are identical in temperature versus
resistance and voltage drop performance. Thermistor T10 is
a 10 kV at 25 C (77 F) and has a different temperature vs
resistance and voltage drop performance. See Thermistors
section on page 55 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. The sensor well is
located directly in the refrigerant path.
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.
T3, T4 — SATURATED CONDENSING TEMPERATURE
SENSORS — These 2 thermistors are clamped to the outside of a return bend of the condenser coils.
040-110*
130-210*
LEGEND
EXV — Electronic Expansion Valve
*And associated modular units.
Fig. 7 — Cooler Thermistor Locations
11
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
12
LEGEND
EXV — Electronic Expansion Valve
Fig. 9 — Compressor Thermistor Locations (T7 and T8)
Fig. 10 — Typical Thermistor Location (30GTN,R210, 315A, 390A, 420A/B Shown)
13
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.
T10 — REMOTE SPACE TEMPERATURE SENSOR —
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 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):
SPT (T10) PART NO. HH51BX006
SENSOR
SEN
5
6
Fig. 11 — Typical Space Temperature
Sensor Wiring
T-55 SPACE
SENSOR
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
TB5
SEN
6
TO CCN
COMM 1
BUS (PLUG)
AT UNIT
PART NO.
Regular Wiring
Plenum Wiring
1895
—
A21451
A48301
8205
884421
D6451
—
M13402
M64430
6130
—
CCN+
5
CCN GND
4
3
CCN-
2
1
Fig. 12 — CCN Communications Bus Wiring
to Optional Space Sensor RJ11 Connector
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.)
2. Insert and secure the red (+) wire to terminal 5 of the
space temperature sensor terminal block.
14
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-ofcharge 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.
Thermostatic Expansion Valves (TXV) —
Model 30GTN,R040-110 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 monitoring the proper amount of refrigerant into the cooler.
All TXVs are adjustable, but should not be adjusted unless
absolutely 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.
Compressor Ground Current Protection Board
(CGF) and Control Relay (CR) — The 30GTN,R130210, and associated modular units (see Table 1) contain one
compressor ground current protection board (CGF) for each
refrigeration circuit. The CGF contains logic that can detect
if the current-to-ground 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 or CPCS. On compressor A1 and B1 a loss-ofcharge switch is also included 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-ofcharge switch, all compressors in that circuit are also shut
down.
Compressor Protection Control System (CPCS)
or Control Relay (CR) — Each 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
Fig. 13 — Compressor Protection Control
System Module
15
Electronic Expansion Valve (EXV) (See Fig. 14)
— Standard units are equipped with a bottom seal 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), resulting in a superheat entering compressor cylinders of approximately 30 F (16.7 C). This increases
performance of cooler by reducing the amount of superheat
needed.
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.
Fig. 14 — Electronic Expansion Valve (EXV)
reset or space and outdoor-air temperature reset features. It
can also be reset from 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 randomly 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 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
start-up 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 start-up
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.
Energy Management Module (Fig. 15) — This
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 fieldsupplied 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 fieldsupplied 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 43 and 45 for further details.
Capacity Control — The control system cycles compressors, 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
16
J2
LEN
J3
TEST 1
PWR
J4
J1
STATUS
CEPL130351-01
CEBD430351-0396-01C
J5
J7
J6
RED LED - STATUS
TEST 2
GREEN LED LEN (LOCAL EQUIPMENT NETWORK)
Fig. 15 — Energy Management Module
The capacity routine runs every 30 seconds. The routine
attempts to maintain the Control Point at the desired set point.
Each time it runs, the control reads the entering and leaving
fluid temperatures. The control determines the rate at which
conditions are changing and calculates 2 variables based on
these conditions. Next, a capacity ratio 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.
17
Table 5A — Part Load Data Percent Displacement, Standard Units
UNIT
30GTN,GTR
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)
CONTROL
STEPS
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
25
A1*
50
A1
75
A1*, B1
100
A1,B1
24
A1*
47
A1
76
A1*,B1
100
A1,B1
31
A1*
44
A1
87
A1*,B1
100
A1,B1
28
A1*
42
A1
87
A1*,B1
100
A1,B1
33
A1*
50
A1
83
A1*,B1
100
A1,B1
19
A1*
27
A1
65
A1*,B1
73
A1,B1
92
A1*,A2,B1
100
A1,A2,B1
22
A1*
34
A1
52
A1*,B1*
67
A1*,B1
78
A1,B1
89
A1*,A2,B1
100
A1,A2,B1
17
A1*
25
A1
42
A1*,B1*
54
A1*,B1
62
A1,B1
79
A1*,A2,B1*
92
A1*,A2,B1
100
A1,A2,B1
18
A1*
27
A1
35
A1*,B1*
44
A1*,B1
53
A1,B1
56
A1*,A2,B1*
65
A1*,A2,B1
74
A1,A2,B1
82
A1*,A2,B1*,B2
91
A1*,A2,B1,B2
100
A1,A2,B1,B2
14
A1*
21
A1
29
A1*,B1*
36
A1*,B1
43
A1,B1
61
A1*,A2,B1*
68
A1*,A2,B1
75
A1,A2,B1
86
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
16
A1*
23
A1
31
A1*,B1*
39
A1*,B1
46
A1,B1
58
A1*,A2,B1*
66
A1*,A2,B1
73
A1,A2,B1
85
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
*Unloaded compressor.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
18
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
30
B1*
44
B1
52
A1*,B1*
63
A1,B1*
78
A1,B1
85
A1,A2,B1*
100
A1,A2,B1
25
B1*
38
B1
42
A1*,B1*
50
A1, B1*
62
A1,B1
79
A1*,A2,B1*
88
A1,A2,B1*
100
A1,A2,B1
18
B1*
27
B1
35
A1*,B1*
44
A1,B1
53
A1,B1
62
A1*,B1*,B2
71
A1,B1*,B2
80
A1,B1,B2
82
A1*,A2,B1*,B2
91
A1,A2,B1*,B2
100
A1,A2,B1,B2
14
B1*
21
B1
29
A1*,B1*
36
A1,B1*
43
A1,B1
53
A1*,B1*,B2
60
A1,B1*,B2
67
A1,B1,B2
86
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
16
A1*
23
A1
31
A1*,B1*
39
A1*,B1
46
A1,B1
58
A1*,A2,B1*
66
A1*,A2,B1
73
A1,A2,B1
85
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
Table 5A — Part Load Data Percent Displacement, Standard Units (cont)
UNIT
30GTN,GTR
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)
CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
13
A1*
20
A1
26
A1*,B1*
33
A1,B1
40
A1,B1
57
A1*,A2,B1*
63
A1*,A2,B1
70
A1,A2,B1
87
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
14
A1*
21
A1
29
A1*,B1*
36
A1*,B1
43
A1,B1
61
A1*,A2,B1*
68
A1*,A2,B1
75
A1,A2,B1
86
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
17
A1*
25
A1
33
A1*,B1*
42
A1*,B1
50
A1,B1
58
A1*,A2,B1*
67
A1*,A2,B1
75
A1,A2,B1
83
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
14
A1*
21
A1
28
A1*,B1*
35
A1*,B1
42
A1,B1
58
A1*,A2,B1*
64
A1*,A2,B1
71
A1,A2,B1
87
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
10
A1*
14
A1
26
A1*,B1*
35
A1*,B1
39
A1,B1
44
A1*,A2,B1*
53
A1*,A2,B1
57
A1,A2,B1
69
A1*,A2,B1*,B2
78
A1*,A2,B1,B2
82
A1,A2,B1,B2
87
A1*,A2,A3,B1*,B2
96
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
11
A1*
15
A1
29
A1*,B1*
38
A1*,B1
42
A1,B1
44
A1*,A2,B1*
53
A1*,A2,B1
58
A1,A2,B1
71
A1*,A2,B1*,B2
80
A1*,A2,B1,B2
85
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
95
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
*Unloaded compressor.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
19
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
13
B1*
20
B1
26
A1*,B1*
33
A1,B1
40
A1,B1
57
A1*,B1*,B2
63
A1,B1*,B2
70
A1,B1,B2
87
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
14
B1*
21
B1
29
A1*,B1*
36
A1,B1*
43
A1,B1
53
A1*,B1*,B2
60
A1,B1*,B2
67
A1,B1,B2
86
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
17
B1*
25
B1
33
A1*,B1*
42
A1,B1*
50
A1,B1
58
A1*,B1*,B2
67
A1,B1*,B2
75
A1,B1,B2
83
A1*,A2,B1*,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2
14
B1*
21
B1
28
A1*,B1*
35
A1,B1*
42
A1,B1
58
A1*,B1*,B2
64
A1,B1*,B2
71
A1,B1,B2
87
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
16
B1*
25
B1
26
A1*,B1*
31
A1,B1*
39
A1,B1
51
A1*,B1*,B2
56
A1,B1*,B2
64
A1,B1,B2
69
A1*,A2,B1*,B2
74
A1,A2,B1*,B2
82
A1,A2,B1,B2
87
A1*,A2,A3,B1*,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
18
B1*
27
B1
29
A1*,B1*
33
A1,B1*
42
A1,B1
55
A1*,B1*,B2
60
A1,B1*,B2
69
A1,B1,B2
71
A1*,A2,B1*,B2
75
A1,A2,B1*,B2
85
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
Table 5A — Part Load Data Percent Displacement, Standard Units (cont)
UNIT
30GTN,GTR
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)
CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
1
2
3
4
5
6
7
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
13
A1*
20
A1
26
A1*,B1*
33
A1*,B1
40
A1,B1
46
A1*,A2,B1*
53
A1*,A2,B1
60
A1,A2,B1
66
A1*,A2,B1*,B2
73
A1*,A2,B1,B2
80
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
93
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
11
A1*
17
A1
23
A1*,B1*
28
A1*,B1
33
A1,B1
39
A1*,A2,B1*
45
A1*,A2,B1
50
A1,A2,B1
56
A1*,A2,B1*,B2
61
A1*,A2,B1,B2
67
A1,A2,B1,B2
73
A1*,A2,A3,B1*,B2
78
A1*,A2,A3,B1,B2
83
A1,A2,A3,B1,B2
89
A1*,A2,A3,B1*,B2,B3
95
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
9
A1*
14
A1
19
A1*,B1*
23
A1*,B1
28
A1,B1
33
A1*,A2,B1*
37
A1*,A2,B1
42
A1,A2,B1
52
A1*,A2,B1*,B2
57
A1*,A2,B1,B2
61
A1,A2,B1,B2
72
A1*,A2,A3,B1*,B2
76
A1*,A2,A3,B1,B2
81
A1,A2,A3,B1,B2
91
A1*,A2,A3,B1*,B2,B3
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
13
A1
25
A1,B1
41
A1,A2,B1
56
A1,A2,B1,B2
78
A1,A2,A3,B1,B2
100
A1,A2,A3,B1,B2,B3
17
A1
33
A1,B1
50
A1,A2,B1
67
A1,A2,B1,B2
83
A1,A2,A3,B1,B2
100
A1,A2,A3,B1,B2,B3
11
A1
25
A1,B1
36
A1,A2,B1
56
A1,A2,B1,B2
67
A1,A2,A3,B1,B2
86
A1,A2,A3,B1,B2,B3
100
A1,A2,A3,A4,B1,B2,B3
9
A1
26
A1,B1
35
A1,A2,B1
51
A1,A2,B1,B2
67
A1,A2,A3,B1,B2
84
A1,A2,A3,B1,B2,B3
100
A1,A2,A3,A4,B1,B2,B3
*Unloaded compressor.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
20
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
13
B1*
20
B1
26
A1*,B1*
33
A1,B1*
40
A1,B1
46
A1*,B1*,B2
53
A1,B1*,B2
60
A1,B1,B2
66
A1*,A2,B1*,B2
73
A1,A2,B1*,B2
80
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
93
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
11
B1*
17
B1
23
A1*,B1*
28
A1,B1*
33
A1,B1
39
A1*,B1*,B2
45
A1,B1*,B2
50
A1,B1,B2
56
A1*,A2,B1*,B2
61
A1,A2,B1*,B2
67
A1,A2,B1,B2
73
A1*,A2,B1*,B2,B3
78
A1,A2,B1*,B2,B3
83
A1,A2,B1,B2,B3
89
A1*,A2,A3,B1*,B2,B3
95
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
9
B1*
14
B1
19
A1*,B1*
23
A1,B1*
28
A1,B1
38
A1*,B1*,B2
43
A1,B1*,B2
47
A1,B1,B2
52
A1*,A2,B1*,B2
57
A1,A2,B1*,B2
61
A1,A2,B1,B2
72
A1*,A2,B1*,B2,B3
76
A1,A2,B1*,B2,B3
81
A1,A2,B1,B2,B3
91
A1*,A2,A3,B1*,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
13
B1
25
A1,B1
41
A1,B1,B2
56
A1,A2,B1,B2
78
A1,A2,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
17
B1
33
A1,B1
50
A1,B1,B2
67
A1,A2,B1,B2
83
A1,A2,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
14
B1
25
A1,B1
44
A1,B1,B2
56
A1,A2,B1,B2
75
A1,A2,B1,B2,B3
86
A1,A2,A3,B1,B2,B3
100
A1,A2,A3,A4,B1,B2,B3
16
B1
26
A1,B1
42
A1,B1,B2
51
A1,A2,B1,B2
67
A1,A2,B1,B2,B3
84
A1,A2,A3,B1,B2,B3
100
A1,A2,A3,A4,B1,B2,B3
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders
UNIT
30GTN,GTR
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)
CONTROL
STEPS
1
2
3
4
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
25
A1*
50
A1
75
A1*,B1
100
A1,B1
24
A1*
47
A1
61
A1*,B1*
76
A1*,B1
100
A1,B1
31
A1*
44
A1
69
A1*,B1*
87
A1*,B1
100
A1,B1
28
A1*
42
A1
67
A1*,B1*
87
A1*,B1
100
A1,B1
33
A1*
50
A1
67
A1*,B1*
83
A1*,B1
100
A1,B1
19
A1*
27
A1
49
A1*,B1*
65
A1*,B1
73
A1,B1
76
A1*,A2,B1*
92
A1*,A2,B1
100
A1,A2,B1
11
A1†
22
A1*
34
A1
41
A1†,B1*
55
A1†,B1
67
A1*,B1
78
A1,B1
89
A1*,A2,B1
100
A1,A2,B1
8
A1†
17
A1*
25
A1
33
A1†,B1*
46
A1†,B1
54
A1*,B1
62
A1,B1
71
A1†,A2,B1*
84
A1†,A2,B1
92
A1*,A2,B1
100
A1,A2,B1
9
A1†
18
A1*
27
A1
35
A1†,B1
44
A1*,B1
53
A1,B1
56
A1†,A2,B1
65
A1*,A2,B1
74
A1,A2,B1
82
A1†,A2,B1,B2
91
A1*,A2,B1,B2
100
A1,A2,B1,B2
*Unloaded compressor.
†Two unloaders, both unloaded.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
21
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
25
B1*
50
B1
75
A1,B1*
100
A1,B1
37
B1*
53
B1
61
A1*,B1*
84
A1,B1*
100
A1,B1
38
B1*
56
B1
69
A1*,B1*
82
A1,B1*
100
A1,B1
38
B1*
58
B1
67
A1*,B1*
80
A1,B1*
100
A1,B1
33
B1*
50
B1
66
A1*,B1*
83
A1,B1*
100
A1,B1
31
B1*
47
B1
49
A1*,B1*
57
A1,B1*
73
A1,B1
76
A1*,A2,B1*
84
A1,A2,B1*
100
A1,A2,B1
15
B1†
30
B1*
44
B1
48
A1,B1†
63
A1,B1*
78
A1,B1
85
A1,A2,B1*
100
A1,A2,B1
—
—
13
B1†
25
B1*
38
B1
50
A1,B1*
62
A1,B1
67
A1*,A2,B1†
75
A1,A2,B1†
88
A1,A2,B1*
100
A1,A2,B1
—
—
—
—
9
B1†
18
B1*
27
B1
35
A1,B1†
44
A1,B1*
53
A1,B1
62
A1,B1†,B2
71
A1,B1*,B2
80
A1,B1,B2
82
A1,A2,B1†,B2
91
A1,A2,B1*,B2
100
A1,A2,B1,B2
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)
UNIT
30GTN,GTR
090, 245B (50 Hz)
100, 255B,
270B (60 Hz)
100, 255B,
270B (50 Hz)
110, 290B,
315B (60 Hz)
110, 290B,
315B (50 Hz)
CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
7
A1†
14
A1*
21
A1
29
A1†,B1
36
A1*,B1
43
A1,B1
49
A1†,A2,B1†
54
A1†,A2,B1*
61
A1†,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1†,A2,B1*,B2
86
A1†,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
8
A1†
16
A1*
23
A1
31
A1†,B1
39
A1*,B1
46
A1,B1
50
A1†,A2,B1*
58
A1†,A2,B1
66
A1*,A2,B1
73
A1,A2,B1
77
A1†,A2,B1*,B2
85
A1†,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
7
A1†
13
A1*
20
A1
26
A1†,B1
33
A1*,B1
40
A1,B1
43
A1†,A2,B1†
50
A1†,A2,B1*
57
A1†,A2,B1
63
A1*,A2,B1
70
A1,A2,B1
74
A1†,A2,B1†,B2
80
A1†,A2,B1*,B2
89
A1†,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
7
A1†
14
A1*
21
A1
29
A1†,B1
36
A1*,B1
43
A1,B1
47
A1†,A2,B1†
54
A1†,A2,B1*
61
A1†,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1†,A2,B1*,B2
86
A1†,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
8
A1†
17
A1*
25
A1
33
A1†,B1
42
A1*,B1
50
A1,B1
58
A1†,A2,B1
67
A1*,A2,B1
75
A1,A2,B1
83
A1†,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
*Unloaded compressor.
†Two unloaders, both unloaded.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
22
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
7
B1†
14
B1*
21
B1
29
A1,B1†
36
A1,B1*
43
A1,B1
46
A1*,B1†,B2
53
A1,B1†,B2
60
A1,B1*,B2
67
A1,B1,B2
72
A1†,A2,B1†,B2
79
A1*,A2,B1†,B2
86
A1,A2,B1†,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
8
B1†
16
B1*
23
B1
31
A1,B1†
39
A1,B1*
46
A1,B1
50
A1*,B1†,B2
58
A1,B1†,B2
66
A1,B1*,B2
73
A1,B1,B2
77
A1*,A2,B1†,B2
85
A1,A2,B1†,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2
7
B1†
13
B1*
20
B1
26
A1,B1†
33
A1,B1*
40
A1,B1
43
A1†,B1†,B2
50
A1*,B1†,B2
57
A1,B1†,B2
63
A1,B1*,B2
70
A1,B1,B2
74
A1†,A2,B1†,B2
80
A1*,A2,B1†,B2
87
A1,A2,B1†,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
7
B1†
14
B1*
21
B1
29
A1,B1†
36
A1,B1*
43
A1,B1
46
A1*,B1†,B2
53
A1,B1†,B2
60
A1,B1*,B2
67
A1,B1,B2
72
A1†,A2,B1†,B2
79
A1*,A2,B1†,B2
86
A1,A2,B1†,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
8
B1†
17
B1*
25
B1
33
A1,B1†
42
A1,B1*
50
A1,B1
58
A1,B1†,B2
67
A1,B1*,B2
75
A1,B1,B2
83
A1,A2,B1†,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2
Table 5B — Part Load Data Percent Displacement, with Accessory Unloaders (cont)
UNIT
30GTN,GTR
CONTROL
STEPS
130 (60 Hz)
130 (50 Hz)
150, 230A, 245A,
255A (60 Hz)
150, 230A, 245A,
255A (50 Hz)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
8
A1†
14
A1*
21
A1
22
A1†,B1*
28
A1†,B1
35
A1*,B1
42
A1,B1
44
A1†,A2,B1†
51
A1†,A2,B1*
58
A1†,A2,B1
64
A1,A2,B1
71
A1,A2,B1
73
A1†,A2,B1†,B2
80
A1†,A2,B1*,B2
87
A1†,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
6
A1†
10
A1*
14
A1
22
A1†,B1*
31
A1†,B1
35
A1*,B1
39
A1,B1
40
A1†,A2,B1*
49
A1†,A2,B1
53
A1*,A2,B1
57
A1,A2,B1
65
A1†,A2,B1*,B2
74
A1†,A2,B1,B2
78
A1*,A2,B1,B2
82
A1,A2,B1,B2
83
A1†,A2,A3,B1*,B2
91
A1†,A2,A3,B1,B2
96
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
6
A1†
11
A1*
15
A1
24
A1†,B1*
33
A1†,B1
38
A1*,B1
42
A1,B1
49
A1†,A2,B1
53
A1*,A2,B1
58
A1,A2,B1
66
A1†,A2,B1*,B2
75
A1†,A2,B1,B2
80
A1*,A2,B1,B2
85
A1,A2,B1,B2
91
A1†,A2,A3,B1,B2
95
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
6
A1†
13
A1
20
*A1
26
A1†,B1
33
A1*,B1
40
A1,B1
46
A1†,A2,B1
53
A1*,A2,B1
60
A1,A2,B1
66
A1†,A2,B1,B2
73
A1*,A2,B1,B2
80
A1,A2,B1,B2
86
A1†,A2,A3,B1,B2
93
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
*Unloaded compressor.
†Two unloaders, both unloaded.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
23
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
8
B1†
14
B1*
21
B1
22
A1*,B1†
28
A1,B1†
35
A1,B1*
42
A1,B1
44
A1†,B1†,B2
51
A1*,B1†,B2
58
A1,B1†,B2
64
A1,B1*,B2
71
A1,B1,B2
73
A1†,A2,B1†,B2
80
A1*,A2,B1†,B2
87
A1,A2,B1†,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
8
B1†
16
B1*
25
B1
31
A1,B1*
39
A1,B1
43
A1*,B1†,B2
47
A1,B1†,B2
56
A1,B1*,B2
64
A1,B1,B2
65
A1,A2,B1†,B2
74
A1,A2,B1*,B2
82
A1,A2,B1,B2
83
A1,A2,A3,B1†,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
9
B1†
18
B1*
27
B1
33
A1,B1*
42
A1,B1
46
A1*,B1†,B2
51
A1,B1†,B2
60
A1,B1*,B2
69
A1,B1,B2
75
A1,A2,B1*,B2
86
A1,A2,B1,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
6
B1†
13
B1*
20
B1
26
A1,B1†
33
A1,B1*
40
A1,B1
46
A1,B1†,B2
53
A1,B1*,B2
60
A1,B1,B2
66
A1,A2,B1†,B2
73
A1,A2,B1*,B2
80
A1,A2,B1,B2
86
A1,A2,A3,B1†,B2
93
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)
UNIT
30GTN,GTR
CONTROL
STEPS
170, 270A,
330A/B (60 Hz)
170, 270A,
330A/B, 360B (50 Hz)
190, 290A, 360A/B,
390B (60 Hz)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
LOADING
%
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
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
9
13
18
21
25
33
37
41
49
53
56
71
74
78
93
96
100
SEQUENCE A
Compressors
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
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†
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,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*
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
*Unloaded compressor.
†Two unloaders, both unloaded.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
24
LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
6
B1†
11
B1*
17
B1
17
A1*,B1†
23
A1,B1†
28
A1,B1*
33
A1,B1
34
A1*,B1†,B2
39
A1,B1†,B2
45
A1,B1*,B2
50
A1,B1,B2
51
A1*,A2,B1†,B2
56
A1,A2,B1†,B2
61
A1,A2,B1*,B2
67
A1,A2,B1,B2
67
A1*,A2,B1†,B2,B3
73
A1,A2,B1†,B2,B3
78
A1,A2,B1*,B2,B3
83
A1,A2,B1,B2,B3
84
A1*,A2,A3,B1†,B2,B3
89
A1,A2,A3,B1†,B2,B3
95
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
5
B1†
9
B1*
14
B1
14
A1*,B1†
19
A1,B1†
23
A1,B1*
28
A1,B1
29
A1†,B1†,B2
34
A1*,B1†,B2
38
A1,B1†,B2
43
A1,B1*,B2
47
A1,B1,B2
48
A1*,A2,B1†,B2
52
A1,A2,B1†,B2
57
A1,A2,B1*,B2
61
A1,A2,B1,B2
63
A1†,A2,B1†,B2,B3
67
A1*,A2,B1†,B2,B3
72
A1,A2,B1†,B2,B3
76
A1,A2,B1*,B2,B3
81
A1,A2,B1,B2,B3
82
A1†,A2,A3,B1†,B2,B3
87
A1*,A2,A3,B1†,B2,B3
91
A1,A2,A3,B1†,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B3,B3
9
B1*
13
B1
18
A1*,B1*
21
A1,B1*
25
A1,B1
33
A1*,B1*,B2
37
A1,B1*,B2
41
A1,B1,B2
49
A1*,A2,B1*,B2
53
A1,A2,B1*,B2
56
A1,A2,B1,B2
71
A1*,A2,B1*,B2,B3
74
A1,A2,B1*,B2,B3
78
A1,A2,B1,B2,B3
93
A1*,A2,A3,B1*,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont)
UNIT
30GTN,GTR
190, 290A, 360A,
390B (50 Hz)
210, 315A, 390A,
420A/B (60 Hz)
210, 315A, 390A,
420A/B (50 Hz)
CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LOADING
%
Displacement
(Approx)
11
17
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
7
9
17
23
26
27
32
35
43
48
51
59
65
67
75
81
84
92
97
100
SEQUENCE A
Compressors
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
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
A1*,A2,A3,A4,B1*,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
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
A1*,A2,A3,A4,B1*,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
*Unloaded compressor.
†Two unloaders, both unloaded.
NOTE: These capacity control steps may vary due to lag compressor sequencing.
25
LOADING
%
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
SEQUENCE B
Compressors
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,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*
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
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,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
capacity. Figure 16 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.
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. For
water circuits, the freeze point is 34 F (1.1 C). For brine
circuits, the freeze point is 8° F (4.4° C) below the cooling
set point (lower of 2 cooling set points for dual configuration). If the cooler suction temperature is below the freeze
point, the unit capacity may not be allowed to increase. If
the Cooler Suction temperature falls 24 to 29° F (13.3 to
16.1° C) below the freeze point minus 2.0 F (1.1 C) for
5 minutes, Mode 7 (Circuit A) or Mode 8 (Circuit B) is initiated and no additional lag compressor stages will be added.
If the Cooler Suction temperature falls 30° F (16.7° C) or
more below the freeze point minus 2.0 F (1.1 C) for 10 minutes, the circuit will shut down.
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.
MINUTES LEFT FOR START — This value is displayed
only in the network display tables (i.e., Service Tool,
Comfortworkst) 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. It is also used to delay
compressor restarts after the unit has shut off its lowest stage
of capacity. Typically, this time period is configured when
multiple machines are located on a single site. For example,
this gives the user the ability to prevent all the units from
restarting at once after a power failure. A value of zero for
this variable does not mean that the unit should be running.
LOADING SEQUENCE — The 30GTN,R compressor efficiency is greatest at partial load. Therefore, the following
sequence list applies to capacity control.
1. The next compressor will be started with unloaders energized on both lead compressors.
2. 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
26
2 STARTS
DEADBAND EXAMPLE
47
7
6
46
45
LWT (F)
LWT (C)
8
44
43
42
5
41
0
200
400
600
TIME (SECONDS)
800
1000
3 STARTS
STANDARD
DEADBAND
MODIFIED
DEADBAND
LEGEND
LWT — Leaving Water
Temperature
Fig. 16 — Deadband Multiplier
T4 is greater than 125 F (51.6 C), in which case all MBBcontrolled fans start immediately. If T3 and T4 are greater
than 95 F (35.0 C) just prior to circuit start-up, all MBBcontrolled fan stages are turned on to prevent excessive discharge pressure during pull-down. Fan sequences are shown
in Fig. 17.
Motormastert 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. 17 for condenser fan staging information.
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 = 2), 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
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.
27
FAN ARRANGEMENT
30GTN,R040-050
30GTN,R060-090, 230B, 245B
30GTN,R100,110, 255B-315B
30GTN,R130 (60 Hz)
POWER
30GTN,R130 (50 Hz), 150-210,
230A-315A, 330A/B-420A/B†
POWER
FAN
NO.
FAN RELAY
1
—
Compressor No. A1
2
—
Compressor No. B1
3
A1
First Stage of Condenser Fans
4
B1
Second Stage of Condenser Fans
1
—
Compressor No. A1
2
—
Compressor No. B1
3, 4
A1
First Stage of Condenser Fans
5, 6
B1
Second Stage of Condenser Fans
1
—
Compressor No. A1
2
—
Compressor No. B1
3, 4
A1
First Stage of Condenser Fans
5, 6, 7, 8
B1
Second Stage of Condenser Fans
5, 7
—
Compressor No. A1
6, 8
—
Compressor No. B1
1, 2
A1
First Stage of Condenser Fans
3, 4, 9, 10
B1
Second Stage of Condenser Fans
5, 7
—
Compressor No. A1
NORMAL CONTROL
6, 8
—
Compressor No. B1
1, 11
A1
First Stage of Condenser Fans, Circuit A
3, 9
A2
Second Stage of Condenser Fans, Circuit A
2, 12
B1
First Stage of Condenser Fans, Circuit B
4, 10
B2
Second Stage of Condenser Fans, Circuit B
*Control box.
†Fan numbers 11 and 12 do not apply to 30GT130-170 and associated modular units (see Table 1).
Fig. 17 — Condenser Fan Sequence
28
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 8 to enter the mode and display
TEST. Press ENTER 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 ENTER . Press
Marquee Display Usage (See Fig. 18 and
Tables 6-24) — The Marquee display module provides
the user interface to the ComfortLink™ control system. The
display has up and down arrow keys, an ESCAPE key, and
an ENTER key. These keys are used to navigate through
the different levels of the display structure. See Table 6. 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 ESCAPE and ENTER keys simultaneously will scroll a clear language text description across
the display indicating the full meaning of each display acronym. Pressing the ESCAPE and ENTER keys when the
display is blank (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 15.
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
ENTER 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 ENTER 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 to stop the display at the item value. Press
the ENTER key again so that the item value flashes. Use
the arrow keys to change the value or state of an item and
press the ENTER key to accept it. Press the ESCAPE key
and the item, value, or units display will resume. Repeat the
process as required for other items.
See Tables 6-24 for further details.
ESCAPE and the
button to enter the OUTS 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 submode 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 submode 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 17) — The dual chiller routine is available 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, the other chiller as the Slave. The Master chiller
Leaving Fluid Temperature thermistor (T1) must be installed in the common leaving chilled water line after the
piping has joined from both chillers. See Fig. 19 for thermistor location.
To configure the two chillers for operation, follow the example shown in Table 17. The Master chiller will be configured with a slave at address 6. Also in this example, the
Master 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 controls the Slave by forcing the Slave’s
CHIL_S_S (CCN) variable, control point (CTPT) and demand limit.
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 17. Similarly, set
the Master/Slave Select variable (MSSL) to SLVE. The variables LLBL, LLBD, an LLDY are not used by the Slave
chiller.
MODE
Run Status
Service Test
Temperature
Pressures
Setpoints
Inputs
Alarm Status
Outputs
Configuration
Time Clock
ESCAPE
ENTER
Operating Modes
Alarms
Fig. 18 — Scrollling Marquee Display
Service Test (See Table 8) — Both main power and
control circuit power must be on.
29
RETURN
FLUID
LEAVING
FLUID
MASTER
CHILLER
SLAVE
CHILLER
INSTALL MASTER CHILLER
LEAVING FLUID
THERMISTOR (T1) HERE
Fig. 19 — Dual Chiller Thermistor Location
Table 6 — Marquee Display Menu Structure)
RUN
STATUS
Auto
Display
(VIEW)
SERVICE TEMPERATURES PRESSURES
SET
TIME
OPERATING ALARMS
TEST
POINTS INPUTS OUTPUTS CONFIGURATION CLOCK
MODES
Manual
Unit
Ckt A
Cooling
Unit
Unit
Display
Unit Time
Modes
Current
Mode
Temperatures
Pressures
(COOL) Discrete Discrete
(DISP)
(TIME)
(MODE)
(CRNT)
On/Off
(UNIT)
(PRC.A)
(GEN.I) (GEN.O)
(TEST)
Machine
Ckt A/B
Ckt A
Ckt B
Head
Ckt A/B
Ckt A
Machine
Unit Date
Reset
Hours/Starts
Outputs
Temperatures
Pressures
Pressure (CRCT)
(CIR.A)
(UNIT)
(DATE)
Alarms
(RUN)
(OUTS)
(CIR.A)
(PRC.B)
(HEAD)
(RCRN)
Compressor Compressor
Ckt B
Unit
Ckt B
Options 1
Schedule
Alarm
Run Hours
Tests
Temperatures
Analog
(CIR.B)
(OPT1)
(SCHD)
History
(HOUR)
(COMP)
(CIR.B)
(4-20)
(HIST)
Compressor
Options 2
Reset
Starts
(OPT2)
History
(STRT)
(RHIS)
Temperature
Reset
(RSET)
Set Point
Select
(SLCT)
LEGEND
Ckt — Circuit
30
Table 7 — Run Status Mode and Sub-Mode Directory
SUB-MODE
VIEW
RUN
HOUR
STRT
KEYPAD
ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
EWT
XXX.X °F
ENTERING FLUID TEMP
LWT
XXX.X °F
LEAVING FLUID TEMP
SETP
XXX.X °F
ACTIVE SETPOINT
CTPT
XXX.X °F
CONTROL POINT
MODE
X
CONTROL MODE
OCC
YES/NO
OCCUPIED
CAP
XXX %
PERCENT TOTAL CAPACITY
STGE
XX
REQUESTED STAGE
ALRM
XX
CURRENT ALARMS & ALERTS
TIME
XX.XX
TIME OF DAY
MNTH
XX
MONTH OF YEAR
DATE
XX
DAY OF MONTH
YEAR
XXXX
YEAR OF CENTURY
HRS.U
XXXX
MACHINE OPERATING HOURS
STR.U
XXXX
MACHINE STARTS
HRS.A
XXXX
CIRCUIT A RUN HOURS
HRS.B
XXXX
CIRCUIT B RUN HOURS
HR.A1
XXXX
COMPRESSOR A1 RUN HOURS
HR.A2
XXXX
COMPRESSOR A2 RUN HOURS
HR.A3
XXXX
COMPRESSOR A3 RUN HOURS
HR.A4
XXXX
COMPRESSOR A4 RUN HOURS
HR.B1
XXXX
COMPRESSOR B1 RUN HOURS
HR.B2
XXXX
COMPRESSOR B2 RUN HOURS
HR.B3
XXXX
COMPRESSOR B3 RUN HOURS
HR.B4
XXXX
COMPRESSOR B4 RUN HOURS
ST.A1
XXXX
COMPRESSOR A1 STARTS
ST.A2
XXXX
COMPRESSOR A2 STARTS
ST.A3
XXXX
COMPRESSOR A3 STARTS
ST.A4
XXXX
COMPRESSOR A4 STARTS
ST.B1
XXXX
COMPRESSOR B1 STARTS
ST.B2
XXXX
COMPRESSOR B2 STARTS
ST.B3
XXXX
COMPRESSOR B3 STARTS
ST.B4
XXXX
COMPRESSOR B4 STARTS
ENTER
ENTER
ENTER
31
COMMENT
0
1
2
3
4
5
6
7
=
=
=
=
=
=
=
=
SERVICE TEST
OFF — LOCAL
OFF — CCN
OFF — TIME
OFF — EMRGCY
ON — LOCAL
ON — CCN
ON — TIME
00.0 — 23.59
1=JAN,2=FEB, etc.
01 — 31
Table 8 — Service Test Mode and Sub-Mode Directory
SUB-MODE
KEYPAD
ENTRY
TEST
ENTER
OUTS
COMP
ENTER
ENTER
ITEM
DISPLAY
ITEM EXPANSION
ON/OFF
SERVICE TEST MODE
FR.A1
ON/OFF
FAN A1 RELAY
FR.A2
ON/OFF
FAN A2 RELAY
EXV.A
0-100%
EXV % OPEN
FR.B1
ON/OFF
FAN B1 RELAY
FR.B2
ON/OFF
FAN B2 RELAY
EXV.B
0-100%
EXV % OPEN
CLR.P
ON/OFF
COOLER PUMP RELAY
RMT.A
ON/OFF
REMOTE ALARM RELAY
CC.A1
ON/OFF
COMPRESSOR A1 RELAY
CC.A2
ON/OFF
COMPRESSOR A2 RELAY
CC.A3
ON/OFF
COMPRESSOR A3 RELAY
CC.A4
ON/OFF
COMPRESSOR A4 RELAY
UL.A1
ON/OFF
UNLOADER A1 RELAY
UL.A2
ON/OFF
UNLOADER A2 RELAY
HGBP
ON/OFF
HOT GAS BYPASS RELAY
CC.B1
ON/OFF
COMPRESSOR B1 RELAY
CC.B2
ON/OFF
COMPRESSOR B2 RELAY
CC.B3
ON/OFF
COMPRESSOR B3 RELAY
CC.B4
ON/OFF
COMPRESSOR B4 RELAY
UL.B1
ON/OFF
UNLOADER B1 RELAY
UL.B2
ON/OFF
UNLOADER B2 RELAY
LEGEND
EXV — Electronic Expansion Valve
32
COMMENT
Use to Enable/Disable Manual Mode
Fan 3 (040-050)
Fans 3,4 (060-110, 230B-315B)
Fans 1,2 (130 [60 Hz])
Fan 1 (130 [50 Hz], 150, 170, 230A- 270A,
330A/B, 360B [50 Hz])
Fans 1,11 (190-210, 290A, 315A,
360A, 360B [60 Hz], 390A/B-420A/B)
Fans 3,9 (130 [50 Hz], 150-210,
230A-315A, 330A/B-420A/B)
Fan 4 (040-050)
Fans 5,6 (060-090, 230B-245B)
Fans 5,6,7,8 (100,110, 255B-315B)
Fans 3,4,9,10 (130 [60 Hz])
Fan 2 (130 [50 Hz], 150, 170, 230A- 270A,
330A/B, 360B [50 Hz])
Fans 2,12 (190-210,290A,315A,
360A, 360B [60 Hz] ,390A/B-420A/B)
Fans 4,10 (130 [50 Hz], 150-210, 230A-315A,
330A/B-420A/B)
Table 9 — Temperature Mode and Sub-Mode Directory
SUB-MODE
UNIT
CIR.A
CIR.B
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
CEWT
XXX.X °F
COOLER ENTERING FLUID
CLWT
XXX.X °F
COOLER LEAVING FLUID
OAT
XXX.X °F
OUTSIDE AIR TEMPERATURE
SPT
XXX.X °F
SPACE TEMPERATURE
SCT.A
XXX.X °F
SATURATED CONDENSING TMP
SST.A
XXX.X °F
SATURATED SUCTION TEMP
SGT.A
XXX.X °F
COMPRESSOR SUCTION TEMP
SUP.A
XXX.X °F
SUCTION SUPERHEAT TEMP
SCT.B
XXX.X °F
SATURATED CONDENSING TMP
SST.B
XXX.X °F
SATURATED SUCTION TEMP
SGT.B
XXX.X °F
COMPRESSOR SUCTION TEMP
SUP.B
XXX.X °F
SUCTION SUPERHEAT TEMP
ENTER
ENTER
COMMENT
Table 10 — Pressure Mode and Sub-Mode Directory
SUB-MODE
PRC.A
KEYPAD ENTRY
ITEM
ENTER
DP.A
SP.A
PRC.B
DP.B
ENTER
SP.B
DISPLAY
XXX.X
PSIG
XXX.X
PSIG
XXX.X
PSIG
XXX.X
PSIG
ITEM EXPANSION
COMMENT
DISCHARGE PRESSURE
SUCTION PRESSURE
DISCHARGE PRESSURE
SUCTION PRESSURE
Table 11 — Set Point Mode and Sub-Mode Directory
SUB-MODE
COOL
HEAD
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
COMMENT
ENTER
CSP.1
XXX.X °F
COOLING SETPOINT 1
Default: 44 F
CSP.2
XXX.X °F
COOLING SETPOINT 2
Default: 44 F
HD.P.A
XXX °F
HEAD PRESSURE SETPOINT A
Default: 113 F
HD.P.B
XXX °F
HEAD PRESSURE SETPOINT B
Default: 113 F
ENTER
Table 12 — Reading and Changing Chilled Fluid Set Point
SUB-MODE
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
CSP.1
44.0 °F
COOLING SETPOINT 1
COMMENT
Default: 44° F
ENTER
44.0 °F
Scrolling stops
ENTER
44.0 °F
Value flashes
COOL
Select 46.0
46.0 °F
ENTER
ESCAPE
CSP.1
Change accepted
46.0 °F
COOLING SETPOINT 1
33
Item/Value/Units scrolls again
Table 13 — Inputs Mode and Sub-Mode Directory
SUB-MODE
GEN.I
CRCT
4-20
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
COMMENT
ENTER
STST
STRT/STOP
START/STOP SWITCH
Enable/Off/Remote Contact Switch Input
FLOW
ON/OFF
COOLER FLOW SWITCH
DLS1
ON/OFF
DEMAND LIMIT SWITCH 1
DLS2
ON/OFF
DEMAND LIMIT SWITCH 2
ICED
ON/OFF
ICE DONE
DUAL
ON/OFF
DUAL SETPOINT SWITCH
FKA1
ON/OFF
COMPRESSOR A1 FEEDBACK
FKA2
ON/OFF
COMPRESSOR A2 FEEDBACK
FKA3
ON/OFF
COMPRESSOR A3 FEEDBACK
FKA4
ON/OFF
COMPRESSOR A4 FEEDBACK
OIL.A
OPEN/CLSE
OIL PRESSURE SWITCH A
FKB1
ON/OFF
COMPRESSOR B1 FEEDBACK
FKB2
ON/OFF
COMPRESSOR B2 FEEDBACK
FKB3
ON/OFF
COMPRESSOR B3 FEEDBACK
FKB4
ON/OFF
COMPRESSOR B4 FEEDBACK
OIL.B
OPEN/CLSE
OIL PRESSURE SWITCH B
DMND
XX.X MA
4-20 MA DEMAND SIGNAL
RSET
XX.X MA
4-20 MA RESET SIGNAL
CSP
XX.X MA
4-20 MA COOLING SETPOINT
ENTER
ENTER
34
Table 14 — Outputs Mode and Sub-Mode Directory
SUB-MODE
GEN.O
CIR.A
CIR.B
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
C.PMP
ON/OFF
COOLER PUMP RELAY
H.GAS
ON/OFF
HOT GAS BYPASS RELAY
FR.A1
ON/OFF
FAN A1 RELAY
FR.A2
ON/OFF
FAN A2 RELAY
CC.A1
ON/OFF
COMPRESSOR A1 RELAY
CC.A2
ON/OFF
COMPRESSOR A2 RELAY
CC.A3
ON/OFF
COMPRESSOR A3 RELAY
CC.A4
ON/OFF
COMPRESSOR A4 RELAY
UL.A1
ON/OFF
UNLOADER A1 RELAY
UL.A2
ON/OFF
UNLOADER A2 RELAY
EXV.A
XXX.X %
EXV % OPEN
FR.B1
ON/OFF
FAN B1 RELAY
FR.B2
ON/OFF
FAN B2 RELAY
CC.B1
ON/OFF
COMPRESSOR B1 RELAY
CC.B2
ON/OFF
COMPRESSOR B2 RELAY
CC.B3
ON/OFF
COMPRESSOR B3 RELAY
CC.B4
ON/OFF
COMPRESSOR B4 RELAY
UL.B1
ON/OFF
UNLOADER B1 RELAY
UL.B2
ON/OFF
UNLOADER B2 RELAY
EXV.B
XXX.X %
EXV % OPEN
ENTER
ENTER
COMMENT
LEGEND
EXV — Electronic Expansion Valve
Table 15 — Configuration Mode and Sub-Mode Directory
SUB-MODE
DISP
CCN
EMM
EXV
LCW
—
—
—
—
KEYPAD ENTRY
ENTER
ITEM
DISPLAY
ITEM EXPANSION
TEST
ON/OFF
TEST DISPLAY LEDS
METR
ON/OFF
METRIC DISPLAY
LANG
X
LANGUAGE SELECTION
LEGEND
Carrier Comfort Network
Energy Management Module
Electronic Expansion Valve
Leaving Chilled Water
35
COMMENT
Off = English
On = Metric
Default: 0
0 = English
1 = Espanol
2 = Francais
3 = Portugues
Table 15 — Configuration Mode and Sub-Mode Directory (cont)
SUB-MODE KEYPAD ENTRY
UNIT
ENTER
OPT1
ENTER
ITEM
TYPE
DISPLAY
X
ITEM EXPANSION
UNIT TYPE
TONS
XXX
UNIT SIZE
CAP.A
XXX
CIRCUIT A % CAPACITY
CMP.A
X
NUMBER CIRC A COMPRESSOR
CYL.A
X
COMPRESSOR A1 CYLINDERS
CMP.B
X
NUMBER CIRC B COMPRESSOR
CYL.B
X
COMPRESSOR B1 CYLINDERS
EXV
YES/NO
EXV MODULE INSTALLED
SH.SP
DF
EXV SUPERHEAT SETPOINT
SH.OF
DF
EXV SUPERHEAT OFFSET
REFG
X
REFRIGERANT
FAN.S
X
FAN STAGING SELECT
FLUD
X
COOLER FLUID
HGB.S
YES/NO
HOT GAS BYPASS SELECT
HPCM
X
HEAD PRESS. CONT. METHOD
HPCT
X
HEAD PRESS. CONTROL TYPE
PRTS
YES/NO
PRESSURE TRANSDUCERS
CURRENTLY NOT SUPPORTED
PMP.I
ON/OFF
COOLER PUMP INTERLOCK
Default: On
CPC
ON/OFF
COOLER PUMP CONTROL
Default: Off
CA.UN
X
NO. CIRCUIT A UNLOADERS
CB.UN
X
NO. CIRCUIT B UNLOADERS
EMM
YES/NO
EMM MODULE INSTALLED
LEGEND
CCN
EMM
EXV
LCW
—
—
—
—
Carrier Comfort Network
Energy Management Module
Electronic Expansion Valve
Leaving Chilled Water
36
COMMENT
Default: 1
1 = Air Cooled
Unit Size
60 Hz
040
50
045
43
050
46
060
43
070
50
080*
56
090*
50
100*
50
110*
54
130*
50
150*
50
170*
50
190*
50
210*
50
*And associated modular units.
50 Hz
43
46
43
50
57
62
54
50
50
52
60
48
50
52
4 = 040, 045 (60 Hz)
6 = 045 (50 Hz), 050-420
4 = 040 (60 Hz)
6 = 040 (50 Hz), 045-420
29
Default: 0
Range: −30 to 30 F
1 = R-22
1 = 2 Stage Independent (190-210, 290A,
315A, 360B [60 Hz], 390A/B-420A/B)
2 = 3 Stage Independent (130 [50 Hz], 150, 170,
230A-270A, 330A/B, 360B [50 Hz])
3 = 2 Stage Common (040-090,
230B,245B)
4 = 3 Stage Common (100-110,
130 [60 Hz], 255B-315B)
Default: 1
1 = Water
2 = Medium Temperature Brine
3 = Low Temperature Brine
(Not Supported)
Default: 2
1 = EXV Control
2 = Set Point Control
3 = Set Point Circuit A, EXV Circuit B
4 = EXV Circuit A, Set Point Circuit B
Default: 1
1 = No Control
2 = Air Cooled
Table 15 — Configuration Mode and Sub-Mode Directory (cont)
SUB-MODE
OPT2
RSET
SLCT
KEYPAD ENTRY
ENTER
ENTER
ENTER
ITEM
CTRL
DISPLAY
X
ITEM EXPANSION
CONTROL METHOD
CCNA
XXX
CCN ADDRESS
CCNB
XXX
CCN BUS NUMBER
BAUD
X
CCN BAUD RATE
LOAD
X
LOADING SEQUENCE SELECT
LLCS
X
LEAD/LAG CIRCUIT SELECT
LCWT
XX.X DF
HIGH LCW ALERT LIMIT
DELY
XX
MIN MINUTES OFF TIME
CRST
X
COOLING RESET TYPE
CRT1
XXX.X °F
NO COOL RESET TEMP
CRT2
XXX.X °F
FULL COOL RESET TEMP
DGRC
XX.X DF
DEGREES COOL RESET
DMDC
X
DEMAND LIMIT SELECT
DM20
XXX %
DEMAND LIMIT AT 20 MA
SHNM
XXX
LOADSHED GROUP NUMBER
SHDL
XXX %
LOADSHED DEMAND DELTA
SHTM
XXX MIN
MAXIMUM LOADSHED TIME
DLS1
XXX %
DEMAND LIMIT SWITCH 1
DLS2
XXX %
DEMAND LIMIT SWITCH 2
LLEN
ENBL/DSBL
LEAD/LAG CHILLER ENABLE
MSSL
SLVE/MAST
MASTER/SLAVE SELECT
Default: Master
SLVA
XXX
SLAVE ADDRESS
Default: 0
Range: 0 to 239
Default: Disable
LLBL
ENBL/DSBL
LEAD/LAG BALANCE SELECT
LLBD
XXX HRS
LEAD/LAG BALANCE DELTA
LLDY
XX MIN
LAG START DELAY
CLSP
X
COOLING SETPOINT SELECT
RL.S
ENBL/DSBL
RAMP LOAD SELECT
CRMP
X.X
COOLING RAMP LOADING
Z.GN
X.X
DEADBAND MULTIPLIER
37
COMMENT
Default: 0
0 = Switch
1 = 7 Day Schedule
2 = Occupancy
3 = CCN Control
Default: 1
Range: 1 to 239
Default: 0
Range: 0 to 239
Default: 3
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
Range: 2 to 60 F
Default: 0 Minutes
Range: 0 to 15 Minutes
0 = No Reset
1 = 4 to 20 mA Input
2 = Outdoor Air Temperature
3 = Return Fluid
4 = Space Temperature
Default: 125 F
Range: 0 to 125 F
Default: 0° F
Range: 0 to 125 F
Default: 0° F
Range: −30 to 30 F
Default: 0
0 = None
1 = Switch
2 = 4 to 20 mA Input
3 = CCN Loadshed
Default: 100%
Range: 0 to 100%
Default: 0
Range: 0 to 99
Default: 0%
Range: 0 to 60%
Default: 60 minutes
Range: 0 to 120 minutes
Default: 80%
Range: 0 to 100%
Default: 50%
Range: 0 to 100%
Default: Disable
Default: 168 hours
Range: 40 to 400 Hours
Default: 5 minutes
Range: 0 to 30 minutes
Default: 0
0 = Single
1 = Dual Switch
2 = Dual Clock
3 = 4 to 20 mA Input
Default: Enable
Default: 1.0
Range: 0.2 to 2.0
Default: 1.0
Range: 1.0 to 4.0
Table 16 — Example of Temperature Reset (Outdoor Air) Configuration
SUB-MODE
RSET
KEYPAD ENTRY
ENTER
ITEM
CRST
DISPLAY
0
ITEM EXPANSION
COOLING RESET TYPE
0
1
2
3
4
=
=
=
=
=
COMMENT
No reset
4 to 20 mA input
Outdoor Air Temp
Return Fluid
Space Temperature
ENTER
0
Scrolling stops
ENTER
0
Value flashes
2
Select 2
2
Change accepted
CRST
2
Item/Value/Units scrolls again
CRT1
125
Range: 0 to 125 F
ENTER
125
Scrolling stops
ENTER
125
Value flashes
75
Select 75
75
Change accepted
CRT1
75
Item/Value/Units scrolls again
CRT2
0
Range: 0 to 125 F
ENTER
0
Scrolling stops
ENTER
0
Value flashes
50
Select 50
50
Change accepted
CRT2
50
Item/Value/Units scrolls again
DGRC
0
Range: −30 to 30 F
ENTER
0
Scrolling stops
ENTER
0
Value flashes
10
Select 10
10
Change accepted
10
Item/Value/Units scrolls again
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
DGRC
NOTE: The example below shows how to configure the chiller for temperature reset by an accessory
outdoor-air temperature sensor. The chiller will be configured for a full reset of 10 degrees at 50 F and
no reset at 75 F.
38
Table 17 — Example of Configuring Dual Chiller Control
SUB-MODE KEYPAD ENTRY ITEM DISPLAY
RSET
ENTER
CRST
0
LLDY
5
ITEM EXPANSION
COMMENT
LAG START DELAY
ENTER
5
Scrolling stops
ENTER
5
Value flashes
10
Select 10
10
Change accepted
ENTER
ESCAPE
LLDY
10
LLBD
168
LEAD/LAG BALANCE DELTA
LLBL
DSBL
LEAD/LAG BALANCE SELECT
No change needed. Default set for weekly changeover
ENTER
DSBL
Scrolling stops
ENTER
DSBL
Value flashes
ENBL
Select Enable
ENBL
Change accepted
ENTER
ESCAPE
LLBL
ENBL
SLVA
0
SLAVE ADDRESS
ENTER
0
Scrolling stops
ENTER
0
Value flashes
6
Select 6
6
Change accepted
ENTER
ESCAPE
SLVA
6
MSSL
MAST
MASTER/SLAVE SELECT
LLEN
DSBL
LEAD/LAG CHILLER ENABLE
No change needed. Default set for Master
ENTER
DSBL
Scrolling stops
ENTER
DSBL
Value flashes
MAST
Select Master
Change accepted
ENTER
LLEN
MAST
ESCAPE
LLEN
MAST
LEAD/LAG CHILLER ENABLE
39
Item/Value/Units scrolls again
Table 18 — Example of Compressor Lead/Lag Configuration
SUB-MODE KEYPAD ENTRY ITEM DISPLAY
OPT2
ENTER
CTRL
0
CCNA
1
CCNB
0
BAUD
3
LOAD
1
LLCS
1
ITEM EXPANSION
COMMENT
CONTROL METHOD
LEAD/LAG CIRCUIT SELECT DEFAULT: 2 (040-070); 1 (080-420)
ENTER
1
Scrolling stops
ENTER
1
Value flashes
3
Select 3
NOTE: Options 1 and/or 3 not valid for sizes 040-070 without Circuit B accessory unloader installed
3
Change accepted
ENTER
LLCS
ESCAPE
3
LEAD/LAG CIRCUIT SELECT Item/Value/Units scrolls again
Table 19 — Time Clock Mode and Sub-Mode Directory
SUB-MODE
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
COMMENT
TIME
ENTER
HH.MM
XX.XX
HOUR AND MINUTE
Military (00.00-23.59)
ENTER
MNTH
XX
MONTH
DOM
XX
DATE OF MONTH
DAY
X
DAY OF WEEK
YEAR
XXXX
YEAR OF CENTURY
MON.O
XX.XX
MONDAY OCCUPIED TIME
MON.U
XX.XX
MONDAY UNOCCUPIED TIME
TUE.O
XX.XX
TUESDAY OCCUPIED TIME
TUE.U
XX.XX
TUESDAY UNOCCUPIED TIME
WED.O
XX.XX
WEDNESDAY OCCUPIED TIME
WED.U
XX.XX
WEDNESDAY UNOCC TIME
THU.O
XX.XX
THURSDAY OCCUPIED TIME
THU.U
XX.XX
THURSDAY UNOCCUPIED TIME
FRI.O
XX.XX
FRIDAY OCCUPIED TIME
FRI.U
XX.XX
FRIDAY UNOCCUPIED TIME
SAT.O
XX.XX
SATURDAY OCCUPIED TIME
SAT.U
XX.XX
SATURDAY UNOCCUPIED TIME
SUN.O
XX.XX
SUNDAY OCCUPIED TIME
SUN.U
XX.XX
SUNDAY UNOCCUPIED TIME
DATE
SCHD
ENTER
40
1=Jan, 2=Feb, etc.
Range 1-31
1=Mon, 2=Tue, etc.
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
Range: 00.00 to
Default: 00.00
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
23.59
Table 20 — Setting an Occupied Time Schedule
SUB-MODE
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
COMMENT
ENTER
MON.O
00.00
MONDAY OCCUPIED TIME
TIME IN MILITARY FORMAT (HH.MM)
ENTER
00.00
Scrolling stops
ENTER
00.00
Hours flash
07.00
Select 7 AM
07.00
Change accepted, minutes flash
07.30
Select 30
07.30
Change accepted
SCHD
ENTER
ENTER
MON.O
ESCAPE
07.30
MONDAY OCCUPIED TIME
Item/Value/Units scrolls again
Table 21 — Operating Mode and Sub-Mode Directory
SUB-MODE
MODE
KEYPAD ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
MD01
ON/OFF
FSM CONTROLLING CHILLER
MD02
ON/OFF
WSM CONTROLLING CHILLER
MD03
ON/OFF
MASTER/SLAVE CONTROL
MD04
ON/OFF
LOW SOURCE PROTECTION
MD05
ON/OFF
RAMP LOAD LIMITED
MD06
ON/OFF
TIMED OVERRIDE IN EFFECT
MD07
ON/OFF
LOW COOLER SUCTION TEMP A
MD08
ON/OFF
LOW COOLER SUCTION TEMP B
MD09
ON/OFF
SLOW CHANGE OVERRIDE
MD10
ON/OFF
MINIMUM OFF TIME ACTIVE
MD11
ON/OFF
LOW SUCTION SUPERHEAT A
MD12
ON/OFF
LOW SUCTION SUPERHEAT B
MD13
ON/OFF
DUAL SETPOINT
MD14
ON/OFF
TEMPERATURE RESET
MD15
ON/OFF
DEMAND LIMIT IN EFFECT
MD16
ON/OFF
COOLER FREEZE PROTECTION
MD17
ON/OFF
LO TMP COOL/HI TMP HEAT
MD18
ON/OFF
HI TMP COOL/LO TMP HEAT
LEGEND
FSM — Flotronic™ System Manager
WSM — Water System Manager
41
COMMENT
Table 22 — Operating Modes
MODE NO.
01
02
03
04
05
ITEM EXPANSION
FSM CONTROLLING CHILLER
WSM CONTROLLING CHILLER
MASTER/SLAVE CONTROL
LOW SOURCE PROTECTION
RAMP LOAD LIMITED
06
TIMED OVERRIDE IN EFFECT
07
LOW COOLER SUCTION TEMP A
08
LOW COOLER SUCTION TEMP B
09
SLOW CHANGE OVERRIDE
10
MINIMUM OFF TIME ACTIVE
11
LOW SUCTION SUPERHEAT A
12
LOW SUCTION SUPERHEAT B
13
DUAL SETPOINT
14
TEMPERATURE RESET
15
DEMAND LIMIT IN EFFECT
16
COOLER FREEZE PROTECTION
17
LO TMP COOL/HI TMP HEAT
18
HI TMP COOL/LO TMP HEAT
DESCRIPTION
Flotronic™ System Manager (FSM) is controlling the chiller
Water System Manager (WSM) is controlling the chiller
Lead/Lag Chiller control is enabled.
Not currently supported.
Ramp load (pulldown) limiting in effect. In this mode, the rate
at which leaving fluid temperature is dropped is limited to a
predetermined value to prevent compressor overloading. See
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.
Timed override is in effect. This is a 1 to 4 hour temporary
override of the programmed schedule, forcing unit to Occupied
mode. Override can be implemented with unit under Local (Enable) or CCN control. Override expires after each use.
Circuit A capacity may be limited due to operation of this mode.
Control will 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.
Circuit B capacity may be limited due to operation of this
mode. Control will 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.
Slow change override is in effect. The leaving fluid temperature
is close to and moving towards the control point.
Chiller is being held off by Minutes Off Time (DELY) found under Options 2 (OPT2) section of Configuration mode.
Circuit A capacity may be limited due to operation of this mode.
Control will attempt to correct this situation for up to 5 minutes
before shutting the circuit down. See Alarms and Alerts section
for more information.
Circuit B capacity may be limited due to operation of this
mode. Control will attempt to correct this situation for up to
5 minutes before shutting the circuit down. See Alarms and
Alerts section for more information.
Dual set point mode is in effect. Chiller controls to CSP.1 during occupied periods and CSP.2 during unoccupied periods.
Both CSP.1 and CSP.2 are located under COOL in the Set
Point mode.
Temperature reset is in effect. In this mode, chiller is using
temperature 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.
Demand limit is in effect. This indicates that the capacity of the
chiller 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.
Cooler fluid temperatures are approaching the Freeze point
(see Alarms and Alerts section for definition). The chiller will be
shut down when either fluid temperature falls below the Freeze
point.
Chiller is in Cooling mode and the rate of change of the leaving
fluid is negative 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.
Chiller is in Cooling mode and the rate of change of the leaving
fluid is positive 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.
42
Table 23 — Alarms Mode and Sub-Mode Directory
SUB-MODE
KEYPAD ENTRY
ITEM
ITEM EXPANSION
CRNT
ENTER
AXXX or TXXX
CURRENTLY ACTIVE ALARMS
RCRN
ENTER
YES/NO
RESET ALL CURRENT ALARMS
HIST
ENTER
AXXX or TXXX
ALARM HISTORY
RHIS
ENTER
YES/NO
RESET ALARM HISTORY
COMMENT
Alarms are shown as AXXX.
Alerts are shown as TXXX.
Alarms are shown as AXXX.
Alerts are shown as TXXX.
Table 24 — Example of Reading and Clearing Alarms
SUB-MODE
KEYPAD ENTRY
ITEM
ITEM EXPANSION
CRNT
ENTER
AXXX or TXXX
CURRENTLY ACTIVE ALARMS
CRNT
ESCAPE
ENTER
COMMENT
ACTIVE ALARMS (AXXX) OR
ALERTS (TXXX) DISPLAYED.
NO
Use to clear active alarms/alerts
NO
NO Flashes
YES
Select YES
NO
Alarms/alerts clear, YES changes to NO
RCRN
ENTER
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.
Temperature Reset — 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 (HH79NZ014 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 25 on page 42 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. 20. 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.
LEGEND
EWT — Entering Water (Fluid) Temperature
LWT — Leaving Water (Fluid) Temperature
Fig. 20 — Standard Chilled Fluid Temperature
Control — No Reset
43
Table 25 — Configuring Temperature Reset
MODE
KEYPAD SUB-MODE KEYPAD ITEM DISPLAY
GREEN LED)
ENTRY
ENTRY
CONFIGURATION
ENTER
ENTER
DISP
TEST ON/OFF
TEST DISPLAY LEDs
UNIT
ENTER
TYPE
X
UNIT TYPE
OPT1
ENTER
FLUD
X
COOLER FLUID
OPT2
ENTER
CTRL
X
CONTROL METHOD
CRST
X
COOLING RESET TYPE
RSET
ENTER
ITEM
EXPANSION
COMMENT
0 = No Reset
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 (Connect to TB5-5,6)
4 = Space Temperature
Default: 125 F (51.7 C)
CRT1 XXX.X F NO COOL RESET TEMP Range: 0 to125 F
Set to 4.0 for CRST= 1
Default: 0° F (−17.8 C)
CRT2 XXX.X F FULL COOL RESET TEMP Range: 0 to 125 F
Set to 20.0 for CRST=1
0° F (0° C)
DGRC XX.X °F DEGREES COOL RESET Default:
Range: −30 to 30° F (−16.7 to 16.7 C)
The following are examples of outdoor air and space temperature resets:
LEGEND
LWT — Leaving Water (Fluid) Temperature
LEGEND
LWT — Leaving Water (Fluid) Temperature
44
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 25.
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 userconfigurable 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 26. 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 2 set point. The demand limit stage that is set to the
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 26
and Fig. 21.
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 26.
The Loadshed Group number is established by the CCN
system designer. The PIC (product integrated control) will
respond to a Redline command from the Loadshed control.
When the Redline command is received, the current stage of
capacity is set to the maximum stages available. Should the
loadshed control send a Loadshed command, the PIC will
reduce the current stages by the value entered for Loadshed
Demand delta. The Maximum Loadshed Time is the 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.
Table 26 — Configuring Demand Limit
MODE
CONFIGURATION
KEYPAD
ENTRY
SUB-MODE
KEYPAD
ENTRY
ITEM
DISPLAY
ITEM EXPANSION
ENTER
DISP
ENTER
TEST
ON/OFF
Test Display LEDs
UNIT
ENTER
TYPE
X
Unit Type
OPT1
ENTER
FLUD
X
Cooler Fluid
OPT2
ENTER
CTRL
X
Control Method
RSET
ENTER
CRST
X
Cooling Reset Type
CRT1
XXX.X °F
CRT2
XXX.X °F
No Cool Reset
Temperature
Full Cool Reset
Temperature
DGRC
XX.X DF
Degrees Cool Reset
DMDC
X
Demand Limit Select
DM20
XXX %
SHNM
XXX
SHDL
XXX%
SHTM
XXX MIN
DLS1
XXX %
DLS2
XXX%
Demand Limit at
20 mA
Loadshed Group
Number
Loadshed Demand
Delta
Maximum Loadshed
Time
Demand Limit
Switch 1
Demand Limit
Switch 2
45
COMMENT
Default: 0
0 = None
1 = Switch
2 = 4 to 20 mA Input
3 = CCN Loadshed
Default: 100%
Range: 0 to 100
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
MAX. ALLOWABLE LOAD (%)
100
50% CAPACITY AT 20 mA
80
60
40 100% CAPACITY AT 4 mA
75% CAPACITY AT 12 mA
20
0
0
2
12
6
8
10
14
DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT (VOLTS DC)
4
16
18
20
Fig. 21 — 4 to 20 mA Demand Limiting
the quick test and initialization features built into the
ComfortLink™ control.
Follow the procedure below to diagnose and correct EXV
problems.
TROUBLESHOOTING
Compressor Protection Control System (CPCS)
Board — The compressor protection board controls the
compressor and compressor crankcase heater.
The ground current protection is provided by the compressor 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 45 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).
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 valve
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 terminal strips on EXV board.
1. Check color coding and wire connections. Make sure that
wires are connected to correct terminals at J6 and J7 terminal strips 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 terminal strips and
at EXVs. Be sure EXV connections are not crossed.
STEP 3 — CHECK RESISTANCE OF EXV MOTOR WINDINGS — Remove plug at J6 and/or J7 terminal strip 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.
Compressor Ground Current (CGC) Board
(30GTN,R130-210, 230A-315A, and 330A/B420A/B) — One board is used for each circuit 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.
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. Use service test to determine if thermistors are shorted or
open.
2. Refer to Thermistors section on page 57 for details on
checking thermistor calibration.
EXV Troubleshooting — If it appears that the EXV is
not properly controlling operating suction pressure or superheat, there are a number of checks that can be made using
46
liquid line service valve. Turn the ENABLE/OFF/REMOTE
contact switch and allow unit to operate. Verify proper
operation of unit.
This process of opening and closing the EXV (EXV.A/
EXV.B under OUTS) can be repeated by using these Service
Test steps and recycling the control as described in the preceding steps. If the valve does not operate as described when
properly connected to the processor and receiving the correct signals, it should be replaced.
If operating problems persist after reassembly, they may
be due to out-of-calibration thermistor(s) or intermittent connections between the EXV board terminals and the EXV plug.
Recheck all wiring connections and voltage signals.
Other possible causes of improper refrigerant flow control could be restrictions in the liquid line. Check for plugged
filter drier(s), restricted metering slots in the EXV, or partially closed liquid line service valves. Formation of ice or
frost on the lower body of the EXV is one symptom of restricted metering slots. Clean or replace the valve if necessary. Wrap a wet cloth around the valve if it is to be replaced
to prevent the heat from damaging the internal components
of the valve.
NOTE: Frosting of the valve is normal during service test
and at initial start-up. The frost should dissipate after 5 to
10 minutes operation of a system that is operating properly.
NOTE: The EXV orifice is a screw-in type and may be removed for inspection and cleaning. Once the top cover has
been removed, the EXV motor may be taken out by removing the 2 cap screws securing motor to valve body. Pull motor, lead screw, and the slide assembly up off the orifice assembly. See Fig. 14. A slot has been cut in top of orifice
assembly to facilitate removal using a large screwdriver. Turn
orifice assembly counterclockwise to remove.
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.
Reassembly of valve is made easier by screwing the slide
and lead screw assembly out of the motor. Align hole in top
of slide with the guide pin in orifice assembly and gently
push slide and lead screw onto orifice assembly about halfway. Screw motor onto lead screw and secure EXV motor
with cap screws. Be careful not to twist or pull on wires from
EXV motor to valve cover pin connections. Check EXV operation in quick step steps.
3. Make sure that thermistor leads are connected to the proper
pin terminals at the J5 terminal strip 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. Remove screws holding top cover of EXV. Carefully remove top cover, using caution to avoid damage to the O-ring
seal and motor leads. If EXV plug was disconnected during this process, reconnect it after the cover is removed.
4. Note position of lead screw (see Fig. 14). If valve has
responded properly to processor signals in Step 5.1 above,
the valve should be fully open and the lead screw should
protrude approximately 1⁄4 in. to 3⁄4 in. above the top of
the motor.
5. Recycle the control by turning the control circuit power
on and switching 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. With the cover lifted off the EXV valve
body, observe the operation of the valve motor and lead
screw. The motor should turn in the counterclockwise (CCW)
direction and the lead screw should move down into the
motor hub until the valve is fully closed. Lead screw movement should be smooth and uniform from the fully open
to the fully closed position.
6. When test has been completed, carefully reassemble
expansion valve. Be careful not to damage motor or
O-ring when reassembling valve. Open compressor service valves and close compressor circuit breakers. Open
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 27.
47
Table 27 — Alarm and Alert Codes
ALARM/
ALERT
CODE
51
ALARM
OR
ALERT
Alert
52
Alert
Circuit A, Compressor 2
Failure
Compressor feedback
signal does not match
relay state
53
Alert
Circuit A, Compressor 3
Failure
Compressor feedback
signal does not match
relay state
54
Alert
Circuit A, Compressor 4
Failure
Compressor feedback
signal does not match
relay state
55
Alert
Circuit B, Compressor 1
Failure
Compressor feedback
signal does not match
relay state
56
Alert
Circuit B, Compressor 2
Failure
Compressor feedback
signal does not match
relay state
57
Alert
Circuit B, Compressor 3
Failure
Compressor feedback
signal does not match
relay state
60
Alarm
Cooler Leaving Fluid
Thermistor Failure (T1)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
Thermistor outside
range of −40 to 245
(−40 to 118 C)
61
64
65
66
67
68
69
73
Alarm
Alert
Alert
Alert
Alert
Alert
Alert
Alert
DESCRIPTION
Circuit A, Compressor 1
Failure
Cooler Entering Fluid
Thermistor Failure (T2)
Circuit A Saturated Condensing Thermistor Failure (T3)
Circuit B Saturated Condensing Thermistor Failure (T4)
Circuit A Saturated Suction Thermistor Failure
(T5)
Circuit B Saturated Suction Thermistor Failure
(T6)
Compressor A1 Suction
Gas Thermistor Failure
(T7)
Compressor B1 Suction
Gas Thermistor Failure
(T8)
Outside Air Thermistor
Failure (T9)
WHY WAS THIS
ALARM
GENERATED?
Compressor feedback
signal does not match
relay state
RESET
METHOD
PROBABLE
CAUSE
Circuit A shut down.
Manual
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
Manual
F
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.
High-pressure or loss-ofcharge switch open, faulty
control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure switch open,
faulty control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure switch open,
faulty control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure switch open,
faulty control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure or loss-ofcharge switch open, faulty
control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure switch open,
faulty control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
High-pressure switch open,
faulty control relay or CPCS
board, loss of condenser
air, liquid valve closed, operation beyond capability.
Thermistor failure, damaged
cable/wire or wiring error.
Chiller shutdown after
pumpdown complete.
Automatic
F
Thermistor failure, damaged
cable/wire or wiring error.
Circuit A shutdown
after pumpdown complete. (EXV only)
Circuit B shutdown
after pumpdown
complete.
Circuit A shutdown
after pumpdown complete. (EXV only)
Circuit B shutdown
after pumpdown
complete.
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.
Temperature reset disabled. Chiller runs under normal control/set
points.
Circuit A shutdown
after pumpdown
complete.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
Automatic
Circuit B shutdown
after pumpdown
complete
Automatic
Faulty expansion valve or
EXV board, faulty cooler
suction thermistor (T5) or
leaving fluid thermistor (T1).
Faulty expansion valve or
EXV board, faulty cooler
suction thermistor (T6) or
leaving fluid thermistor (T1).
F
F
F
F
F
F
F
74
Alert
Space Temperature
Thermistor Failure (T10)
Thermistor outside
range of −40 to 245 F
(−40 to 118 C)
77
Alert
78
Alert
Circuit A Saturated
Suction Temperature
exceeds Cooler Leaving
Fluid Temperature
Circuit B Saturated
Suction Temperature
exceeds Cooler Leaving
Fluid Temperature
Saturated suction is
greater than leaving
fluid temperature for
more than 5 minutes
Saturated suction is
greater than leaving
fluid temperature for
more than 5 minutes
48
ACTION TAKEN
BY CONTROL
Manual
Manual
Manual
Manual
Automatic
Table 27 — Alarm and Alert Codes (cont)
ALARM/ ALARM
ALERT
OR
DESCRIPTION
CODE ALERT
112
Alert
Circuit A High Suction
Superheat
WHY WAS THIS
ACTION TAKEN
ALARM
BY CONTROL
GENERAED?
If EXV is greater than
Circuit A shutdown
98%, suction superheat is after pumpdown
greater than 75 F (41.7 C) complete.
and saturated suction temperature is less than MOP
for 5 minutes
RESET
METHOD
PROBABLE
CAUSE
Manual
Manual
Faulty expansion valve
or EXV board, low refrigerant charge,
plugged filter drier,
faulty suction gas thermistor (T7) or cooler
thermistor (T5).
Faulty expansion 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).
113
Alert
Circuit B High Suction
Superheat
If EXV is greater than
Circuit B shutdown
98%, suction superheat is after pumpdown
greater than 75 F (41.7 C) complete.
and saturated suction temperature is less than MOP
for 5 minutes
114
Alert
Circuit A Low Suction
Superheat
Circuit A shutdown
after pumpdown
complete.
Automatic restart
after first daily
occurrence. Manual
restart thereafter.
115
Alert
Circuit B Low Suction
Superheat
Circuit B shutdown
after pumpdown
complete.
Automatic restart
after first daily
occurrence. Manual
restart thereafter.
Faulty expansion valve
or EXV board, faulty
suction gas thermistor
(T8) or cooler thermistor (T6).
116
Alert
Circuit A Low Cooler
Suction Temperature
If EXV is greater than
10%, and either suction
superheat is less than
19 F (10.6 C) or saturated
suction temperature is
greater than MOP for
5 minutes
If EXV is greater than
10%, and either suction
superheat is less than
19 F (10.6 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
1. Mode 7 initiated.
No additional
capacity increases. Alert
not tripped.
1. Automatic reset
if corrected.
2. Circuit shutdown
without going
through pumpdown.
2. Manual
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.
1. Mode 8 initiated.
No additional
capacity increases. Alert
not tripped.
1. Automatic reset
if corrected.
2. Circuit shutdown
without going
through pumpdown.
2. Manual
Oil pressure switch open
after 1 minute of continuous operation
Circuit shutdown
Manual
without going
through pumpdown.
117
Alert
Circuit B Low Cooler
Suction Temperature
118
Alert
Circuit A Low Oil
Pressure
119
Alert
Circuit B Low Oil
Pressure
LEGEND
CCN
CPCS
CXB
EMM
EXV
FSM
MBB
MOP
WSM
—
—
—
—
—
—
—
—
—
Circuit shutdown
Manual
without going
through pumpdown.
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 pump failure, low
oil level, switch failure
or compressor circuit
breaker tripped.
Oil pump failure, low
oil level, switch failure
or compressor circuit
breaker tripped.
*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/CSP.2
−8° F (4.4 C) for dual set point configuration.
Carrier Comfort Network
Compressor Protection Control System
Compressor Expansion Board
Energy Management Module
Electronic Expansion Valve
Flotronic™ System Manager
Main Base Board
Maximum Operating Pressure
Water System Manager
NOTE: The following table shows illegal configurations:
1 Zero compressors in a circuit
2 Four compressors in a circuit with two unloaders
Four compressors in a circuit with one unloader and hot gas
3 bypass
4 Two unloaders and hot gas bypass in a circuit.
5 More than one compressor quantity difference between circuits
6 Fluid type of low temperature brine
cooled head pressure control with common fan staging and
7 Air
different head pressure control methods for each circuit.
49
Table 27 — Alarm and Alert Codes (cont)
ALARM/ ALARM
ALEERT
OR
DESCRIPTION
CODE ALERT
150
Alarm Emergency Stop
WHY WAS THIS
ALARm
GENERATED?
CCN emergency stop
command received
151
Alarm
Illegal Configuration
152
Alarm
Unit Down Due to
Failure
One or more of the
illegal configurations
shown in the Note below exists.
Both circuits are down
due to alarms/alerts.
153
Alarm
Real Time Clock Hardware Failure
Internal clock on MBB
fails
154
Alarm
155
Alert
Serial EEPROM Hardware Failure
Serial EEPROM Storage Failure
Hardware failure with
MBB
Configuration/storage
failure with MBB
156
Alarm
Configuration/storage
failure with MBB
157
Alarm
Critical Serial
EEPROM Storage
Failure
A/D Hardware Failure
170
Alert
172
Alarm
173
Alert
174
Alert
176
Alert
177
Alert
200
Alarm
201
Alarm
202
Alarm
ACTION TAKEN
BY CONTROL
RESET
METHOD
Chiller shutdown without going through
pumpdown.
PROBABLE
CAUSE
Automatic once CCN
command for EMSTOP
returns to
normal
Chiller is not allowed to Manual once configustart.
ration errors are
corrected
CCN Network
command.
Chiller is unable to run. Automatic once
alarms/alerts are
cleared that prevent
the chiller from
starting.
Occupancy schedule
Automatic when corwill not be used. Chiller rect clock control
defaults to Local On
restarts.
mode.
Chiller is unable to run.
Manual
Alarm notifies user
that chiller is
100% down.
No Action
Manual
Chiller is not allowed to
run.
Manual
Chiller is not allowed to
run.
Loss of CommunicaCompressors A3, A4
tion with CXB
and B3 and unloaders
A2/B2 unable to
operate.
Loss of CommunicaMBB loses communiChiller shutdown withtion with EXV
cation with EXV
out going through
pumpdown.
Loss of CommunicaMBB loses communi4 to 20 mA temperation with EMM
cation with EMM
ture reset disabled.
Demand Limit set to
100%. 4 to 20 mA set
point disabled.
4 to 20 mA Cooling Set If configured with EMM Set point function disPoint Input Failure
and input less than
abled. Chiller controls
2 mA or greater than
to CSP1.
22 mA
4 to 20 mA TemperaIf configured with EMM Reset function disture Reset Input Failand input less than
abled. Chiller returns
ure
2 mA or greater than
to normal set point
22 mA
control.
4 to 20 mA Demand
If configured with EMM Demand limit function
Limit Input Failure
and input less than
disabled. Chiller re2 mA or greater than
turns to 100% demand
22 mA
limit control.
Cooler Pump Interlock If configured for cooler Cooler pump shut off.
Failure to Close at
pump control and
Chiller shutdown withStart-Up
cooler pump interlock
out going through
not closed within
pumpdown.
1 minute after pump is
started
Cooler Pump Interlock If configured for cooler Cooler pump shut off.
Opened During Normal pump control and inter- Chiller shutdown withOperation
lock opens while cooler out going through
pump relay is on
pumpdown.
Cooler Pump Interlock If configured for cooler Chiller is not allowed to
Closed When Pump is pump control and inter- start.
Off
lock closes while
cooler pump relay
is off
Manual
Hardware failure with
peripheral device
MBB loses communication with CXB
50
Automatic
Automatic
Automatic
Configuration error.
See Note on
page 49.
Main Base Board
failure.
Main Base Board
failure.
Potential failure of
MBB. Download current operating software. Replace MBB
if error occurs
again.
Main Base Board
failure.
Main Base Board
failure.
Wiring error, faulty
wiring or failed CXB
module.
Wiring error, faulty
wiring or failed EXV
module.
Wiring error, faulty
wiring or failed
Energy Management Module (EMM).
Automatic
Faulty signal generator,
wiring error, or faulty
EMM.
Automatic
Faulty signal generator,
wiring error, or faulty
EMM.
Automatic
Faulty signal generator,
wiring error, or faulty
EMM.
Manual
Failure of cooler pump
or controls.
Manual
Failure of cooler pump
or controls.
Manual
Failure of cooler pump
relay or interlock,
welded contacts.
Table 27 — Alarm and Alert Codes (cont)
ALARM/
OR
ALEERT ALARM
DESCRIPTION
ALERT
CODE
203
Alert
Loss of Communication with Slave Chiller
204
Alert
206
Alert
207
Alarm
208
Alarm
950
Alert
951
Alert
CCN
CPCS
CXB
EMM
EXV
FSM
MBB
MOP
WSM
—
—
—
—
—
—
—
—
—
WHY WAS THIS
ALARm
GENERATED?
Master MBB loses
communication with
Slave MBB
ACTION TAKEN
BY CONTROL
RESET
METHOD
Dual chiller control disabled. Chiller runs as a
stand-alone machine.
Automatic
PROBABLE
CAUSE
Wiring error, faulty wiring, failed Slave MBB
module, power loss at
Slave chiller, wrong
slave address.
Loss of CommunicaSlave MBB loses com- Dual chiller control disAutomatic
Wiring error, faulty wirtion with Master Chiller munication with Master abled. Chiller runs as a
ing, failed Master MBB
MBB
stand-alone machine
module, power loss at
Master chiller.
High Leaving Chilled
LWT read is greater
Alert only. No action
Automatic
Building load greater
Water Temperature
than LCW Alert Limit,
taken.
than unit capacity, low
Total capacity is 100%
water/brine flow or
and LWT is greater
compressor fault.
than LWT reading one
Check for other
minute ago
alarms/alerts.
Cooler Freeze Protec- Cooler EWT or LWT is Chiller shutdown with- Automatic for first Faulty thermistor (T1/
tion
less than freeze*
out going through
occurrence of day. T2), low water flow.
pumpdown. Cooler
Manual reset
pump continues to run thereafter.
(if control enabled).
Low Cooler Fluid Flow Cooler EWT is less
Chiller shutdown withManual
Faulty cooler pump,
than LWT by 3° F
out going through
low water flow, plugged
(1.7° C) for 1 minute
pumpdown. Cooler
fluid strainer.
after a circuit is started pump shut off (if control enabled).
Loss of CommunicaNo communications
WSM forces removed.
Automatic
Failed module, wiring
tion with WSM
have been received by Chiller runs under own
error, failed transMBB within 5 minutes control.
former, loose connecof last transmission
tion plug, wrong
address.
Loss of CommunicaNo communications
FSM forces removed.
Automatic
Failed module, wiring
tion with FSM
have been received by Chiller runs under own
error, failed transMBB within 5 minutes control.
former, loose connecof last transmission
tion plug, wrong
address.
LEGEND
Carrier Comfort Network
Compressor Protection Control System
Compressor Expansion Board
Energy Management Module
Electronic Expansion Valve
Flotronic™ System Manager
Main Base Board
Maximum Operating Pressure
Water System Manager
*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/CSP.2
−8° F (4.4 C) for dual set point configuration.
NOTE: The following table shows illegal configurations:
1 Zero compressors in a circuit
2 Four compressors in a circuit with two unloaders
Four compressors in a circuit with one unloader and hot gas
3 bypass
4 Two unloaders and hot gas bypass in a circuit.
5 More than one compressor quantity difference between circuits
6 Fluid type of low temperature brine
cooled head pressure control with common fan staging and
7 Air
different head pressure control methods for each circuit.
51
Table 28 — Oil Charge
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.
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.
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,R040-110, 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,R130-210, 230A-315A, AND 330A/B-420A/B UNIT
CONTROLAND 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.
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.
Compressors — If lead compressor on either refrigerant 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 compressors to run.
COMPRESSOR REMOVAL — Access to the 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 reinstalled prior to start-up.
2.
3.
Following the installation of the new compressor:
Tighten discharge valves to —
20 to 25 ft-lb (27 to 34 N-m)
80 to 90 ft-lb (109 to 122 N-m)
Compressor(s)
06E250
06E265,275,299
Tighten suction valves to —
80 to 90 ft-lb (109 to 122 N-m)
90 to 120 ft-lb (122 to 163 N-m)
06E250
06E265,275,299
4.
5.
6.
Tighten the following fittings to —
120 in.-lb (13.5 N-m)
High-Pressure Switch
OIL CHARGE (Refer to Table 28) — All units are factory
charged with oil. Acceptable oil level for each compressor is
from 1⁄8 to 3⁄8 of sight glass.
When additional oil or a complete charge is required, use
only Carrier-approved compressor oil.
Approved oils are as follows:
Petroleum Specialties, Inc. — Cryol 150 (factory oil charge)
Texaco, Inc.
— Capella WF-32
Witco Chemical Co.
— Suniso 3GS
7.
8.
9.
52
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.
Close the shutoff valves, if installed, in the cooler fluid
lines. Remove the cooler fluid piping.
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. 22. Remove the cooler
waterside strainer.
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. 22.
Remove the insulation on the refrigerant connection end
of the cooler.
Unbolt the suction flanges from the cooler head. Save the
bolts.
Remove the liquid lines by breaking the silver-soldered
joints at the cooler liquid line nozzles.
On 30GTN,GTR080-110 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.
Remove the screws in the cooler feet. Slide the cooler
slightly to the left to clear the refrigerant tubing. Save all
screws.
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. 22.
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.
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,GTR080-110 and 230B-315B 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 57, 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.
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. 23. If
any of these tubes have developed a leak, plug the tube(s)
as described under Tube Plugging section on page 54.
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.
Fig. 22 — Cooler Thermistor Locations
53
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 24 shows an Elliott tube plug and a cross-sectional
view of a plug in place.
Fig. 24 — Eliott Tube Plug
Table 29 — Plugs
COMPONENTS FOR
PLUGGING
For
Tubes
Brass
Pin
Brass
Ring
For HoleswithoutTubes
Brass
Pin
Brass
Ring
Loctite
Locquic
Use extreme care when installing plugs to prevent damage to the tube sheet section between the holes.
Retubing (See Table 29) — 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 tube
sheet. 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.
SIZES 040-050
SIZES 060,070
SIZES 080,090*
SIZES 100,110*
PART NUMBER
853103-500*
853002-570*
853103-1*
853002-631*
No. 675†
‘‘N’’†
*Order directly from: Elliott Tube Company,
Dayton, Ohio
†Can be obtained locally.
Tube information follows:
in.
• Tube sheet hole diameter . . . . . . . . . . . . 0.631
• Tube OD . . . . . . . . . . . . . . . . . . . . . . . . . 0.625
• Tube ID after rolling . . . . . . . . . . . . . . . 0.581
(includes expansion due
to
to clearance)
0.588
mm
16.03
15.87
14.76
to
14.94
NOTE: Tubes next to gasket webs must be flush with tube
sheet (both ends).
SIZES 130,150*
SIZES 170,190*
SIZE 210*
*And associated modular units (see Table 1).
Fig. 23 — Typical Tube Sheets, Cover Off (Non-Removable Tubes)
54
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.
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:
5⁄8-in. Diameter Perimeter Bolts . . . . . . 150 to 170 ft-lb
(201 to 228 N-m)
1⁄2-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. 25. 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.
Do not use high-pressure water or air to clean coils —
fin damage may result.
Condenser Fans — Each fan is supported by a formed
wire mount bolted to fan deck and covered with a wire guard.
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. 26A and 26B (standard and low-noise applications).
Tighten setscrews to 15 6 1 ft-lb (20 6 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. 6 0.12 in.
(54 6 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. 27.
IMPORTANT: Check for proper fan rotation (clockwise viewed from above). If necessary, switch any 2
power leads to reverse fan rotation.
Condenser Coils
COIL CLEANING — Clean coils with a vacuum cleaner,
fresh water, compressed air, or a bristle brush (not wire). Units
SIZES 080,090* WITH 18-BOLT HEADS
SIZES 080,090* WITH 14-BOLT HEADS
SIZES 130,150*
SIZES 100,110* WITH 22-BOLT HEADS
SIZES 100,110* WITH 16-BOLT HEADS
SIZES 170,190*
*And associated modular units.
Fig. 25 — Cooler Head Bolt Tightening Sequence (Typical Tube Sheet)
55
SIZE 210*
DIMENSION
A
B
Standard
0.509 (13 mm)
0.889 (22 mm)
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 29 F (16 C) superheat.
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. 27), 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.
FAN TYPE
Low Noise (Optional)
1.509 (38 mm)
1.139 (29 mm)
NOTE: Fan rotation is clockwise as viewed from top of unit.
Fig. 26A — Condenser Fan Adjustment —
Standard 50 and 60 Hz Units and
60 Hz Low Noise Fan Option Units
PLASTIC FAN
PROPELLER
CLEARANCE
OF 0.25 INCHES
(6.4 MM)
FAN DECK
SURFACE
FAN ORIFICE
Fig. 26B — Condenser Fan Adjustment —
50 Hz Low Noise Fan Option Units
NOTE: Dimensions are in millimeters. Dimensions in [ ] are in inches.
Fig. 27 — Condenser Fan Adjustment,
Units with High-Static Fan Option
Refrigerant Feed Components — Each circuit has
all necessary refrigerant controls.
ELECTRONIC EXPANSION VALVE (EXV) — A cutaway
view of valve is shown in Fig. 28.
Fig. 28 — Electronic Expansion Valve (EXV)
56
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.
PL-EXVB
1
1
BRN
2
2
J7
3
4
5
3
4
5
WHT
RED
BLK
GRN
A
E
D
LIQUID LINE SERVICE VALVE — This valve is located
immediately ahead of filter drier, and has a 1⁄4-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.
EXV-B
B
C
Thermistors — Electronic control uses 4 to 10 thermistors to sense temperatures used to control the operation
of chiller.
Thermistors T1-T9 are identical in their temperature vs
resistance and voltage drop performance. Thermistor T10 is
a 10 kV input channel and has a different set of temperature
vs resistance and voltage drop performance. Resistances at
various temperatures are listed in Tables 30A-31B.
PL-EXVA
1
2
J6
3
4
5
1
2
3
4
5
A
BRN
WHT
RED
BLK
GRN
E
D
EXV-A
B
C
LOCATION — General locations of thermistor sensors are
shown in Fig. 7-10. See Table 2 for pin connection points.
ELECTRONIC EXPANSION VALVES (EXVs)
Sensor T2 is installed directly in the fluid circuit. Relieve all pressure or drain fluid before removing.
Fig. 29 — Printed Circuit Board Connector
REPLACING THERMISTOR T2
1. Remove and discard original sensor and coupling. Do not
disassemble new coupling. Install assembly as received.
See Fig. 30.
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
11⁄4 turns more using a back-up wrench. Ferrules are now
attached to the sensor, which can be withdrawn from coupling for service.
NOTE: The EXV orifice is a screw-in type that can be removed for inspection and cleaning. Once the top cover has
been removed, the EXV motor may be taken out by removing the 2 cap screws securing motor to valve body. Pull motor, lead screw, and the piston sleeve up off the orifice assembly. See Fig. 28. A slot has been cut in top of orifice
assembly to facilitate removal using a large screwdriver. Turn
orifice assembly counterclockwise to remove.
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.
Reassembly of valve is made easier by screwing the piston sleeve and lead screw assembly out of the motor. Align
hole in top of piston sleeve with the guide pin in orifice assembly and gently push piston sleeve and lead screw onto
orifice assembly about half way. Screw motor onto lead screw
and secure EXV motor with cap screws. Be careful not to
twist or pull on wires from EXV motor to valve cover pin
connections. 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.
FLUID-SIDE TEMPERATURE SENSOR (T1) AND
REFRIGERANT TEMPERATURE SENSOR (T5, T6, T7, T8)
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.
FLUID-SIDE TEMPERATURE SENSOR (T2)
NOTE: Dimensions in (
) are in millimeters.
Fig. 30 — Thermistors (Temperature Sensors)
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.
57
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 receivers 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).
MAIN BASE BOARD
1
1
2
2
3
3
THERMISTORS T3 AND T4 — These thermistors are located on header end of condenser coil. They are clamped on
a return bend.
4
5
5
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. 31). Using the voltage reading obtained, read
the sensor temperature from Tables 30A-31B. 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.
BLU
6
6
7
7
8
8
BLU
PNK
PNK
TB5
TB5
TB5
TB5
T10
5
6
T9
7
8
9
9
OUTDOOR-AIR TEMP
(ACCESSORY)
10
10
1
11
2
T2
COOLER ENTERING
FLUID TEMP
1
T1
COOLER LEAVING
FLUID TEMP
4
T4
SATURATED
CONDENSING TEMPCIRCUIT B
6
T6
SATURATED
SUCTION TEMPCIRCUIT B*
3
T3
SATURATED
CONDENSING TEMPCIRCUIT A
5
T5
SATURATED
SUCTION TEMPCIRCUIT A*
2
12
J8
REMOTE SPACE TEMP
(ACCESSORY)
4
3
13
4
14
1
15
2
16
3
17
4
18
5
19
6
20
1
21
2
22
3
23
4
24
5
25
6
26
T1-T6, T9, T10 THERMISTORS
EXV BOARD
J5
12 11 10
12 11
T7
7
9
7 6
5 4
3
2 1
10 9
8
CKTA*
8
T8
CKTB*
COMPRESSOR RETURN GAS TEMP
T7, T8 THERMISTORS
*Not used on FIOP (Factory-Installed Option) unit with TXV (Thermostatic Expansion Valve).
Fig. 31 — Thermistor Connections to J5 and J8
Processor Boards
58
Table 30A — 5K Thermistor Temperatures (°F) vs Resistance/Voltage Drop
(For Thermistors T1-T9)
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
VOLTAGE
DROP
(V)
4.538
4.523
4.508
4.493
4.476
4.460
4.444
4.427
4.409
4.391
4.373
4.354
4.335
4.316
4.296
4.276
4.255
4.234
4.213
4.191
4.169
4.146
4.123
4.100
4.076
4.052
4.027
4.002
3.976
3.951
3.924
3.898
3.871
3.844
3.816
3.788
3.760
3.731
3.702
3.673
3.643
3.613
3.583
3.552
3.522
3.490
3.459
3.428
3.396
3.364
3.331
3.299
3.266
3.234
3.201
3.168
3.134
3.101
3.068
3.034
3.000
2.966
2.933
2.899
2.865
2.831
2.797
2.764
2.730
2.696
2.662
2.628
2.594
2.561
2.527
2.494
2.461
2.427
2.395
2.362
2.329
2.296
2.264
2.232
RESISTANCE
(Ohms)
TEMP
(F)
98,010
94,707
91,522
88,449
85,486
82,627
79,871
77,212
74,648
72,175
69,790
67,490
65,272
63,133
61,070
59,081
57,162
55,311
53,526
51,804
50,143
48,541
46,996
45,505
44,066
42,679
41,339
40,047
38,800
37,596
36,435
35,313
34,231
33,185
32,176
31,202
30,260
29,351
28,473
27,624
26,804
26,011
25,245
24,505
23,789
23,096
22,427
21,779
21,153
20,547
19,960
19,393
18,843
18,311
17,796
17,297
16,814
16,346
15,892
15,453
15,027
14,614
14,214
13,826
13,449
13,084
12,730
12,387
12,053
11,730
11,416
11,112
10,816
10,529
10,250
9,979
9,717
9,461
9,213
8,973
8,739
8,511
8,291
8,076
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
(V)
2.200
2.168
2.137
2.105
2.074
2.043
2.013
1.982
1.952
1.923
1.893
1.864
1.835
1.806
1.778
1.749
1.722
1.694
1.667
1.640
1.613
1.587
1.561
1.535
1.510
1.485
1.460
1.436
1.412
1.388
1.365
1.342
1.319
1.296
1.274
1.253
1.231
1.210
1.189
1.169
1.148
1.128
1.109
1.089
1.070
1.051
1.033
1.015
0.997
0.980
0.963
0.946
0.929
0.913
0.896
0.881
0.865
0.850
0.835
0.820
0.805
0.791
0.777
0.763
0.750
0.736
0.723
0.710
0.698
0.685
0.673
0.661
0.650
0.638
0.627
0.616
0.605
0.594
0.584
0.573
0.563
0.553
0.543
0.534
59
RESISTANCE
(Ohms)
TEMP
(F)
7,868
7,665
7,468
7,277
7,091
6,911
6,735
6,564
6,399
6,238
6,081
5,929
5,781
5,637
5,497
5,361
5,229
5,101
4,976
4,855
4,737
4,622
4,511
4,403
4,298
4,196
4,096
4,000
3,906
3,814
3,726
3,640
3,556
3,474
3,395
3,318
3,243
3,170
3,099
3,031
2,964
2,898
2,835
2,773
2,713
2,655
2,597
2,542
2,488
2,436
2,385
2,335
2,286
2,239
2,192
2,147
2,103
2,060
2,018
1,977
1,937
1,898
1,860
1,822
1,786
1,750
1,715
1,680
1,647
1,614
1,582
1,550
1,519
1,489
1,459
1,430
1,401
1,373
1,345
1,318
1,291
1,265
1,240
1,214
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
(V)
0.525
0.515
0.506
0.497
0.489
0.480
0.471
0.463
0.455
0.447
0.440
0.432
0.424
0.417
0.410
0.403
0.396
0.389
0.382
0.376
0.369
0.363
0.357
0.351
0.345
0.339
0.333
0.327
0.322
0.316
0.311
0.306
0.301
0.295
0.291
0.286
0.281
0.276
0.272
0.267
0.263
0.258
0.254
0.250
0.246
0.242
0.238
0.234
0.230
0.226
0.223
0.219
0.216
0.212
0.209
0.205
0.202
0.199
0.196
0.192
0.189
0.186
0.183
0.181
0.178
0.175
0.172
0.169
0.167
0.164
0.162
0.159
0.157
0.154
0.152
0.150
0.147
0.145
0.143
0.141
0.138
0.136
0.134
RESISTANCE
(Ohms)
1,190
1,165
1,141
1,118
1,095
1,072
1,050
1,029
1,007
986
965
945
925
906
887
868
850
832
815
798
782
765
750
734
719
705
690
677
663
650
638
626
614
602
591
581
570
561
551
542
533
524
516
508
501
494
487
480
473
467
461
456
450
445
439
434
429
424
419
415
410
405
401
396
391
386
382
377
372
367
361
356
350
344
338
332
325
318
311
304
297
289
282
Table 30B — 5K Thermistor Temperatures (°C) vs Resistance/Voltage Drop
(For Thermistors T1-T9)
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
15
VOLTAGE
DROP
(V)
4.547
4.520
4.493
4.464
4.433
4.402
4.369
4.335
4.300
4.264
4.226
4.187
4.146
4.104
4.061
4.017
3.971
3.924
3.876
3.827
3.777
3.725
3.673
3.619
3.564
3.509
3.453
3.396
3.338
3.279
3.221
3.161
3.101
3.041
2.980
2.919
2.858
2.797
2.737
2.675
2.615
2.554
2.494
2.434
2.375
2.316
2.258
2.200
RESISTANCE
(Ohms)
TEMP
(C)
100 260
94 165
88 480
83 170
78 125
73 580
69 250
65 205
61 420
57 875
54 555
51 450
48 536
45 807
43 247
40 845
38 592
38 476
34 489
32 621
30 866
29 216
27 633
26 202
24 827
23 532
22 313
21 163
20 079
19 058
18 094
17 184
16 325
15 515
14 749
14 026
13 342
12 696
12 085
11 506
10 959
10 441
9 949
9 485
9 044
8 627
8 231
7 855
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
62
63
VOLTAGE
DROP
(V)
2.143
2.087
2.031
1.976
1.923
1.870
1.817
1.766
1.716
1.667
1.619
1.571
1.525
1.480
1.436
1.393
1.351
1.310
1.270
1.231
1.193
1.156
1.120
1.085
1.051
1.019
0.987
0.956
0.926
0.896
0.868
0.841
0.814
0.788
0.763
0.739
0.716
0.693
0.671
0.650
0.629
0.609
0.590
0.571
0.553
0.536
0.519
0.502
60
RESISTANCE
(Ohms)
TEMP
(C)
7 499
7 161
6 840
6 536
6 246
5 971
5 710
5 461
5 225
5 000
4 786
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363
2 272
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 118
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)
0.487
0.471
0.457
0.443
0.429
0.415
0.403
0.390
0.378
0.367
0.355
0.345
0.334
0.324
0.314
0.305
0.295
0.287
0.278
0.270
0.262
0.254
0.247
0.239
0.232
0.226
0.219
0.213
0.207
0.201
0.195
0.189
0.184
0.179
0.174
0.169
0.164
0.160
0.155
0.151
0.147
0.143
0.139
0.135
RESISTANCE
(Ohms)
1 079
1 041
1 006
971
938
906
876
836
805
775
747
719
693
669
645
623
602
583
564
547
531
516
502
489
477
466
456
446
436
427
419
410
402
393
385
376
367
357
346
335
324
312
299
285
Table 31A — 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
4.750
4.741
4.733
4.724
4.715
4.705
4.696
4.686
4.676
4.665
4.655
4.644
4.633
4.621
4.609
4.597
4.585
4.572
4.560
4.546
4.533
4.519
4.505
4.490
4.476
4.461
4.445
4.429
4.413
4.397
4.380
4.363
4.346
4.328
4.310
4.292
4.273
4.254
4.235
4.215
4.195
4.174
4.153
4.132
4.111
4.089
4.067
4.044
4.021
3.998
3.975
3.951
3.927
3.903
3.878
3.853
3.828
3.802
3.776
3.750
3.723
3.697
3.670
3.654
3.615
3.587
3.559
3.531
3.503
3.474
3.445
3.416
3.387
3.357
3.328
3.298
3.268
3.238
3.208
3.178
3.147
3.117
3.086
3.056
3.025
RESISTANCE
(Ohms)
TEMP
(F)
196,453
189,692
183,300
177,000
171,079
165,238
159,717
154,344
149,194
144,250
139,443
134,891
130,402
126,183
122,018
118,076
114,236
110,549
107,006
103,558
100,287
97,060
94,020
91,019
88,171
85,396
82,729
80,162
77,662
75,286
72,940
70,727
68,542
66,465
64,439
62,491
60,612
58,781
57,039
55,319
53,693
52,086
50,557
49,065
47,627
46,240
44,888
43,598
42,324
41,118
39,926
38,790
37,681
36,610
35,577
34,569
33,606
32,654
31,752
30,860
30,009
29,177
28,373
27,597
26,838
26,113
25,396
24,715
24,042
23,399
22,770
22,161
21,573
20,998
20,447
19,903
19,386
18,874
18,384
17,904
17,441
16,991
16,552
16,131
15,714
15,317
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
2.963
2.932
2.901
2.870
2.839
2.808
2.777
2.746
2.715
2.684
2.653
2.622
2.592
2.561
2.530
2.500
2.470
2.439
2.409
2.379
2.349
2.319
2.290
2.260
2.231
2.202
2.173
2.144
2.115
2.087
2.059
2.030
2.003
1.975
1.948
1.921
1.894
1.867
1.841
1.815
1.789
1.763
1.738
1.713
1.688
1.663
1.639
1.615
1.591
1.567
1.544
1.521
1.498
1.475
1.453
1.431
1.409
1.387
1.366
1.345
1.324
1.304
1.284
1.264
1.244
1.225
1.206
1.187
1.168
1.150
1.132
1.114
1.096
1.079
1.062
1.045
1.028
1.012
0.996
0.980
0.965
0.949
0.934
0.919
0.905
61
RESISTANCE
(Ohms)
TEMP
(F)
14,925
14,549
14,180
13,824
13,478
13,139
12,814
12,493
12,187
11,884
11,593
11,308
11,031
10,764
10,501
10,249
10,000
9,762
9,526
9,300
9,078
8,862
8,653
8,448
8,251
8,056
7,869
7,685
7,507
7,333
7,165
6,999
6,838
6,683
6,530
6,383
6,238
6,098
5,961
5,827
5,698
5,571
5,449
5,327
5,210
5,095
4,984
4,876
4,769
4,666
4,564
4,467
4,370
4,277
4,185
4,096
4,008
3,923
3,840
3,759
3,681
3,603
3,529
3,455
3,383
3,313
3,244
3,178
3,112
3,049
2,986
2,926
2,866
2,809
2,752
2,697
2,643
2,590
2,539
2,488
2,439
2,391
2,343
2,297
2,253
2,209
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
0.876
0.862
0.848
0.835
0.821
0.808
0.795
0.782
0.770
0.758
0.745
0.733
0.722
0.710
0.699
0.687
0.676
0.666
0.655
0.645
0.634
0.624
0.614
0.604
0.595
0.585
0.576
0.567
0.558
0.549
0.540
0.532
0.523
0.515
0.507
0.499
0.491
0.483
0.476
0.468
0.461
0.454
0.447
0.440
0.433
0.426
0.419
0.413
0.407
0.400
0.394
0.388
0.382
0.376
0.370
0.365
0.359
0.354
0.349
0.343
0.338
0.333
0.328
0.323
0.318
0.314
0.309
0.305
0.300
0.296
0.292
0.288
0.284
0.279
0.275
0.272
0.268
0.264
RESISTANCE
(Ohms)
2,166
2,124
2,083
2,043
2,003
1,966
1,928
1,891
1,855
1,820
1,786
1,752
1,719
1,687
1,656
1,625
1,594
1,565
1,536
1,508
1,480
1,453
1,426
1,400
1,375
1,350
1,326
1,302
1,278
1,255
1,233
1,211
1,190
1,169
1,148
1,128
1,108
1,089
1,070
1,052
1,033
1,016
998
981
964
947
931
915
900
885
870
855
841
827
814
800
787
774
762
749
737
725
714
702
691
680
670
659
649
639
629
620
610
601
592
583
574
566
557
Table 31B — 10K Thermistor Temperatures (°C) vs Resistance/Voltage Drop
(For Thermistor T10)
TEMP
(F)
−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
4.748
4.733
4.716
4.700
4.682
4.663
4.644
4.624
4.602
4.580
4.557
4.533
4.508
4.482
4.455
4.426
4.397
4.367
4.335
4.303
4.269
4.235
4.199
4.162
4.124
4.085
4.044
4.003
3.961
3.917
3.873
3.828
3.781
3.734
3.686
3.637
3.587
3.537
3.485
3.433
3.381
3.328
3.274
3.220
3.165
3.111
RESISTANCE
(Ohms)
TEMP
(F)
200,510
188,340
177,000
166,342
156,404
147,134
138,482
130,402
122,807
115,710
109,075
102,868
97,060
91,588
86,463
81,662
77,162
72,940
68,957
65,219
61,711
58,415
55,319
52,392
49,640
47,052
44,617
42,324
40,153
38,109
36,182
34,367
32,654
31,030
29,498
28,052
26,686
25,396
24,171
23,013
21,918
20,883
19,903
18,972
18,090
17,255
16,464
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
3.000
2.944
2.889
2.833
2.777
2.721
2.666
2.610
2.555
2.500
2.445
2.391
2.337
2.284
2.231
2.178
2.127
2.075
2.025
1.975
1.926
1.878
1.830
1.784
1.738
1.692
1.648
1.605
1.562
1.521
1.480
1.439
1.400
1.362
1.324
1.288
1.252
1.217
1.183
1.150
1.117
1.086
1.055
1.025
0.996
0.968
62
RESISTANCE
(Ohms)
TEMP
(F)
15,714
15,000
14,323
13,681
13,071
12,493
11,942
11,418
10,921
10,449
10,000
9,571
9,164
8,776
8,407
8,056
7,720
7,401
7,096
6,806
6,530
6,266
6,014
5,774
5,546
5,327
5,117
4,918
4,727
4,544
4,370
4,203
4,042
3,889
3,743
3,603
3,469
3,340
3,217
3,099
2,986
2,878
2,774
2,675
2,579
2,488
2,400
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
0.913
0.887
0.862
0.837
0.813
0.790
0.767
0.745
0.724
0.703
0.683
0.663
0.645
0.626
0.608
0.591
0.574
0.558
0.542
0.527
0.512
0.497
0.483
0.470
0.457
0.444
0.431
0.419
0.408
0.396
0.386
0.375
0.365
0.355
0.345
0.336
0.327
0.318
0.310
0.302
0.294
0.287
0.279
0.272
0.265
RESISTANCE
(Ohms)
2,315
2,235
2,157
2,083
2,011
1,943
1,876
1,813
1,752
1,693
1,637
1,582
1,530
1,480
1,431
1,385
1,340
1,297
1,255
1,215
1,177
1,140
1,104
1,070
1,037
1,005
974
944
915
889
861
836
811
787
764
742
721
700
680
661
643
626
609
592
576
561
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 source is auxiliary control power, independent of main unit power. This assures compressor protection
even when main unit power disconnect switch is off.
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,R070 (50 Hz), 080-110 and 230B-315B 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 board 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 32. 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,R130-210, 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).
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. 32, 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. 20. 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-ofcharge. Switch settings are listed in Table 32. 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-of-charge switch is wired in series with the highpressure switch on each circuit’s lead compressor.
Table 32 — Pressure Switch Settings,
psig (kPa)
SWITCH
High Pressure
Loss-of-Charge
CUTOUT
426 ± 7
(2936 ± 48)
7 (48.2)
CUT-IN
320 ± 20
(2205 ± 138)
22 (151.6)
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.
LEGEND
T — Thermistor
Fig. 32 — Cooler Heater Cables
63
Relief Devices — Fusible plugs are located in each circuit 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.
7.
Other Safeties — There are several other safeties that
are provided by microprocessor control. For details refer to
Alarms and Alerts section on page 47.
10.
5.
6.
8.
9.
11.
(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.
Check tightness of all electrical connections.
Oil should be visible in the compressor sight glass. See
Fig. 31. An acceptable oil level in the compressor is from
1⁄8 to 3⁄8 of sight glass. Adjust the oil level as required.
No oil should be removed unless the crankcase heater
has been energized for at least 24 hours. See Oil Charge
section on page 52 for Carrier-approved oils.
Electrical power source must agree with unit
nameplate.
Crankcase heaters must be firmly locked into compressors, and must be on for 24 hours prior to start-up.
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.
Check compressor suspension. Mounting rails must be
floating freely on the springs.
Perform service test to verify proper settings.
PRE-START-UP
IMPORTANT: Before beginning Pre-Start-Up or
Start-Up, 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.
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
*Lead compressor only.
Fig. 33 — Compressor Connections
(Lead Compressor Shown)
64
NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-8.
Unbalanced 3-Phase Supply Voltage — Never operate a motor where a phase imbalance between phases is greater than
2%. To determine percent voltage imbalance:
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.
max voltage deviation
from avg voltage
% Voltage Imbalance = 100 x
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.
START-UP AND OPERATION
AB = 243 v
BC = 236 v
AC = 238 v
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.
1. Determine average voltage:
243 + 236 + 238
Average voltage =
3
717
=
3
= 239 v
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:
4
% Voltage Imbalance = 100 x
239
= 1.7%
This voltage imbalance is satisfactory as it is below the
maximum allowable of 2%.
Operating Limitations
TEMPERATURES (See Table 33) — 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 33 — Temperature Limits for Standard Units
TEMPERATURE
Maximum Ambient Temperature
Minimum Ambient Temperature
Maximum Cooler EWT*
Maximum Cooler LWT
Minimum Cooler LWT†
F
125
0
95
70
38
C
52
−18
35
21
3.3
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.
LEGEND
EWT — Entering Fluid (Water) Temperature
LWT — Leaving Fluid (Water) Temperature
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 34. 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.
*For sustained operation, EWT should not exceed 85 F (29.4 C).
†Unit requires modification below this temperature.
Low-Ambient Operation — If operating temperatures below 0° F (−18 C) are expected, refer to separate installation
instructions for low-ambient operation using accessory Motormastert 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.
Operation below minimum flow rate could subject tubes
to frost pinching in tube sheet, resulting in failure of
cooler.
VOLTAGE
Main Power Supply — Minimum and maximum acceptable
supply voltages are listed in the Installation Instructions.
65
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,R040,045 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.
Consult application data section in the Product Data literature and job design requirements to determine flow rate
requirements for a particular installation.
Table 34 — Nominal and Minimum Cooler
Fluid Flow Rates
30GTN,R
UNIT
SIZE
040
045
050
060
070
080,230B
090,245B
100,255B,270B
110,290B,315B
130
150,230A-255A
170,270A,330A/B,
360B (50 Hz)
190,290A,360A/B (60 Hz),
360A (50 Hz),390B
210,315A,390A,420A/B
NOMINAL FLOW MINIMUM FLOW
RATE*
RATE (See Notes)
Gpm
L/s
Gpm
L/s
86
5.43
36.8
2.32
101
6.37
37.7
2.38
123
7.76
37.7
2.38
151
9.53
47.5
3.00
173
10.91
47.5
3.00
192
12.11
66.7
4.20
216
13.62
59.5
3.75
240
15.14
84.1
5.30
264
16.65
84.1
5.30
300
18.9
110
6.9
348
21.9
110
6.9
384
24.2
120
7.5
432
27.2
120
7.5
480
30.2
148
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) leavingfluid temperature, 54 F (12.2 C) entering-fluid temperature, 95 F
(35 C) ambient. Fouling factor is .00001 ft2 • hr • F/Btu (.000018 m2
• K/W).
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
Normal Air Conditioning
Process Type Cooling
Low Ambient Unit Operation
V
3
6 to 10
6 to 10
N
3.25
6.5 to 10.8
6.5 to 10.8
Operation Sequence — 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
66
APPENDIX A — CCN TABLES
UNIT (Configuration Settings)
DESCRIPTION
Unit Type
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Unit Size
Circuit A1% Capacity
Number Circ A Compressor
Compressor A1 Cylinders
Number Circ B Compressor
Compressor B1 Cylinders
EXV Module Installed
EXV Superheat Setpoint
EXV MOP
EXV Superheat Offset
EXV Circ. A Min Position
EXV Circ. B Min Position
Refrigerant
15
16
Low Pressure Setpoint
Fan Staging Select
STATUS
1 = Air Cooled
2 = Water Cooled
3 = Split System
4 = Heat Machine
5 = Air Cooled Heat Reclaim
15 to 300
0 to 100
1 to 4
4 or 6
1 to 4
4 or 6
No/Yes
10 to 40
40 to 80
− 20 to 20
0 to 100
0 to 100
1 = R22
2 = R134A
3 to 60
1 = 2 Stage indpt.
2 = 3 Stage indpt.
3 = 2 Stage common
4 = 3 Stage common
DEFAULT
1
UNITS
POINT
UNIT TYP
20
50
1
6
1
6
Yes
29.0
50.0
0.0
8.0
8.0
1
TONS
%
SIZE
CAP A
NUMCA
NUM CYLA
NUMCB
NUM CYLB
EXV BRD
SH SP
MOP SP
SH OFFST
EXVAMINP
EXVBMINP
REFRIG T
10.0
1
PSI
^F
°F
^F
%
%
LOW PRES
FAN TYPE
OPTIONS1 (Options Configuration)
1
DESCRIPTION
Cooler Fluid
2
3
Hot Gas Bypass Select
Head Press. Cont. Method
4
Head Press. Control Type
5
6
7
8
9
10
Pressure Transducers
Cooler Pump Interlock
Cooler Pump Control
No. Circuit A Unloaders
No. Circuit B Unloaders
EMM Module Installed
STATUS
1 = Water
2 = Med. Brine
3 = Low Brine
No/Yes
1 = EXV controlled
2 = Setpoint controlled
3 = Setpoint-A, EXV-B
4 = EXV-A, Setpoint-B
0 = None
1 = Air Cooled
2 = Water Cooled
No/Yes
Off/On
Off/On
0-2
0-2
No/Yes
67
DEFAULT
1
POINT
FLUIDTYP
No
2
HGBV FLG
HEAD MET
0
HEAD
No
On
Off
1
1
No
PRESS TY
LOCK FLG
CPC
NUNLA
NUNLB
EMM BRD
TYP
CONFIGURATION SCREEN (TYPE 10)
OPTIONS2 (Options Configuration)
1
DESCRIPTION
Control Method
2
Loading Sequence Select
3
Lead/Lag Sequence Select
4
Cooling Setpoint Select
5
6
7
8
Ramp Load Select
High LCW Alert Limit
Minutes off time
Deadband Multiplier
STATUS
0 = Switch
1 = 7 day sched.
2 = Occupancy
3 = CCN
1 = Equal loading
2 = Staged loading
1 = Automatic
2 = Circuit A leads
3 = Circuit B leads
0 = Single
1 = Dual, remote switch controlled
2 = Dual, clock controlled
3 = 4-20 ma input
ON/OFF
2 to 60
0 to 15
1.0 to 4.0
DEFAULT
0
UNITS
POINT
CONTROL
1
SEQ
TYPE
1
LEAD
TYP
0
CLSP
TYP
OFF
60.0
0
1.0
^F
min
RAMP EBL
LCW LMT
DELAY
Z GAIN
DISPLAY (STDU SETUP)
1
2
3
4
DESCRIPTION
STDU Password
Password Enable
Metric Display
Language
STATUS
nnnn
enable/disable
Off/On
0 = ENGLISH
1 = FRANCAIS
2 = ESPANOL
3 = PORTUGUES
DEFAULT
1111
enable
Off
0
UNITS
POINT
PASSWORD
PASS EBL
DISPUNIT
LANGUAGE
CONFIG (TIMED OVERRIDE SETUP)
1
2
3
DESCRIPTION
Schedule Number
Override Time Limit
Timed Override Hours
STATUS
0-99
0-4
0-4
DEFAULT
0
0
0
UNITS
hours
hours
POINT
SCHEDNUM
OTL
OTL EXT
ALARMDEF (Alarm Definition Table)
1
2
3
4
5
DESCRIPTION
Alarm Routing Control
ALRM_CNT
Equipment Priority
EQP_TYPE
Comm Failure Retry Time
Re-alarm Time
Alarm System Name
STATUS
00000000
DEFAULT
00000000
0 to 7
4
1 to 240
1 to 255
XXXXXXXX
10
30
30_PIC
68
UNITS
min
min
POINT
RETRY_TM
RE-ALARM
ALRM_NAM
RESETCON (Temperature Reset and Demand Limit)
1
2
DESCRIPTION
COOLING RESET
Cooling Reset Type
3
4
5
6
7
No Cool Reset Temp
Full Cool Reset Temp
Degrees Cool Reset
DEMAND LIMIT
Demand Limit Select
8
9
10
11
12
13
14
15
16
17
18
19
20
STATUS
Demand Limit at 20mA
Loadshed Group Number
Loadshed Demand Delta
Maximum Loadshed Time
Demand Limit Switch 1
Demand Limit Switch 2
LEAD/LAG
Lead/Lag Enable
Master/Slave Select
Slave Address
Lead/Lag Balance Select
Lead/Lag Balance Delta
Lag Start Delay
DEFAULT
0 = No Reset
1 = 4-20 ma input
2 = External temp-OAT
3 = Return fluid
4 = External temp-SPT
0 to 125
0 to 125
−30 to 30
0
0
1
2
3
0
0
0
0
0
0
0
UNITS
CRST
0.0
125.0
0.0
= None
= External switch input
= 4-20 ma input
= Loadshed
to 100
to 99
to 60
to 120
to 100
to 100
°F
°F
^F
CT
CT
CT
DMD
100
0
0
60
80
50
Enable/Disable
Slave/Master
0 to 239
Enable/Disable
40 to 400
0 to 30
POINT
%
Disable
Master
0
Disable
168
5
TYP
NO
FULL
DEG
CTRL
%
min
%
%
DMT20MA
SHED NUM
SHED DEL
SHED TIM
DLSWSP1
DLSWSP2
hours
mins
LL ENA
MS SEL
SLV ADDR
LL BAL
LL BAL D
LL DELAY
BRODEFS (Broadcast POC Definition Table)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
CCN Time/Date Broadcast
CCN OAT Broadcast
Global Schedule Broadcst
CCN Broadcast Acker
Daylight Savings Start
Month
Week
Day
Minutes to add
Daylight Savings Stop
Month
Week
Day
Minutes to subtract
STATUS
Yes/No
Yes/No
Yes/No
Yes/No
DEFAULT
No
No
No
No
1
1
1
0
to
to
to
to
12
5
7
99
1
1
0
0
1
1
1
0
to
to
to
to
12
5
7
99
1
1
0
0
69
UNITS
POINT
CCNBC
OATBC
GSBC
CCNBCACK
min
STARTM
STARTW
STARTD
MINADD
min
STOPM
STOPW
STOPD
MINSUB
GENUNIT (General Unit Parameters)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
Control Mode
STATUS
0 = Service Test
1 = OFF - local control
2 = OFF-CCN control
3 = OFF-timeclock
4 = Emergency stop
5 = ON-local control
6 = ON-CCN control
7 = ON-timeclock
Yes/No
Start/Stop
Normal
0-100
0-100
nn
snnn.n
snnn.n
snnn.n
snnn.n
snnn.n
Enable/Emstop
nn
Occupied
CCN Chiller
Alarm State
Active Demand Limit
Percent Total Capacity
Requested Stage
Load/Unload Factor
Active Setpoint
Control Point
Entering Fluid Temp
Leaving Fluid Temp
Emergency Stop
Minutes Left for Start
CIRCA
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Circuit A Analog Values
Percent Total Capacity
Percent Available Cap
Discharge Pressure
Suction Pressure
Saturated Condensing Tmp
Saturated Suction Temp
Compressor Suction Temp
Suction Superheat Temp
EXV % Open
CIRCA
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
Circuit A Discretes
Fan A1 Relay
Fan A2 Relay
Oil Pressure Switch
Compressor A1 Relay
Compressor A2 Relay
Compressor A3 Relay
Compressor A4 Relay
Unloader A1 Relay
Unloader A2 Relay
Hot Gas Bypass Relay
UNITS
%
%
°F
°F
°F
°F
min
POINT
MODE
FORCEABLE
N
OCC
CHIL S S
ALM
DEM LIM
CAP T
STAGE
SMZ
SP
CTRL PNT
EWT
LWT
EMSTOP
MIN LEFT
N
Y
N
Y
N
N
N
N
Y
N
N
Y
N
AN (Circuit A Analog values)
STATUS
UNITS
0-100
0-100
nnn.n
nnn.n
snnn.n
snnn.n
snnn.n
snnn.n
0-100.0
%
%
PSI
PSI
°F
°F
°F
^F
%
POINT
CAPA T
CAPA A
DP A
SP A
TMP SCTA
TMP SSTA
CTA TMP
SH A
EXV A
FORCEABLE
N
N
N
N
N
N
N
N
N
DO (Circuit A Discrete Parameters)
STATUS
UNITS
ON/OFF
ON/OFF
OPEN/CLOSE
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
POINT
FAN A1
FAN A2
OILSW A
K A1 RLY
K A2 RLY
K A3 RLY
K A4 RLY
UNL A1
UNL A2
HGAS
70
FORCEABLE
N
N
N
N
N
N
N
N
N
N
CIRCB
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Circuit B Analog Values
Percent Total Capacity
Percent Available Cap
Discharge Pressure
Suction Pressure
Saturated Condensing Tmp
Saturated Suction Temp
Compressor Suction Temp
Suction Superheat Temp
EXV % Open
CIRCB
1
2
3
4
5
6
7
8
9
10
11
AN (Circuit B Analog Parameters)
DESCRIPTION
Circuit B Discretes
Fan B1 Relay
Fan B2 Relay
Oil Pressure Switch
Compressor B1 Relay
Compressor B2 Relay
Compressor B3 Relay
Compressor B4 Relay
Unloader B1 Relay
Unloader B2 Relay
Hot Gas Bypass Relay
STATUS
UNITS
0-100
0-100
nnn.n
nnn.n
snnn.n
snnn.n
snnn.n
snnn.n
0-100.0
%
%
PSI
PSI
°F
°F
°F
^F
%
POINT
FORCEABLE
CAPB T
CAPB A
DP B
SP B
TMP SCTB
TMP SSTB
CTB TMP
SH B
EXV B
N
N
N
N
N
N
N
N
N
DO (Circuit B Discrete Parameters)
STATUS
UNITS
ON/OFF
ON/OFF
OPEN/CLOSE
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
POINT
FORCEABLE
FAN B1
FAN B2
OILSW B
K B1 RLY
K B2 RLY
K B3 RLY
K B4 RLY
UNL B1
UNL B2
HGAS
N
N
N
N
N
N
N
N
N
N
OPTIONS (Unit Parameters)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
DESCRIPTION
UNIT Analog Values
Cooler Entering Fluid
Cooler Leaving Fluid
Temperature Reset
4-20 MA Reset Signal
Outside Air Temperature
Space Temperature
Demand Limit
4-20 MA Demand Signal
Demand Limit Switch 1
Demand Limit Switch 2
CCN Loadshed Signal
Pumps
Cooler Pump Relay
Miscellaneous
Dual Setpoint Switch
Cooler Flow Switch
Ice Done
STATUS
UNITS
POINT
FORCEABLE
snnn.n
snnn.n
°F
°F
COOL EWT
COOL LWT
N
N
nn.n
snnn.n
snn.n
ma
°F
°F
RST
OAT
SPT
N
Y
Y
nn.n
ON/OFF
ON/OFF
Normal/Redline/Shed
ma
LMT MA
DMD SW1
DMD SW2
DL STAT
N
N
N
N
ON/OFF
COOL
PMP
N
ON/OFF
ON/OFF
ON/OFF
DUAL IN
COOLFLOW
ICE
N
N
N
71
MA
STRTHOUR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
DESCRIPTION
Machine Operating Hours
Machine Starts
STATUS
nnnnn
nnnnn
UNITS
hours
POINT
HR MACH
CY MACH
Circuit A Run Hours
Compressor A1 Hours
Compressor A2 Hours
Compressor A3 Hours
Compressor A4 Hours
Circuit B Run Hours
Compressor B1 Hours
Compressor B2 Hours
Compressor B3 Hours
Compressor B4 Hours
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
hours
hours
hours
hours
hours
hours
hours
hours
hours
hours
HR
HR
HR
HR
HR
HR
HR
HR
HR
HR
Circuit A Starts
Compressor A1 Starts
Compressor A2 Starts
Compressor A3 Starts
Compressor A4 Starts
Circuit B Starts
Compressor B1 Starts
Compressor B2 Starts
Compressor B3 Starts
Compressor B4 Starts
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
nnnnn
CIRA
A1
A2
A3
A4
CIRB
B1
B2
B3
B4
CY CIRA
CY A1
CY A2
CY A3
CY A4
CY CIRB
CY B1
CY B2
CY B3
CY B4
ALARMS
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
DESCRIPTION
Active Alarm #1
Active Alarm #2
Active Alarm #3
Active Alarm #4
Active Alarm #5
Active Alarm #6
Active Alarm #7
Active Alarm #8
Active Alarm #9
Active Alarm #10
Active Alarm #11
Active Alarm #12
Active Alarm #13
Active Alarm #14
Active Alarm #15
Active Alarm #16
Active Alarm #17
Active Alarm #18
Active Alarm #19
Active Alarm #20
Active Alarm #21
Active Alarm #22
Active Alarm #23
Active Alarm #24
Active Alarm #25
STATUS
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
Axxx
NOTE: Alerts will displayed as Txxx
72
UNITS
POINT
ALARM01C
ALARM02C
ALARM03C
ALARM04C
ALARM05C
ALARM06C
ALARM07C
ALARM08C
ALARM09C
ALARM10C
ALARM11C
ALARM12C
ALARM13C
ALARM14C
ALARM15C
ALARM16C
ALARM17C
ALARM18C
ALARM19C
ALARM20C
ALARM21C
ALARM22C
ALARM23C
ALARM24C
ALARM25C
CURRMODS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
DESCRIPTION
FSM controlling chiller
WSM controlling chiller
Master/Slave control
Low source protection
Ramp Load Limited
Timed Override in effect
Low Cooler Suction TempA
Low Cooler Suction TempB
Slow Change Override
Minimum OFF Time
Low Suction Superheat A
Low Suction Superheat B
Dual Setpoint
Temperature Reset
Demand Limit in effect
Cooler Freeze Prevention
Lo Tmp Cool/Hi Tmp Heat
Hi Tmp Cool/Lo Tmp Heat
STATUS
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
UNITS
POINT
MODE 1
MODE 2
MODE 3
MODE 4
MODE 5
MODE 6
MODE 7
MODE 8
MODE 9
MODE 10
MODE 11
MODE 12
MODE 13
MODE 14
MODE 15
MODE 16
MODE 17
MODE 18
SETPOINT
1
2
3
4
5
6
7
8
DESCRIPTION
COOLING
Cool Setpoint 1
Cool Setpoint 2
RAMP LOADING
Cooling Ramp Loading
HEAD PRESSURE
Head Press. Stpt A
Head Press. Stpt B
STATUS
UNITS
POINT
DEFAULTS
−20 to 70
−20 to 70
°F
°F
CSP1
CSP2
44
44
0.2 to 2.0
°F/min
CRAMP
1.0
80 to 140
80 to 140
°F
°F
HSP A
HSP B
113
113
LID DEFAULT SCREEN DEFINITION
TABLE TYPE 19 HEX
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
(SYSTEM PRIMARY MESSAGE)
(SYSTEM SECONDARY MESSAGE)
Machine Operating Hours
Entering Chilled Water
Leaving Chilled Water
Control Point
Percent Total Capacity
Active Demand Limit
Operating Setpoint
Circuit A Total Cap
Circuit B Total Cap
Machine Starts
STATUS
UNITS
POINT
DISPLAY
nnnnn
snnn.n
snnn.n
snnn.n
0-100
0-100
snnn.n
0-100
0-100
nnnnn
hours
°F
°F
°F
%
%
°F
%
%
HR MACH
EWT
LWT
CTRL PNT
CAP T
DEM_LIM
SP
CAPA T
CAPB T
CY MACH
HR MACH
EWT
LWT
CTRL PNT
CAP T
DEM_LIM
SP
CAPA T
CAPB T
CY MACH
73
CSM/FSM EQUIPMENT TABLE (Type 621H, Block 2)
LINE
1
DESCRIPTION
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
unused
Percent Total Capacity Running
Service Runtime
unused
unused
unused
Power Fail Auto Restart
Percent Available Capacity On
2
3
4
5
6
7
8
9
POINT
CHILSTAT
CAP T
HR MACH
ASTART
CAP A
WSM EQUIPMENT PART COOL SOURCE MAINTENANCE TABLE
SUPERVISOR MAINTENANCE TABLE
DESCRIPTION
WSM Active?
Chilled water temp
Equipment status
Commanded state
CHW setpoint reset value
Current CHW setpoint
STATUS
Yes
46.5 °F
On
Enable/Disable/None
2.0 ^F
44.0 °F
POINT
WSMSTAT
CHWTEMP
CHLRST
CHLRENA
CHWRVAL
CHWSTPT
OCCUPANCY MAINTENANCE TABLE
OCCUPANCY SUPERVISORY
DESCRIPTION
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
STATUS
0,1
0-8
Yes/No
0-4 hours
0:00
0:00
0:00
0:00
0:00
74
POINT
MODE
PER-NO
OVERLAST
OVR HRS
STRTTIME
ENDTIME
NXTOCDAY
NXTOCTIM
NXTUNDAY
NXTUNTIM
PRVUNDAY
PRVUNTIM
Copyright 1999 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 533-099
Printed in U.S.A.
Form 30GTN-1T
Pg 76
5-99
Replaces: New
Tab 5c
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
START-UP CHECKLIST FOR COMFORTLINK™ CHILLER SYSTEMS
(Remove and use for job file)
A. Preliminary Information
JOB NAME
LOCATION
INSTALLING CONTRACTOR
DISTRIBUTOR
START-UP PERFORMED BY
EQUIPMENT:
Chiller:
MODEL #
SERIAL #
COMPRESSORS:
CIRCUIT A
1) M#
CIRCUIT B
1) M#
S#
S#
MTR#
MTR#
2) M#
2) M#
S#
S#
MTR#
MTR#
3) M#
3) M#
S#
S#
MTR#
MTR#
4) M#
S#
MTR#
COOLER:
MODEL #
MANUFACTURED BY
SERIAL #
DATE
TYPE OF EXPANSION VALVES (check one):
EXV
TXV
AIR-HANDLING EQUIPMENT:
MANUFACTURER
MODEL #
SERIAL #
ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 533-099
Printed in U.S.A.
Form 30GTN-1T
Pg CL-1
5-99
Replaces: New
Tab 5c
B. Preliminary Equipment Check (YES or NO)
IF SO, WHERE
IS THERE ANY SHIPPING DAMAGE?
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 (YES or NO)
ARE ALL AIR HANDLERS OPERATING?
(refer to air-handling equipment Installation and Start-Up Instructions)
ARE ALL CHILLED FLUID VALVES OPEN?
IS THE FLUID PIPING CONNECTED PROPERLY?
HAS ALL AIR BEEN VENTED FROM THE COOLER LOOP?
IS THE CHILLED WATER (FLUID) PUMP (CWP) OPERATING?
IS THE CWP ROTATION CORRECT?
CWP MOTOR AMPERAGE:
Rated
Actual
C. Unit Start-Up (insert check mark as each item is completed)
CHECK THAT THE CHILLER HAS BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CHILLED
FLUID PUMP STARTER.
ASSURE THAT THE 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)
ASSURE CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF 24 HOURS PRIOR TO START-UP.
ASSURE COMPRESSOR OIL LEVEL IS CORRECT.
ASSURE BOTH LIQUID LINE SERVICE VALVES ARE BACKSEATED.
ASSURE ALL COMPRESSOR DISCHARGE SERVICE VALVES ARE BACKSEATED.
ASSURE 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 GE H-10-B
ELECTRONIC LEAK DETECTOR.
LOCATE, REPAIR, AND REPORT ANY R-22 LEAKS.
CL-2
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C. Unit Start-Up (cont)
CHECK VOLTAGE IMBALANCE:
AB
AC
AB + AC + BC (divided by 3) = AVERAGE VOLTAGE =
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE
VOLTAGE IMBALANCE =
(MAX. DEVIATION)
AVERAGE VOLTAGE
BC
V
=
x 100 =
% VOLTAGE IMBALANCE
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER!
CALL LOCAL POWER COMPANY FOR ASSISTANCE.
ASSURE THAT 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 PROTECTION IF REQUIRED:
GALLONS (LITERS) OF BRINE 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.
ARE ALL CABLES AND PIN CONNECTORS TIGHT? (Y/N)
ARE EXV, EMM, AND CXB BOARDS (IF INSTALLED) AND DISPLAY CONNECTIONS TIGHT?
CL-3
C. Unit Start-Up (cont)
TO START THE CHILLER: (insert check mark as each item is completed)
TURN THE EMERGENCY ON/OFF SWITCH (SW2) TO ON POSITION.
LEAVE THE ENABLE/OFF/REMOTE CONTACT SWITCH (SW1) IN THE OFF POSITION.
NOTE: USE ESCAPE KEY TO GO UP ONE LEVEL IN THE STRUCTURE.
USE ARROW/ESCAPE KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER KEY AND ‘DISP’ WILL BE
DISPLAYED. PRESS DOWN ARROW KEY TO DISPLAY ‘UNIT’. PRESS ENTER KEY. RECORD CONFIGURATION
INFORMATION BELOW:
UNIT (Configuration Settings)
DESCRIPTION
STATUS
DEFAULT
= Air Cooled
= Water Cooled
= Split System
= Heat Machine
= Air Cooled Heat Reclaim
UNITS
Unit Type
1
2
3
4
5
Unit Size
15 to 300
20
TONS
Circuit A1% Capacity
0 to 100
50
%
Number Circ A Compressor
1 to 4
1
Compressor A1 Cylinders
4 or 6
6
Number Circ B Compressor
1 to 4
1
Compressor B1 Cylinders
4 or 6
6
EXV Module Installed
No/Yes
Yes
EXV Superheat Setpoint
10 to 40
29.0
^F
EXV Superheat Offset
− 20 to 20
0.0
^F
EXV Circ. A Min Position
0 to 100
8.0
%
EXV Circ. B Min Position
0 to 100
8.0
%
Refrigerant
1 = R22
2 = R134A
1
Fan Staging Select
1
2
3
4
=
=
=
=
2
3
2
3
Stage
Stage
Stage
Stage
indpt.
indpt.
common
common
VALUE
1
1
PRESS ESCAPE KEY TO DISPLAY ‘UNIT’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT1’.
PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW:
OPTIONS1 (Options Configuration)
DESCRIPTION
STATUS
DEFAULT
Cooler Fluid
1 = Water
2 = Med. Brine
3 = Low Brine
Hot Gas Bypass Select
No/Yes
No
Head Press. Cont. Method
1
2
3
4
2
Head Press. Control Type
0 = None
1 = Air Cooled
2 = Water Cooled
0
Pressure Transducers
No/Yes
No
Cooler Pump Interlock
Off/On
On
Cooler Pump Control
Off/On
Off
No. Circuit A Unloaders
0-2
1
No. Circuit B Unloaders
0-2
1
EMM Module Installed
No/Yes
No
=
=
=
=
1
EXV controlled
Setpoint controlled
Setpoint-A, EXV-B
EXV-A, Setpoint-B
CL-4
VALUE
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)
DESCRIPTION
STATUS
=
=
=
=
DEFAULT
Control Method
0
1
2
3
CCN Address
1 to 239
CCN Bus Number
0 to 239
0
CCN Baud Rate
1
2
3
4
5
3
Loading Sequence Select
1 = Equal loading
2 = Staged loading
1
Lead/Lag Sequence Select
1 = Automatic
2 = Circuit A leads
3 = Circuit B leads
1
High LCW Alert Limit
2 to 60
60.0
^F
Minutes off time
0 to 15
0
min
=
=
=
=
=
Switch
7 day sched.
Occupancy
CCN
UNITS
VALUE
0
1
2400
4800
9600
19,200
38,400
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)
DESCRIPTION
STATUS
DEFAULT
UNITS
COOLING RESET
Cooling Reset Type
0
1
2
3
4
=
=
=
=
=
No Reset
4-20 ma input
External temp-OAT
Return fluid
External temp-SPT
0
No Cool Reset Temp
0 to 125
Full Cool Reset Temp
0 to 125
125.0
°F
Degrees Cool Reset
−30 to 30
0.0
^F
Demand Limit Select
0
1
2
3
0
Demand Limit at 20mA
0 to 100
100
Loadshed Group Number
0 to 99
0
Loadshed Demand Delta
0 to 60
0
%
Maximum Loadshed Time
0 to 120
60
min
Demand Limit Switch 1
0 to 100
80
%
Demand Limit Switch 2
0 to 100
50
%
Lead/Lag Enable
Enable/Disable
Disable
Master/Slave Select
Slave/Master
Master
Slave Address
0 to 239
0
Lead/Lag Balance Select
Enable/Disable
Disable
Lead/Lag Balance Delta
40 to 400
168
hours
Lag Start Delay
0 to 30
5
mins
0.0
°F
DEMAND LIMIT
=
=
=
=
None
External switch input
4-20 ma input
Loadshed
%
LEAD/LAG
CL-5
VALUE
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 (Cooling Setpoint Select)
DESCRIPTION
STATUS
=
=
=
=
DEFAULT
Cooling Setpoint Select
0
1
2
3
Single
Dual Switch
Dual Clock
4 to 20 mA Input
Ramp Load Select
Enable/Disable
Enable
Cooling Ramp Loading
0.2 to 2.0
1.0
Deadband Multiplier
1.0 to 4.0
1.0
UNITS
VALUE
0
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:
SETPOINT
DESCRIPTION
STATUS
UNITS
DEFAULTS
Cool Setpoint 1
−20 to 70
°F
44
Cool Setpoint 2
−20 to 70
°F
44
0.2 to 2.0
°F/min
1.0
Head Press. Stpt A
80 to 140
°F
113
Head Press. Stpt B
80 to 140
°F
113
VALUE
COOLING
RAMP LOADING
Cooling Ramp Loading
HEAD PRESSURE
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. 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 TEMPERATURES FOR T3, T5 AND T7 BELOW.
PRESS ESCAPE TO DISPLAY ‘CIR.A’ AGAIN AND PRESS THE DOWN ARROW KEY TO DISPLAY ‘CIR.B’. PRESS
ENTER AND USE THE DOWN ARROW KEYS TO RECORD TEMPERATURES FOR T4, T6 AND T8 BELOW. USING A
DC VOLTMETER, MEASURE AND RECORD THE VOLTAGE FOR EACH THERMISTOR AT THE LOCATION SHOWN.
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
T4 (SCT.B)
MBB, J8 PINS 15,16
T5 (SST.A)
MBB, J8 PINS 24,25 (EXV UNITS ONLY)
T6 (SST.B)
MBB, J8 PINS 18,19 (EXV UNITS ONLY)
T7 (SGT.A)
EXV, J5 PINS 11,12 (EXV UNITS ONLY)
T8 (SGT.B)
EXV, J5 PINS 9,10 (EXV UNITS ONLY)
T9 (OAT)
MBB, J8 PINS 7,8
T10 (SPT)
MBB, J8 PINS 5,6
CL-6
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. ‘PASS’ 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 ‘FR.A1’. 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. USE THE ARROW KEYS TO SELECT THE DESIRED PERCENTAGE FOLLOWED BY THE
ENTER KEY WHEN TESTING EXPANSION VALVES. CHECK OFF THE FOLLOWING THAT APPLY AFTER BEING TESTED:
FR.A1
(CHECK ROTATION)
EXV.A
FR.A2
(CHECK ROTATION)
FR.B1
(CHECK ROTATION)
FR.B2
(CHECK ROTATION)
EXV.B
CLR.P
(TB5-10,12)
RMT.A
TB5-11,12)
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
WITHOUT TURNING THE COMPRESSOR(S) ON. MAKE SURE ALL SERVICE VALVES ARE OPEN AND COOLER
PUMP HAS BEEN TURNED ON BEFORE STARTING COMPRESSORS. CHECK OFF EACH ITEM AFTER
SUCCESSFUL TEST: LEAD COMPRESSORS (A1/B1) WILL BE TURNED ON BEFORE ANY LAG COMPRESSORS CAN
BE STARTED. 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.
CC.A1
CC.A2
CC.A3
CC.A4
UL.A1
UL.A2
HGBP
(IF INSTALLED)
CC.B1
CC.B2
CC.B3
CC.B4
UL.B1
UL.B2
TXV UNITS ONLY: CHECK AND ADJUST SUPERHEAT.
CL-7
N/A
Copyright 1999 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 533-099
Printed in U.S.A.
Form 30GTN-1T
Pg CL-8
5-99
Replaces: New
Tab 5c