30GN040-420 Flotronic™ II Reciprocating Liquid Chillers 50/60 Hz Controls, Operation, and Troubleshooting with Microprocessor Controls and Electronic Expansion Valves CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-5 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Low-Voltage Relay Module . . . . . . . . . . . . . . . . . . . 4 Electronic Expansion Valve Module . . . . . . . . . . . 4 Options Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Keypad and Display Module (Also Called HSIO or LID) . . . . . . . . . . . . . . . . . . 4 Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electronic Expansion Valve (EXV) . . . . . . . . . . . . 4 Thermostatic Expansion Valves (TXV) . . . . . . . . 4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compressor Protection Control Module (CPCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 24 • EXV UNITS • TXV UNITS Pumpout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 • EXV UNITS • TXV UNITS Keypad and Display Module (Also Called HSIO or LID) . . . . . . . . . . . . . . . . . 24 • ACCESSING FUNCTIONS AND SUBFUNCTIONS • AUTOMATIC DEFAULT DISPLAY • AUTOMATIC DISPLAY OPERATION/DEFAULT DISPLAY • KEYPAD OPERATING INSTRUCTIONS • STATUS FUNCTION • TEST FUNCTION • HISTORY FUNCTION • SET POINT FUNCTION • SERVICE FUNCTION • SCHEDULE FUNCTION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 47-64 Checking Display Codes . . . . . . . . . . . . . . . . . . . . 47 Page Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . 48 Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . 48 Lag Compressor Stoppage . . . . . . . . . . . . . . . . . . 48 Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48 • POWER FAILURE EXTERNAL TO THE UNIT Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Compressor Alarm/Alert Circuit . . . . . . . . . . . . . 50 Electronic Expansion Valve (EXV) . . . . . . . . . . . 55 • EXV OPERATION • CHECKOUT PROCEDURE Thermostatic Expansion Valve (TXV) . . . . . . . . . 57 Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 • LOCATION • THERMISTOR REPLACEMENT (T1, T2, T7, T8) Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . 60 • TROUBLESHOOTING • TRANSDUCER REPLACEMENT Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 • PROCESSOR MODULE (PSIO), 4IN/4OUT MODULE (SIO), LOW-VOLTAGE RELAY MODULE (DSIO-LV), AND EXV DRIVER MODULE (DSIO-EXV) • RED LED • GREEN LED • PROCESSOR MODULE (PSIO) • LOW-VOLTAGE RELAY MODULE (DSIO) • 4IN/4OUT MODULE (SIO) ACCESSORY UNLOADER INSTALLATION . . . 64-68 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 • 040-110, 130 (60 Hz) UNITS (And Associated Modular Units) • 130 (50 Hz), 150-210 UNITS (And Associated Modular Units) FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,70 REPLACING DEFECTIVE PROCESSOR MODULE (PSIO) . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 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. 563-079 Printed in U.S.A. Form 30GN-3T Pg 1 7-95 Replaces: 30G-1T Tab 5c Table 1 — Unit Sizes and Modular Combinations SAFETY CONSIDERATIONS UNIT MODEL 30GN 040 045 050 060 070 080 090 100 110 130 150 170 190 210 230 245 255 270 290 315 330 360 390 420 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. 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 SECTION A UNIT 30GN — — — — — — — — — — — — — — 150 150 150 170 190 210 170 190 210 210 SECTION B UNIT 30GN — — — — — — — — — — — — — — 080 090 100 100 110 110 170 190/170* 190 210 *60 Hz units/50 Hz units. The Flotronic II control system cycles compressor unloaders and/or compressors to maintain the selected leaving fluid temperature set point. It automatically positions the EXV to maintain the specified refrigerant superheat entering the compressor cylinders. It also cycles condenser fans on and off to maintain suitable head pressure for each circuit. Safeties are continuously monitored to prevent the unit from operating under unsafe conditions. A scheduling function, programmed by the user, controls the unit occupied/unoccupied schedule. The control also operates a test program that allows the operator to check output signals and ensure components are operable. The control system consists of a processor module (PSIO), a low-voltage relay module (DSIO-LV), 2 EXVs, an EXV driver module (DSIO-EXV), a 6-pack relay board, a keypad and display module (also called HSIO or LID), thermistors, and transducers to provide inputs to the microprocessor. A standard options module (SIO) is used to provide additional functions. See Fig. 1 for a typical 30GN Control Panel. GENERAL IMPORTANT: This publication contains controls, operation and troubleshooting data for 30GN040-420 Flotronic™ II chillers. Circuits are identified as circuits A and B, and compressors are identified as A1, A2, etc. in circuit A, and B1, B2, etc. in circuit B. Use this guide in conjunction with separate Installation Instructions booklet packaged with the unit. The 30G Series standard Flotronic II chillers feature microprocessor-based electronic controls and an electronic expansion valve (EXV) in each refrigeration circuit. NOTE: The 30GN040 and 045 chillers with a factoryinstalled brine option have thermal expansion valves (TXV) instead of the EXV. Unit sizes 230-420 are modular units which are shipped as separate sections (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. MAJOR SYSTEM COMPONENTS Processor Module — This module contains the operating software and controls the operation of the machine. It continuously monitors information received from the various transducers and thermistors and communicates with the relay modules and 6-pack relay board to increase or decrease the active stages of capacity. The processor module 2 COMM 3 PWR POINT NUMBER OF FIRST CHANNEL X X EXV LV STATUS STATUS COMM COMM 5VDC 1 Potter & Brumfield CZ770 HK35AA002 2 COMM 1 COMM 3 4- 3+ J5 PWR S1 J4 J4 X X S2 EQUIP GND 99NA505322 D FUSE 1 LO C A L / ENABLE SW1 STOP CCN FUSE 3 F U SE 9 5 6 1 2 3 TEST ENTR – 0 • HIST CLR F 8 4 SET EXPN E U SE FU S 7 SCHD SRVC STAT FUSE 2 GFI - CO ( 5 AMP MAX ) CB5 CB6 30GT510568 – LEGEND CCN — Carrier Comfort Network TB — Terminal Block Fig. 1 — 30GN Control Panel (040-110 Unit Shown) 3 Table 2 — LOCAL/ENABLE-STOP-CCN Switch Positions and Operation also controls the EXV driver module (as appropriate), commanding it to open or close each EXV in order to maintain the proper superheat entering the cylinders of each lead compressor. Information is transmitted between the processor module and relay module, the EXV driver module, and the keypad and display module through a 3-wire communications bus. The options module is also connected to the communications bus. For the Flotronic™ II chillers, the processor monitors system pressure by means of 6 transducers, 3 in each lead compressor. Compressor suction pressure, discharge pressure, and oil pressure are sensed. If the processor senses high discharge pressure or low suction pressure, it immediately shuts down all compressors in the affected circuit. During operation, if low oil pressure is sensed for longer than one minute, all compressors in the affected circuit are shut down. At startup, the oil pressure signal is ignored for 2 minutes. If shutdown occurs due to any of these pressure faults, the circuit is locked out and the appropriate fault code is displayed. SWITCH POSITION STOP LOCAL/ENABLE CCN Stop — Run — UNIT OPERATION Unit Unit Unit Unit Cannot Run Can Run Cannot Run Can Run CONFIGURATION AND SET POINT CONTROL Keypad Control CCN Control Read/Write Read Only Read/Limited Write Read Only Read Only Read/Write Read/Limited Read Only Write In the CCN position, the chiller is under remote control and responds only to CCN network commands. The occupied/ unoccupied conditions are defined by the network. All keypad and display functions can be read at the chiller regardless of position of the switch. CCN run or stop condition is established by a command from the CCN network. It is not possible to force outputs from the CCN network, except that an emergency stop command shuts down the chiller immediately and causes ‘‘ALARM 52’’ to be displayed. Low-Voltage Relay Module — This module closes contacts to energize compressor unloaders and/or compressors. It also senses the status of the safeties for all compressors and transmits this information to the processor. Electronic Expansion Valve (EXV) — The microprocessor controls the EXV (if so equipped) through the EXV driver module. Inside the expansion valve is a linear actuator stepper motor. The lead compressor in each circuit has a thermistor and a pressure transducer located in the suction manifold after the compressor motor. The thermistor measures the temperature of the superheated gas entering the compressor cylinders. The pressure transducer measures the refrigerant pressure in the suction manifold. The microprocessor converts the pressure reading to a saturated temperature. The difference between the temperature of the superheated gas and the saturation temperature is the superheat. The microprocessor controls the position of the electronic expansion valve stepper motor to maintain 30 F (17 C) superheat. At initial unit start-up, the EXV position is at zero. After that, the microprocessor keeps accurate track of the valve position in order to use this information as input for the other control functions. The control monitors the superheat and the rate of change of superheat to control the position of the valve. The valve stroke is very large, which results in very accurate control of the superheat. Electronic Expansion Valve Module (If So Equipped) — This module receives signals from the processor and operates the electronic expansion valves. Options Module — This module allows the use of Flotronic II features such as dual set point, remote reset, demand limit, hot gas bypass, and accessory unloaders. The options module also allows for reset and demand limit to be activated from a remote 4-20 mA signal. The options module is installed at the factory. Keypad and Display Module (Also Called HSIO or LID) — This device consists of a keypad with 6 function keys, 5 operative keys, 12 numeric keys, and an alphanumeric 8-character LCD (liquid crystal display). Key usage is explained in Accessing Functions and Subfunctions section on page 24. Control Switch — Control of the chiller is defined by the position of the LOCAL/ENABLE-STOP-CCN switch. This is a 3-position manual switch that allows the chiller to be put under the control of its own Flotronic II controls, manually stopped, or put under the control of a Carrier Comfort Network (CCN). Switch allows unit operation as shown in Table 2. In the LOCAL/ENABLE position, the chiller is under local control and responds to the scheduling configuration and set point data input at its own local interface device (keypad and display module). Thermostatic Expansion Valves (TXV) — Model 30GN040 and 045 units with factory-installed brine option are equipped with conventional thermostatic expansion valves with liquid line solenoids. The liquid line solenoid valves are not intended to be a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system. 4 The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 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 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. Sensors — The Flotronic™ II chiller control system gathers information from sensors to control the operation of the chiller. The units use 6 standard pressure transducers and 4 standard thermistors to monitor system pressures and temperatures at various points within the chiller. Sensors are listed in Table 3. Fig. 2 — Compressor Protection Control Module Table 3 — Thermistor and Transducer Locations Sensor T1 T2 T7 T8 T10 Sensor DPT-A SPT-A OPT-A DPT-B SPT-B OPT-B THERMISTORS Location Cooler Leaving Fluid Temp Cooler Entering Fluid Temp Compressor Suction Gas Temp Circuit A Compressor Suction Gas Temp Circuit B Remote Temperature Sensor (Accessory) PRESSURE TRANSDUCERS Location Compressor A1 Discharge Pressure Compressor A1 Suction Pressure Compressor A1 Oil Pressure Compressor B1 Discharge Pressure Compressor B1 Suction Pressure Compressor B1 Oil Pressure Fig. 3 — Compressor Ground Fault Module Compressor Protection Control Module (CPCS) — Each compressor on models 30GN070 (50 Hz), 080- ground of any compressor winding exceeds 2.5 amps. If this condition occurs, the CPCS module shuts down the compressor. A high-pressure switch with a trip pressure of 426 ± 7 psig (2936 ± 48 kPa), is wired in series with the CPCS. If this switch opens during operation, the compressor stops and the failure is detected by the processor when the signal contacts open. The compressor is locked off. If the lead compressor in either circuit is shut down by the high-pressure switch or ground current protector, all compressors in the circuit are locked off. 110, and 230B-315B, has its own CPCS as standard equipment. See Fig. 2. All 30GN040-060 and 070 (60 Hz) units feature the CPCS as an accessory, and CR (control relay) as standard equipment. The 30GN130-210 and associated modular units have a CR as standard equipment. The CPCS or CR is used to control and protect the compressors and crankcase heaters. The CPCS provides the following functions: • compressor contactor control • crankcase heater control • compressor ground current protection • status communication to processor board • high-pressure protection The CR provides all of the same functions as the CPCS with the exception of compressor ground current protection. Ground current protection is accomplished by using a CGF (compressor ground fault module) in conjunction with the CR. The CGF (See Fig. 3) provides the same ground fault function as the CPCS for units where the CPCS is not utilized. One large relay is located on the CPCS board. This relay (or CR) controls the crankcase heater and compressor contactor. The CPCS also provides a set of signal contacts that the microprocessor monitors to determine the operating status of the compressor. If the processor board determines that the compressor is 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- OPERATION DATA Capacity Control — The control system cycles compressor to give capacity control steps as shown in Tables 4A-4C. The unit controls leaving chilled fluid temperature. Entering fluid temperature is used by the microprocessor in determining the optimum time to add or subtract steps of capacity, but is not a control set point. The chilled fluid temperature set point can be automatically reset by the return temperature reset or space and outdoor-air temperature reset features. It can also be reset from an external 4 to 20 mA signal, or from a network signal. The operating sequences shown are some of many possible loading sequences for the control of the leaving fluid temperature. If a circuit has more unloaders than another, that circuit will always be the lead circuit. 5 Table 4A — Capacity Control Steps, 040-070 UNIT 30GN 040 (60 Hz) A1†,B1 040 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1 040 (50 Hz) 045 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1** 045 (50 Hz) 050 (60 Hz) A1†,B1 045 (50 Hz) 050 (60 Hz) A1†,B1** 045 (50 Hz) 050 (60 Hz) A1†**,B1 045 (50 Hz) 050 (60 Hz) A1†**,B1** 045 (50 Hz) 050 (60 Hz) A1†,B1** CONTROL STEPS 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 6 7 LOADING SEQUENCE A % Displacement Compressors (Approx) 25 A1* 50 A1 75 A1*, B1 100 A1,B1 25 A1* 50 A1 75 A1*,B1 100 A1,B1 24 A1* 47 A1 76 A1*,B1 100 A1,B1 24 A1* 47 A1 61 A1*,B1* 76 A1*,B1 100 A1,B1 — — — — — — — — — — — — 31 A1* 44 A1 87 A1*,B1 100 A1,B1 31 A1* 44 A1 69 A1*,B1* 87 A1*,B1 100 A1,B1 18 A1†† 31 A1* 73 A1††,B1 87 A1*,B1 100 A1,B1 18 A1†† 31 A1* 44 A1 56 A1††,B1* 73 A1††,B1 87 A1*,B1 100 A1,B1 — — — — — — — — — — — — — — *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader(s), accessory. ††Two unloaders, both unloaded. 6 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 21 B1†† 37 B1* 53 B1 68 A1,B1†† 84 A1,B1* 100 A1,B1 — — — — — — — — 38 B1* 56 B1 69 A1*,B1* 82 A1,B1* 100 A1,B1 — — — — — — — — — — — — — — — — — — — — — — — — 20 B1†† 38 B1* 56 B1 51 A1*,B1†† 64 A1,B1†† 82 A1,B1* 100 A1,B1 Table 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN 045 (50 Hz) 050 (60 Hz) A1†**,B1** 050 (50 Hz) 060 (60 Hz) A1†,B1 050 (50 Hz) 060 (60 Hz) A1†,B1** 050 (50 Hz) 060 (60 Hz) A1†**,B1 050 (50 Hz) 060 (60 Hz) A1†**,B1** 050 (50 Hz) 060 (60 Hz) A1†,B1** 050 (50 Hz) 060 (60 Hz) A1†**,B1** 060 (50 Hz) 070 (60 Hz) A1†,B1 060 (50 Hz) 070 (60 Hz) A1†,B1** 060 (50 Hz) 070 (60 Hz) A1†**,B1 060 (50 Hz) 070 (60 Hz) A1†**,B1** 060 (50 Hz) 070 (60 Hz) A1†,B1** CONTROL STEPS 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 LOADING SEQUENCE A % Displacement Compressors (Approx) 18 A1†† 31 A1* 44 A1 56 A1††,B1* 73 A1††,B1 87 A1*,B1 100 A1,B1 28 A1* 42 A1 87 A1*,B1 100 A1,B1 28 A1* 42 A1 67 A1*,B1* 87 A1*,B1 100 A1,B1 15 A1†† 28 A1* 73 A1††,B1 87 A1*,B1 100 A1,B1 15 A1†† 28 A1* 42 A1 53 A1,B1* 73 A1††,B1 87 A1*,B1 100 A1,B1 — — — — — — — — — — — — 15 A1†† 28 A1* 42 A1 53 A1††,B1* 73 A1††,B1 87 A1*,B1 100 A1,B1 33 A1* 50 A1 83 A1*,B1 100 A1,B1 33 A1* 50 A1 67 A1*,B1* 83 A1*,B1 100 A1,B1 16 A1†† 33 A1* 66 A1††,B1 83 A1* 100 A1,B1 16 A1†† 33 A1* 50 A1 66 A1††,B1 83 A1*,B1 100 A1,B1 — — — — — — — — — — — — *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader(s), accessory. ††Two unloaders, both unloaded. 7 LOADING SEQUENCE B % Displacement Compressors (Approx) 20 B1†† 38 B1* 56 B1 64 A1,B1†† 82 A1,B1* 100 A1,B1 — — — — — — — — — — 38 B1* 58 B1 67 A1*,B1* 80 A1,B1* 100 A1,B1 — — — — — — — — — — — — — — — — — — — — — — — — 18 B1†† 38 B1* 58 B1 60 A1,B1†† 80 A1,B1* 100 A1,B1 18 B1†† 38 B1* 58 B1 60 A1,B1†† 80 A1,B1* 100 A1,B1 — — — — — — — — — — 33 B1* 50 B1 66 A1*,B1* 83 A1,B1* 100 A1,B1 — — — — — — — — — — — — — — — — — — — — — — 16 B1†† 33 B1* 50 B1 66 A1,B1†† 83 A1,B1* 100 A1,B1 Table 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN 060 (50 Hz) 070 (60 Hz) A1†**,B1| 070 (50 Hz) A1†,B1 070 (50 Hz) A1†,B1** 070 (50 Hz) A1†**,B1 070 (50 Hz) A1†**,B1** 070 (50 Hz) A1†,B1| 070 (50 Hz) A1†**,B1| CONTROL STEPS 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 LOADING SEQUENCE A % Displacement Compressors (Approx) 16 A1†† 33 A1* 50 A1 66 A1††,B1 83 A1*,B1 100 A1,B1 19 A1* 27 A1 65 A1*,B1 73 A1,B1 92 A1*,A2,B1 100 A1,A2,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†† 19 A1* 57 A1††,B1 65 A1*,B1 73 A1,B1 84 A1††,A2,B1 92 A1*,A2,B1 100 A1,A2,B1 11 A1†† 19 A1* 27 A1 41 A1††,B1* 57 A1††,B1 65 A1*,B1 73 A1,B1 84 A1††,A2,B1 92 A1*,A2,B1 100 A1,A2,B1 — — — — — — — — — — — — — — 11 A1†† 19 A1* 27 A1 41 A1††,B1* 57 A1††,B1 65 A1*,B1 73 A1,B1 84 A1††,A2,B1 92 A1*,A2,B1 100 A1,A2,B1 *Unloaded compressor. †Compressor unloader, standard. **One compressor unloader, accessory. ††Two unloaders, both unloaded. \ Two compressor unloaders, accessory. 8 LOADING SEQUENCE B % Displacement Compressors (Approx) 16 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†† 31 B1* 47 B1 57 A1*,B1* 73 A1,B1 84 A1,A2,B1* 100 A1,A2,B1 15 B1†† 31 B1* 47 B1 54 A1*,B1* 73 A1,B1 84 A1,A2,B1* 100 A1,A2,B1 — — — — — — Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units UNIT 30GN CONTROL STEPS 080, 230B (60 Hz) A1†,B1† 080, 230B (60 Hz) A1†**, B1† 080, 230B (60 Hz) A1†,B1†** 080, 230B (60 Hz) A1†**,B1†** 080, 230B (50 Hz) A1†,B1† 080, 230B (50 Hz) A1†**,B1† 080, 230B (50 Hz) A1†,B1†** 080, 230B (50 Hz) A1†**,B1†** 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 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 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 LOADING SEQUENCE A % Displacement Compressors (Approx) 22 A1* 34 A1 52 A1*,B1* 67 A1*,B1 78 A1,B1 89 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 — — — — — — — — — — — — — — — — 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 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 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 — — — — — — — — — — — — — — — — — — 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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. 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 — — — — — — — — — — — — — — — — — — 15 B1†† 30 B1* 44 B1 48 A1,B1†† 63 A1,B1* 78 A1,B1 85 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 — — 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 — — — — — — — — — — — — — — — — — — — — — — 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 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 — — — — NOTE: These capacity control steps may vary due to lag compressor sequencing. 9 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS 090, 245B (60 Hz) A1†,B1† 090, 245B (60 Hz) A1†**,B1† 090, 245B (60 Hz) A1†,B1†** 090, 245B (60 Hz) A1†**,B1†** 090, 245B (50 Hz) A1†,B1† 090, 245B (50 Hz) A1†**,B1† 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 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 — — — — — — — — — — — — — — — — — — — — — — — — 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 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 7 A1†† 14 A1* 21 A1 29 A1††,B1 36 A1*,B1 43 A1,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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 — — — — — — — — — — — — — — — — — — — — — — — — 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 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 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — NOTE: These capacity control steps may vary due to lag compressor sequencing. 10 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 090, 245B (50 Hz) A1†,B1†** 090, 245B (50 Hz) A1†**,B1†** 100, 255B, 270B (60 Hz) A1†,B1† 100, 255B, 270B (60 Hz) A1†**,B1† 100, 255B, 270B (60 Hz) A1†,B1†** 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 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) — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 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 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. 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 79 A1*,A2,B1††,B1 86 A1,A2,B1††,B1 93 A1,A2,B1*,B2 100 A1,2,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 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 11 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 100, 255B, 270B (60 Hz) A1†**,B1†** 100, 255B, 270B (50 Hz) A1†,B1† 100, 255B, 270B (50 Hz) A1†**,B1† 100, 255B, 270B (50 Hz) A1†,B1†** 100, 255B, 270B (50 Hz) A1†**,B1†** 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 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 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 7 A1†† 13 A1* 20 A1 26 A1††,B1 33 A1*,B1 40 A1,B1 50 A1††,A2,B1* 57 A1††,A2,B1 63 A1*,A2,B1 70 A1,A2,B1 80 A1††,A2,B1*,B2 87 A1††,A2,B1,B2 93 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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — 7 B1†† 13 B1* 20 B1 26 A1,B1†† 33 A1,B1* 40 A1,B1 50 A1*,B1††,B2 57 A1,B1††,B2 63 A1,B1*,B2 70 A1,B1,B2 80 A1*,A2,B1††,B2 87 A1,A2,B1††,B2 93 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 12 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 110, 290B, 315B (60 Hz) A1†,B1† 110, 290B, 315B (60 Hz) A1†**,B1† 110, 290B, 315B (60 Hz) A1†,B1†** 110, 290B, 315B (60 Hz) A1†**,B1†** 110, 290B, 315B (50 Hz) A1†,B1† CONTROL STEPS 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 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 7 A1†† 14 A1* 21 A1 29 A1††,B1 36 A1*,B1 43 A1,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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 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. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 79 A1*,A2,B1††,B2 86 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 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 13 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT 30GN 110, 290B, 315B (50 Hz) A1†**,B1† 110, 290B, 315B (50 Hz) A1†,B1†** 110, 290B, 315B (50 Hz) A1†**,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 — — — — — — — — — — — — — — — — — — — — — — — — 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. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — 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 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 14 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units UNIT 30GN 130 (60 Hz) A1†,B1† 130 (60 Hz) A1†**,B1† 130 (60 Hz) A1†,B1†** 130 (60 Hz) A1†**,B1†** 130 (50 Hz) A1†,B1† CONTROL STEPS 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 15 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 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 8 A1†† 14 A1* 21 A1 22 A1††,B1* 28 A1††,B1 35 A1*,B1 42 A1,B1 51 A1††,A2,B1* 58 A1††,A2,B1 64 A1*,A2,B1 71 A1,A2,B1 80 A1††,A2,B1*,B2 87 A1††,A2,B1,B2 93 A1*,A2,B1,B2 100 A1,A2,B1,B2 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 8 B1†† 14 B1* 21 B1 22 A1*,B1†† 28 A1,B1†† 35 A1,B1* 42 A1,B1 51 A1*,B1††,B2 58 A1,B1††,B2 64 A1,B1*,B2 71 A1,B1,B2 80 A1*,A2,B1††,B2 87 A1,A2,B1††,B2 93 A1,A2,B1*,B2 100 A1,A2,B1,B2 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 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 15 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN 130 (50 Hz) A1†**,B1† 130 (50 Hz) A1†,B1†** 130 (50 Hz) A1†**,B1†** 150, 230A, 245A, 255A (60 Hz) A1†,B1† CONTROL STEPS 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 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 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†† 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 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. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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,B3 91 A1,A2,A3,B1*,B2,B3 100 A1,A2,A3,B1,B2,B3 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 — — — — — — — — 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 16 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN 150, 230A, 245A, 255A (60 Hz) A1†**,B1† 150, 230A, 245A, 255A (60 Hz) A1†,B1†** 150, 230A, 245A, 255A (60 Hz) A1†**,B1†** 150, 230A, 245A, 255A (50 Hz) A1†,B1† 150, 230A, 245A, 255A (50 Hz) A1†**,B1† 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 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LOADING SEQUENCE A % Displacement Compressors (Approx) 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†† 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 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 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. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 85 A1,A2,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,kB1 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 — — — — — — — — 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — NOTE: These capacity control steps may vary due to lag compressor sequencing. 17 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 150, 230A, 245A, 255A (50 Hz) A1†,B1†** 150, 230A, 245A, 255A (50 Hz) A1†**,B1†** 170, 270A, 330A/B (60 Hz) A1†,B1† 170, 270A, 330A/B (60 Hz) A1†**,B1† 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 15 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 21 22 23 LOADING SEQUENCE A % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 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 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 6 A1†† 11 A1* 17 A1 17 A1††,B1* 23 A1††,B1 28 A1*,B1 33 A1,B1 34 A1††,A2,B1* 39 A1††,A2,B1 45 A1*,A2,B1 50 A1,A2,B1 51 A1††,A2,B1*,B2 56 A1††,A2,B1,B2 61 A1*,A2,B1,B2 67 A1,A2,B1,B2 67 A1††,A2,A3,B1*,B2 73 A1††,A2,A3,B1,B2 78 A1*,A2,A3,B1,B2 83 A1,A2,A3,B1,B2 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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 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 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 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — NOTE: These capacity control steps may vary due to lag compressor sequencing. 18 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 170, 270A, 330A/B (60 Hz) A1†,B1†** 170, 270A, 330A/B (60 Hz) A1†**,B1†** 170, 270A, 330A/B,360B (50 Hz) A1†,B1† CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 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 LOADING SEQUENCE A % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 6 A1†† 11 A1* 17 A1 17 A1††,B1* 23 A1††,B1 28 A1*,B1 33 A1,B1 34 A1††,A2,B1* 39 A1††,A2,B1 45 A1*,A2,B1 50 A1,A2,B1 51 A1††,A2,B1*,B2 56 A1††,A2,B1,B2 61 A1*,A2,B1,B2 67 A1,A2,B1,B2 67 A1††,A2,A3,B1*,B2 73 A1††,A2,A3,B1,B2 78 A1*,A2,A3,B1,B2 83 A1,A2,A3,B1,B2 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 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 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. 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 6 11 17 17 23 28 33 34 39 45 50 51 56 61 67 67 73 78 83 84 89 95 100 9 14 19 23 28 38 43 47 52 57 61 72 76 81 91 96 100 SEQUENCE B Compressors B1†† B1* B1 A1*,B1†† A1,B1†† A1,B1* A1,B1 A1*,B1††,B2 A1,B1††,B2 A1,B1*,B2 A1,B1,B2 A1*,A2,B1††,B2 A1,A2,B1††,B2 A1,A2,B1*,B2 A1,A2,B1,B2 A1*,A2,B1††,B2,B3 A1,A2,B1††,B2,B3 A1,A2,B1*,B2,B3 A1,A2,B1,B2,B3 A1*,A2,A3,B1††,B2,B3 A1,A2,A3,B1††,B2,B3 A1,A2,A3,B1*,B2,B3 A1,A2,A3,B1,B2,B3 B1†† B1* B1 A1*,B1†† A1,B1†† A1,B1* A1,B1 A1*,B1††,B2 A1,B1††,B2 A1,B1*,B2 A1,B1,B2 A1*,A2,B1††,B2 A1,A2,B1††,B2 A1,A2,B1*,B2 A1,A2,B1,B2 A1*,A2,B1††,B2,B3 A1,A2,B1††,B2,B3 A1,A2,B1*,B2,B3 A1,A2,B1,B2,B3 A1*,A2,A3,B1††,B2,B3 A1,A2,A3,B1††,B2,B3 A1,A2,A3,B1*,B2,B3 A1,A2,A3,B1,B2,B3 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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 19 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1† 170, 270A, 330A/B, 360B (50 Hz) A1†,B1†** 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1†** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 5 A1†† 9 A1* 14 A1 14 A1††,B1* 19 A1††,B1 23 A1*,B1 28 A1,B1 28 A1††,A2,B1* 33 A1††,A2,B1 37 A1*,A2,B1 42 A1,A2,B1 48 A1††,A2,B1*,B2 52 A1††,A2,B1,B2 57 A1*,A2,B1,B2 61 A1,A2,B1,B2 67 A1††,A2,A3,B1*,B2 72 A1††,A2,A3,B1,B2 76 A1*,A2,A3,B1,B2 81 A1,A2,A3,B1,B2 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,B2,B3 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 5 A1†† 9 A1* 14 A1 14 A1††,B1* 19 A1††,B1 23 A1*,B1 28 A1,B1 28 A1††,A2,B1* 33 A1††,A2,B1 37 A1*,A2,B1 42 A1,A2,B1 43 A1††,A2,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,A3,B1††,B2 67 A1††,A2,A3,B1*,B2 72 A1††,A2,A3,B1,B2 76 A1*,A2,A3,B1,B2 81 A1,A2,A3,B1,B2 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,B2,B3 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 5 B1†† 9 B1* 14 B1 14 A1*,B1†† 19 A1,B1†† 23 A1,B1* 28 A1,B1 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 67 A1*,A2,B1††,B2,B3 72 A1,A2,B1††,B2,B3 76 A1,A2,B1*,B2,B3 81 A1,A2,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,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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 20 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 190, 290A, 360A/B, 390B (60 Hz) A1,B1 190, 290A, 360A/B, 390B (60 Hz) A1**,B1 190, 290A, 360A/B, 390B (60 Hz) A1,B1** 190, 290A, 360A/B, 390B (60 Hz) A1**,B1** 190, 290A, 360A, 390B (50 Hz) A1,B1 190, 290A, 360A, 390B (50 Hz) A1**,B1 CONTROL STEPS 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 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 7 8 9 10 11 12 LOADING SEQUENCE A % Displacement Compressors (Approx) 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 9 A1* 13 A1 21 A1*,B1 25 A1,B1 37 A1*,A2,B1 41 A1,A2,B1 53 A1*,A2,B1,B2 56 A1,A2,B1,B2 74 A1*,A2,A3,B1,B2 78 A1,A2,A3,B1,B2 96 A1*,A2,A3,B1,B2,B3 100 A1,A2,A3,B1,B2,B3 — — — — — — — — — — — — — — — — — — — — — — — — 9 A1* 13 A1 18 A1*,B1* 21 A1*,B1 25 A1,B1 33 A1*,A2,B1* 37 A1*,A2,B1 41 A1,A2,B1 49 A1*,A2,B1*,B2 53 A1*,A2,B1,B2 56 A1,A2,B1,B2 71 A1*,A2,A3,B1*,B2 74 A1*,A2,A3,B1,B2 78 A1,A2,A3,B1,B2 93 A1*,A2,A3,B1*,B2,B3 96 A1*,A2,A3,B1,B2,B3 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* 17 A1 28 A1*,B1 33 A1,B1 44 A1*,A2,B1 50 A1,A2,B1 61 A1*,A2,B1,B2 67 A1,A2,B1,B2 78 A1*,A2,A3,B1,B2 83 A1,A2,A3,B1,B2 94 A1*,A2,A3,B1,B2,B3 100 A1,A2,A3,B1,B2,B3 *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING SEQUENCE B % Displacement Compressors (Approx) 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 — — — — — — — — — — — — — — — — — — — — — — — — 9 B1* 13 B1 21 A1,B1* 25 A1,B1 37 A1,B1*,B2 41 A1,B1,B2 53 A1,A2,B1*,B2 56 A1,A2,B1,B2 74 A1,A2,B1*,B2,B3 78 A1,A2,B1,B2,B3 96 A1,A2,A3,B1*,B2,B3 100 A1,A2,A3,B1,B2,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 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 — — — — — — — — — — — — — — — — — — — — — — — — NOTE: These capacity control steps may vary due to lag compressor sequencing. 21 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 190, 290A, 360A, 390B (50 Hz) A1,B1** 190, 290A, 360A, 390B (50 Hz) A1**,B1** 210, 315A, 390A, 420A/B (60 Hz) A1,B1 210, 315A, 390A, 420A/B (60 Hz) A1**,B1 210, 315A, 390A, 420A/B (60 Hz) A1,B1** CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 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 % Displacement (Approx) — — — — — — — — — — — — 11 17 22 28 33 39 44 50 55 61 67 72 78 83 89 94 100 11 25 36 56 67 86 100 8 11 22 25 33 36 52 56 63 67 83 86 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,B1 A1,A2,B1 A1,A2,B1,B2 A1,A2,A3,B1,B2 A1,A2,A3,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 A1* A1 A1*,B1 A1,B1 A1*,A2,B1 A1,A2,B1 A1*,A2,B1,B2 A1,A2,B1,B2 A1*,A2,A3,B1,B2 A1,A2,A3,B1,B2 A1*,A2,A3,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1*,A2,A3,A4,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 — — — — — — — — — — — — — — *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING % Displacement (Approx) 11 17 28 33 44 50 61 67 78 83 94 100 11 17 22 28 33 39 44 50 55 61 67 72 78 83 89 94 100 14 25 44 56 75 86 100 — — — — — — — — — — — — — — 9 14 21 25 40 44 51 56 71 75 82 86 96 100 SEQUENCE B Compressors B1* B1 A1,B1* A1,B1 A1,B1*,B2 A1,B1,B2 A1,A2,B1*,B2 A1,A2,B1,B2 A1,A2,B1*,B2,B3 A1,A2,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 B1 A1,B1 A1,B1,B2 A1,A2,B1,B2 A1,A2,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 — — — — — — — — — — — — — — B1* B1 A1,B1* A1,B1 A1,B1*,B2 A1,B1,B2 A1,A2,B1*,B2 A1,A2,B1,B2 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,A4,B1*,B2,B3 A1,A2,A3,A4,B1,B2,B3 NOTE: These capacity control steps may vary due to lag compressor sequencing. 22 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE 210, 315A, 390A, 420A/B (60 Hz) A1**,B1** 210, 315A, 390A, 420A/B (50 Hz) A1,B1 210, 315A, 390A, 420A/B (50 Hz) A1**,B1 210, 315A, 390A, 420A/B (50 Hz) A1,B1** 210, 315A, 390A, 420A/B (50 Hz) A1**,B1** CONTROL STEPS 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 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOADING % Displacement (Approx) 8 11 17 22 25 28 33 36 48 52 56 59 63 67 78 83 86 92 97 100 9 26 35 51 67 84 100 6 9 23 26 32 35 48 51 65 67 81 84 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*,A2,A3,A4,B1*,B2,B3 A1*,A2,A3,A4,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 A1 A1,B1 A1,A2,B1 A1,A2,B1,B2 A1,A2,A3,B1,B2 A1,A2,A3,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 A1* A1 A1*,B1 A1,B1 A1*,A2,B1 A1,A2,B1 A1*,A2,B1,B2 A1,A2,B1,B2 A1*,A2,A3,B1,B2 A1,A2,A3,B1,B2 A1*,A2,A3,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1*,A2,A3,A4,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 — — — — — — — — — — — — — — 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. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded. LOADING % Displacement (Approx) 9 14 17 21 25 37 40 44 48 51 56 67 71 75 78 82 86 92 96 100 16 26 42 51 67 84 100 — — — — — — — — — — — — — — 11 16 20 26 36 42 46 51 62 67 78 84 94 100 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 A1*,A2,A3,A4,B1*,B2,B3 A1,A2,A3,A4,B1*,B2,B3 A1,A2,A3,A4,B1,B2,B3 B1 A1,B1 A1,B1,B2 A1,A2,B1,B2 A1,A2,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1,A2,A3,A4,B1,B2,B3 — — — — — — — — — — — — — — B1* B1 A1,B1* A1,B1 A1,B1*,B2 A1,B1,B2 A1,A2,B1*,B2 A1,A2,B1,B2 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,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 NOTE: These capacity control steps may vary due to lag compressor sequencing. 23 Head Pressure Control Keypad and Display Module (Also Called HSIO or LID) — The only function of this module is to allow EXV UNITS (All 30GN units except 040 and 045 with optional brine) — The microprocessor controls the condenser fans in order to maintain the lowest condensing temperature possible, thus the highest unit efficiency. Instead of using the conventional head pressure control methods, the fans are controlled by the position of the EXV and suction superheat. As the condensing temperature drops, the EXV opens to maintain the proper suction superheat. Once the EXV is fully open, if the condensing temperature continues to drop, the suction superheat begins to rise. Once the suction superheat is greater than 40 F (22.2 C), a fan stage is removed after 2 minutes. As the condensing temperature rises, the EXV closes to maintain the proper suction superheat. Once the EXV has closed to 39.5% open (600 steps open), a fan stage is added after 2 minutes. During start-up, all the condenser fans are started when the condensing temperature reaches 95 F (35 C) to prevent excessive discharge pressure during pulldown. See Table 5 for condenser fan sequence of operation. For low-ambient operation, the lead fan in each circuit can be equipped with the optional or accessory Motormastert III head pressure controller. This control has its own sensor which is mounted on a return bend in the liquid portion of the condenser. It will vary the fan speed to maintain a saturated condensing temperature of 100 F. The controls automatically default to condensing temperature control during this first stage of condenser-fan operation. When subsequent fan stages start, the controls revert to EXV fan control. TXV UNITS (30GN040,045 with optional brine only) — Head pressure control is based on set point control. The microprocessor stages the condenser fans to maintain the set point temperature specified by the controller. the operator to communicate with the processor. It is used to enter configurations and set points and to read data, perform tests, and set schedules. This device consists of a keypad with 6 function keys, 5 operative keys, 12 numeric keys (0 to 9, •, and -), and an alphanumeric, 8-character LCD. See Fig. 4. See Table 6 for key usage. IMPORTANT: When entering multiple character inputs beginning with a zero, a decimal point must be entered in place of the first zero. When entering an input of zero, only the decimal point need be entered. ACCESSING FUNCTIONS AND SUBFUNCTIONS — See Tables 6 - 8. Table 7 shows the 6 functions (identified by name) and the subfunctions (identified by number). AUTOMATIC DEFAULT DISPLAY — When keypad has not been used for 10 minutes, display automatically switches to the rotating automatic default display. This display has 7 parts, listed below, which appear in continuous rotating sequence. DISPLAY TUE 15:45 LOCAL ON CLOCK ON 8 MODE COOL 1 2 ALARMS 3 MINS EXPANSION TODAY IS TUE, TIME IS 15:45 (3:45 PM) UNIT IN LOCAL MODE UNIT IS ON VIA CLOCK SCHEDULE TEMPERATURE RESET IN EFFECT NUMBER OF STAGES IS 1 THERE ARE 2 ALARMS 3 MINUTES REMAINING IN THE OFF-TO-ON TIME DELAY 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. The pumpout cycle starts immediately upon starting the lead compressor and continues until the saturated suction temperature is 10° F (5.6° C) below the saturated suction temperature at start-up, is 10° F (5.6° C) below the cooler leaving fluid temperature, or reaches a saturated suction temperature of –15 F (–26 C). No pumpout is necessary if the saturated suction temperature is below –15 F (–26 C). At this point, the EXV starts to open and continues to open gradually to provide a controlled start-up to prevent liquid flood-back to the compressor. At shutdown, the pumpout cycle continues until the saturated suction temperature for that circuit is 10° F (5.5° C) below the saturated suction temperature when pumpout is initiated, or saturated suction temperature reaches –15 F (–26 C). At that point, the compressor shuts down and the EXV continues to move until fully closed. TXV UNITS — Pumpout is based on timed pumpout. On a command for start-up, the lead compressor starts. After 10 seconds, the liquid line solenoid opens. At shutdown, the liquid line solenoid closes, and the lead compressor continues to run for 10 seconds before stopping. Fig. 4 — Keypad and Display Module 24 Table 5 — Condenser Fan Sequence FAN ARRANGEMENT 30GN FAN NUMBER(S) FAN CONTACTOR (FC) CONTROLLED BY 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 First Stage Microprocessor 4 FC-B2 Second Stage Microprocessor 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3, 4 FC-A2 First Stage Microprocessor 5, 6 FC-B2 Second Stage Microprocessor 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 4 FC-B2 First Stage Microprocessor 3, 4, 5, 6 FC-A2, FC-B2, FC-A3, FC-B3 Second Stage Microprocessor 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 4 FC-B2 First Stage Microprocessor 5, 7, 6, 8 FC-A3, FC-B3 Second Stage Microprocessor 3, 4, 5, 6, 7, 8 FC-A2, FC-A3, FC-B2, FC-B3 Third Stage Microprocessor 5, 7 FC-A1 Compressor A1 6, 8 FC-B1 Compressor B1 First Stage Microprocessor 040-050 060,070 080,090 (and associated modular units*) 100,110 (and associated modular units*) 130-170 (and associated modular units*) 190,210 (and associated modular units*) 3, 9 FC-A2 4, 10 FC-B2 1, 3, 9 FC-A2, FC-A3 2, 4, 10 FC-B2, FC-B3 5, 7 FC-A1 Compressor A1 6, 8 FC-B1 Compressor B1 3, 9 FC-A2 4, 10 FC-B2 First Stage Microprocessor 1, 3, 9, 11 FC-A2, FC-A3 2, 4, 10, 12 FC-B2, FC-B3 Second Stage Microprocessor Second Stage Microprocessor *See Table 1. †Control box. KEYPAD OPERATING INSTRUCTIONS (Refer to Table 9.) 1. White keys on left side of keypad are shown and operated in these instructions according to the following ex- AUTOMATIC DISPLAY OPERATION/DEFAULT DISPLAY — This display automatically rotates as follows: ample: keypad entry , then the white key marked . 2. The standard display uses abbreviations. Expanded in- DOW — Day of Week HH — Hour(s) MM — Minute(s) formation scrolls through the display whenever is pressed. The default rotating display is displayed every 2 seconds if there has been no manual input from the keypad for 10 minutes. To return to automatic display, enter means press the at any time. 25 key Table 6 — Keypad and Display Module Usage FUNCTION KEYS 3. All functions are made up of a group of subfunctions. To enter a subfunction, first press subfunction number desired. Then press the function key in which the subfunction resides. To move within that subfunction, press USE STATUS — For displaying diagnostic codes and current operating information about the machine. HISTORY — For displaying run time, cycles and previous alarms. SERVICE — For entering specific unit configuration information. TEST — For checking inputs and outputs for proper operation. SCHEDULE — For entering occupied/unoccupied schedules for unit operation. SET POINT — For entering operating set points and day/time information. OPERATIVE KEYS the or arrow. For example, a enters the Temperature Information subfunction. 4. At any time, another subfunction may be entered by pressing the subfunction number, then the function key. 5. Prior to starting unit, check leaving fluid set point for correct setting. Refer to Set Point Function section on page 38. 6. Depending on system configuration, all displays may not be shown. All displays are shown unless marked with the following symbol: †Must be configured. For additional unit start-up procedures, see separate Installation, Start-Up, and Service Instructions supplied with unit. USE EXPAND — For displaying a non-abbreviated expansion of the display. CLEAR — For clearing the screen of all displays. UP ARROW — For returning to previous display position. DOWN ARROW — For advancing to next display position. ENTER — For entering data. Table 7 — Functions and Subfunctions SUBFUNCTION NO. Status 1 Automatic Display Alarm Display Mode (Operating) Display Capacity Stages Set Points (Current Operating) Temperatures Pressures Analog Inputs Discrete Inputs Outputs — 2 3 4 5 6 7 8 9 10 11 Test FUNCTIONS Schedule Outputs Override Compressors and Unloaders Calibrate Transducers — Clock Select — Period 3 — — — — — — Period 4 Period 5 Period 6 Period 7 Period 8 HOLIDAYS Period 1 Period 2 26 Service History Set Point Log On and Log Off Version (Software) Factory Configuration Field Configuration Service Configuration — — — — — — Run Time Set Points (Chiller Fluid) Reset Set Points Demand Limit Set Points Date and Time Leaving Chiller Fluid Alert Limit — — — — — — Starts Alarm History — — — — — — — — Table 8 — Accessing Functions and Subfunctions KEYPAD ENTRY OPERATION DISPLAY RESPONSE To access a function, press subfunction no. and function name key. Display shows subfunction group. To move to other elements, scroll up or down using arrow keys. NOTE: These displays do not show if control is not configured for reset. When the last element in a subfunction has been displayed, the first element is repeated. To move to next subfunction it is not necessary to use subfunction number. Press function name key to advance display through all subfunctions within a function and then back to the first. To move to another function, either depress function name key for desired function (display shows the first subfunction), or Access a specific subfunction by using the subfunction number and the function name key. EXPANSION RESET RESET SETPOINTS CRT1 x COOL RESET AT 20 MA CRT2N x COOL RTEMP (NO RESET) CRT2F x COOL RTEMP (FULL RESET) CRT2D x COOL DEGREES RESET RESET RESET SETPOINTS CRT1 x COOL RESET AT 20 MA DEMAND DEMAND LIMIT SETPOINTS TIME CURRENT TIME AND DAY OF WEEK SETPOINT UNIT SETPOINTS X ALARMS THERE ARE n ALARMS STAGE CAPACITY STAGING INFORMATION Table 9 — Keypad Directory STATUS SUBFUNCTION KEYPAD ENTRY 1 AUTOMATIC DISPLAY 2 ALARMS/ALERTS DISPLAY Refer to Automatic Display Operation/Default Display section on page 25. X ALARMS Number of Tripped Alarms/Alerts R S AL Reset all Alarms/Alerts ALARM* X } ALARM* X ALARM* X ALARM* X ALARM* X To toggle between inputs (Yes/No) Press: 3 MODES COMMENT (no) or Displays Tripped Alarms/Alerts (yes) X MODES Number of Modes in Effect X MODE } X MODE X MODE X MODE 27 Displays Mode in Effect Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 4 STAGE 5 SET POINT 6 TEMPERATURE DISPLAY COMMENT STAGE Capacity Staging Information COOL X Number of Requested Stages CAPT X Percent of Total Capacity CAPA X Percent Circuit A Total Capacity CAPB X Percent Circuit B Total Capacity AVAIL X Percent Available Capacity AV A X Percent Circuit A Available Capacity AV B X Percent Circuit B Available Capacity LMT X† Demand Limit Set Point (percent) CIRA X Circuit A Compressor Relay Status CIRB X Circuit B Compressor Relay Status SMZ X Load/Unload Factor for Compressors Factor = 1 Unloader Factor = 0.6 SETPOINT Fluid Set Point Information SET X Set Point (F) MSP X Modified Set Point = Set Point + Reset (F) TW X Actual Control Temperature (F) TEMPS Temperature Information (F) EWT X Cooler Entering Fluid Temperature (F) LWT X Cooler Leaving Fluid Temperature (F) SCTA X Circuit A Saturated Condenser Temperature (F) SSTA X Circuit A Saturated Suction Temperature (F) CTA X Compressor A1 Suction Temperature (F) SHA X Circuit A Suction Superheat (F) SCTB X Circuit B Saturated Condenser Temperature (F) SSTB X Circuit B Saturated Suction Temperature (F) CTB X Compressor B1 Suction Temperature (F) SHB X Circuit B Suction Superheat (F) SPC X Space Temperature (F) OAT X Outdoor-Air Temperature (F) LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 28 Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 7 PRESSURE 8 ANALOG 9 INPUTS 10 OUTPUTS DISPLAY COMMENT PRESSURE Refrigerant System Pressure (psig) MM DD YY Date of Last Calibration DPA X Circuit A Discharge Pressure (psig) SPA X Circuit A Suction Pressure (psig) XXXX XXX Circuit A Discharge/Suction (psig) OPA X Circuit A Oil Pressure Differential (psig) DPB X Circuit B Discharge Pressure (psig) SPB X Circuit B Suction Pressure (psig) XXXX XXX Circuit B Discharge/Suction (psig) OPB X Circuit B Oil Pressure Differential (psig) ANALOG Status of Analog Inputs REF X Transducer Supply Voltage (volts) LMT X† Demand 4-20 mA Signal (mA) RST X† Reset 4-20 mA Signal (mA) SW INPUT Status of Switch Inputs SPW X† Dual Set Point Switch (open/closed) DL1 X† Demand Limit Switch 1 (open/closed) DL2 X† Demand Limit Switch 2 (open/closed) OUTPUTS Status of Outputs ALMR X Alarm Relay K3 (on/off) FRA1 X Fan Relay K1 (on/off) FRA2 X Fan Relay K2 (on/off) FRB1 X Fan Relay K4 (on/off) FRB2 X Fan Relay K5 (on/off) CHWP X† Cooler Water Pump Relay K6 (on/off) ULA1 X Unloader A1 (on/off)** ULA2 X† Unloader A2 (on/off)** ULB1 X Unloader B1 (on/off)** ULB2 X† Unloader B2 (on/off)** LLSA X Liquid Line Solenoid A LLSB X Liquid Line Solenoid B EXVA X EXVA Percent Open† LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 29 Table 9 — Keypad Directory (cont) STATUS (cont) SUBFUNCTION KEYPAD ENTRY 10 OUTPUTS (cont) DISPLAY COMMENT EXVB X EXVB Percent Open** HGBA X† Hot Gas Bypass Relay Circuit A (on/off)** HGBB X† Hot Gas Bypass Relay Circuit B (on/off)** MMA X† MotormasterT A Output Percent** MMB X† Motormaster B Output Percent** TEST To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position. To operate a test, scroll to desired test. Then, press to start test. Press to stop test. SUBFUNCTION KEYPAD ENTRY DISPLAY 1 OUTPUTS To toggle between inputs (Yes/No) Press: COMMENT OUTPUTS Test Outputs 8.8.8.8.8.8.8.8 Display Check ALMR X Energize Alarm Relay K3 (on/off) FRA1 X Energize Fan Relay A1 K1 (on/off) FRA2 X Energize Fan Relay A2 K2 (on/off) FRB1 X Energize Fan Relay B1 K4 (on/off) FRB2 X Energize Fan Relay B2 K5 (on/off) CHWP X† Energize Cooler Water Pump K6 (on/off) LSVA X Energize Liquid Line Solenoid A (on/off)** LSVB X Energize Liquid Line Solenoid B (on/off)** EXVA X Enter Desired EXVA Position (percent)** EXVB X Enter Desired EXVB Position (percent)** HGBA X† Energize Hot Gas Bypass Relay A (on/off)** HGBB X† Energize Hot Gas Bypass Relay B (on/off)** MMA X† Enter Desired Motormaster A Output Signal (percent)** MMB X† Enter Desired Motormaster B Output Signal (percent)** (no) or (yes) During compressor test, compressors start and run for 10 seconds. Compressor service valves and liquid line valves must be open. Energize crankcase heaters 24 hours prior to performing compressor tests. SUBFUNCTION KEYPAD ENTRY DISPLAY 2 COMPRESSORS AND UNLOADERS 30 COMMENT COMP Compressor and Unloader Test CPA1 X Test Compressor A1 (on/off) CPA2 X† Test Compressor A2 (on/off)** Table 9 — Keypad Directory (cont) TEST (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY 2 COMPRESSORS AND UNLOADERS (cont) 3 CALIBRATE TRANSDUCERS COMMENT CPA3 X† Test Compressor A3 (on/off)** CPA4 X† Test Compressor A4 (on/off)** CPB1 X Test Compressor B1 (on/off) CPB2 X† Test Compressor B2 (on/off)** CPB3 X† Test Compressor B3 (on/off)** CPB4 X† Test Compressor B4 (on/off)** UNA1 X Energize Unloader A1 (on/off)** UNA2 X† Energize Unloader A2 (on/off)** UNB1 X Energize Unloader B1 (on/off)** UNB2 X† Energize Unloader B2 (on/off)** XDR CAL Transducer Calibration CDPA X Circuit A Discharge Pressure (psig) CSPA X Circuit A Suction Pressure (psig) COPA X Circuit A Oil Pressure (psig) CDPB X Circuit B Discharge Pressure (psig) CSPB X Circuit B Suction Pressure (psig) COPB X Circuit B Oil Pressure (psig) SCHEDULE The Schedule function key is used to configure the occupancy schedule. The clock select subfunction can be used for unoccupied shutdown or unoccupied setback depending on the cooling set point control configuration. The Schedule function described is for clock 1, which is the internal clock. Password required for all subfunctions except override. SUBFUNCTION KEYPAD ENTRY DISPLAY 1 OVERRIDE COMMENT OVRD X Number of Override Hrs (0 - 4 Hrs) OVRD 3 Extended Occupied Time For example, to extend current occupied mode for 3 hrs, press: 2 CLOCK SELECT CLOCK XX Type of Clock Control 0 = No Clock, 1 = Clock 1 (Internal) 3 PERIOD 1 PERIOD 1 Period 1 Time Schedule Yes = Schedule Operational for that day OCC HH.MM Occupied Time UNO HH.MM Unoccupied Time MON X Monday Flag (yes/no) TUE X Tuesday Flag (yes/no) WED X Wednesday Flag (yes/no) THU X Thursday Flag (yes/no) LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 31 Table 9 — Keypad Directory (cont) SCHEDULE (cont) SUBFUNCTION KEYPAD ENTRY 3 PERIOD 1 (cont) To toggle between inputs (Yes/No) Press: (no) or DISPLAY COMMENT FRI X Friday Flag (yes/no) SAT X Saturday Flag (yes/no) SUN X Sunday Flag (yes/no) HOL X Holiday Flag (yes/no) (yes) 4 PERIOD 2 PERIOD 2 Period 2 Time Schedule PERIOD 3 ... PERIOD 7 Period 3 ... Period 7 Time Schedule 10 PERIOD 8 PERIOD 8 Period 8 Time Schedule 11 HOLIDAYS HOLIDAYS Define Calendar Holidays DAT MM.DD Holiday Date 1 DAT MM.DD.NN Holiday Date 30 5 PERIOD 3 ... 9 PERIOD 7 ... New = Unassigned Holiday Date For example: To enter July 4th holiday press: 07.04.01 . Display shows Jul 04. For further information on the Schedule function and its operation, refer to Schedule Function section on page 44. SERVICE To view and modify configurations, the password must be entered under the log on subfunction. SUBFUNCTION KEYPAD ENTRY DISPLAY 1 LOG ON AND LOG OFF COMMENT PASSWORD Enter Password/Disable Password Protection LOGGEDON Logged On At this time, configurations may be modified. When finished viewing and/or modifying configurations, log out as follows: 2 VERSION LOGGEDON — LOG OFF Disable Password Protection EXIT LOG Logged Off/Enable Password Protection VERSION Software Information XXXXXXXX Version No. of Software (CESRXX) The next 3 subfunctions provide the ability to modify configurations. Refer to separate Installation, Start-Up, and Service Instructions supplied with unit for further information on changing configurations. To change a configuration, enter the new configuration and press while on the correct configuration. 3 FACTORY CONFIGURATION 32 FACT CFG Factory Configuration Codes XXXXXXXX Configuration Code 1 XXXXXXXX Configuration Code 2 XXXXXXXX Configuration Code 3 XXXXXXXX Configuration Code 4 Table 9 — Keypad Directory (cont) SERVICE (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY 3 FACTORY CONFIGURATION (cont) 4 FIELD CONFIGURATION COMMENT XXXXXXXX Configuration Code 5 XXXXXXXX Configuration Code 6 XXXXXXXX Configuration Code 7 FLD CFG Adjustable Field Configuration ENO X CCN Element Address BUS X CCN Bus Number BAUD X CCN Baud Rate FLUID X Cooler Fluid Select (water/medium brine) UNITS X Display Unit Select (English/Metric) DELAY X Delay at Power Up (minutes) NULA X No. Circuit A Unloaders NULB X No. Circuit B Unloaders HGB X Hot Gas Bypass Select (used, not used) SEQT X Loading Sequence Select (equal circuit, staged circuit) LEADT X Lead/Lag Sequence Type OPS X MM X Oil Pressure Switch Select (enable/disable) Head Pressure Control Type (none, air cooled, water cooled) MotormasterT Select CSPTYP X Cooling Set Point Control Select CRTYP X Cooling Reset Control Select ERTYP X External Reset Sensor Select OATSEL X Outdoor-Air Sensor Select LSTYP X Demand Limit Control Select RAMP X Ramp Load Select (enable, disable) LOCK X Cooler Pump Interlock Select CPC X Cooler Pump Control Select REMA X Remote Alarm Option Select (yes/no) ALRST X Allow Local/Stop/CCN Reset of Alarms (yes/no) HEADT X To toggle between inputs (Yes/No) Press: 5 SERVICE CONFIGURATION (no) or (yes) SRV CFG Service Configurations XXXXXXXX Configuration Code 8 XXXXXXXX Configuration Code 9 REFRIG X Refrigerant TDTYP X Pressure Transducer Select OPS X Oil Transducer Set Point (psig) LPS X Low Pressure Set Point (psig) FANTYP X Fan Staging Select SH X EXV Superheat Set Point (F) MOP X EXV MOP Set Point (F) ZM X Z Multiplier LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 33 Table 9 — Keypad Directory (cont) HISTORY SUBFUNCTION KEYPAD ENTRY 1 RUN TIME 2 STARTS 3 ALARM/ALERT HISTORY†† DISPLAY COMMENT RUN TIME Run Time Information HR X Total Hrs Unit Has a Comp Operating HRA X Circuit A Run Time HRB X Circuit B Run Time HA1 X Circuit A, Comp A1 Operating Hours HA2 X Circuit A, Comp A2 Operating Hours** HA3 X Circuit A, Comp A3 Operating Hours** HA4 X Circuit A, Comp A4 Operating Hours** HB1 X Circuit B, Comp B1 Operating Hours HB2 X Circuit B, Comp B2 Operating Hours** HB3 X Circuit B, Comp B3 Operating Hours** HB4 X Circuit B, Comp B4 Operating Hours** STARTS Starts Information CY X Cycles from Stage 0 to Stage 1 CYA X Circuit A Starts CYB X Circuit B Starts CA1 X Circuit A, Comp A1 Starts CA2 X Circuit A, Comp A2 Starts** CA3 X Circuit A, Comp A3 Starts** CA4 X Circuit A, Comp A4 Starts** CB1 X Circuit B, Comp B1 Starts CB2 X Circuit B, Comp B2 Starts** CB3 X Circuit B, Comp B3 Starts** CB4 X Circuit B, Comp B4 Starts** ALRMHIST Last 10 Alarms/Alerts ALARM X ALARM X ALARM X ALARM X ALARM X } Alarm/Alert Description ALARM X ALARM X ALARM X ALARM X ALARM X LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 34 Table 9 — Keypad Directory (cont) SET POINT To read a set point, go to proper subfunction and read desired set point. To change a set point, enter new set point value, then press LOCAL/ENABLE-STOP-CCN switch must be in LOCAL/ENABLE or STOP position. SUBFUNCTION KEYPAD ENTRY 1 SET POINTS 2 RESET SET POINTS 3 DEMAND SET POINTS 4 DATE AND TIME DISPLAY . COMMENT SET POINT Unit Set Point CSP1 X Chiller Fluid Set Point 1 (F) CSP2 X Chiller Fluid Set Point 2 (F) HSPA X Head Pressure Set Point Circuit A (F) HSPB X Head Pressure Set Point Circuit B (F) CRAMP X Cooling Ramp Loading Rate (F) RESET Reset Set Points CRT1 X Cooling reset at 20 mA (F) CRT2N X Reference Temperature at No Reset (F) CRT2F X Reference Temperature at Full Reset (F) CRT2D X Total Degrees of Reset (F) CRT3N X Chiller Fluid DT at No Reset (F) CRT3F X Chiller Fluid DT at Full Reset (F) CRT3D X Total Degrees of Reset (F) DEMAND Demand Set Points DLS1 X† Demand Switch 1 Set Point (percent) DLS2 X† Demand Switch 2 Set Point (percent) DL20 X Demand Limit at 20 mA (percent) DLGN X Loadshed Group Number LSDD X Loadshed Demand (percent) TIME X Minimum Loadshed Time (minutes) DATE.TIME Date, Time and Day of Week DOW.HR.MIN Day 1 = Mon, 2 = Tues. . .7 = Sun Hours are displayed in 24-hr time. Decimal point serves as colon. MM.DD.YR Month.Day.Year. When entering date, enter a decimal point between entries. Each entry must be two numbers. 5 LEAVING CHILLER FLUID ALERT LIMIT LMT X Leaving Chiller Fluid Alert Limit (F) LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. **If applicable. ††Not manually resettable. NOTE: If metric option is selected under , temperature expressed as Celsius and pressure will be expressed as kPa. 35 To reset alarms/alerts using keypad and display module: STATUS FUNCTION — This function shows the rotating display, current status of alarm and alert (diagnostic) codes, capacity stages, operating modes, chilled water set point, all measured system temperatures and pressures, superheat values, pressure switch positions, analog inputs, and switch inputs. These subfunctions are defined on pages 36 and 37. KEYPAD ENTRY (Rotating Display) plays and then press KEYPAD ENTRY to move to the individual dis- Example 1 — Reading Alarm Codes DISPLAY RESPONSE RSAL DSB Reset all alarms/alerts function disabled RSAL ENB Reset all alarms/alerts function enabled Example 2 — Reading Current Operating Modes to enter the alarm/alert dis- plays. Press after a code has been displayed. The meaning of the code scrolls across the screen. See Example 1. KEYPAD ENTRY COMMENTS (Modes) — The operating mode codes are displayed to indicate the operating status of the unit at a given time. See Table 10. To enter the MODES subfunction, press and press the key to determine if more than one mode applies. See Example 2 to read current mode with expansion. (Alarms/Alerts) — Alarms and alerts are messages that one or more faults have been detected. Each fault is assigned a code number which is reported with the alarm or alert. See Table 10 for code definitions. The codes indicate failures that cause the unit to shut down, terminate an option (such as reset) or result in the use of a default value as set point. Up to 10 codes can be stored at once. To view them in sequence, press DISPLAY RESPONSE COMMENTS DISPLAY RESPONSE COMMENTS TUE 15:45 LOCAL ON CLOCK ON 8 MODE COOL 1 0 ALARMS 3 MINS Keypad has not been used for at least 10 minutes. Rotating summary display appears on screen 2 MODES There are 2 modes currently in effect LOCAL ON Unit is on by chiller on/off switch 8 MODE Temperature reset is in effect TUE 12:45 LOCAL ON CLOCK ON 13 MODE 8 MODE COOL 1 2 ALARMS 3 MINS Keypad has not been used for at least 10 minutes. Alternating summary display appears on screen 2 ALARMS 2 alarms/alerts detected RSAL DSB Reset all alarms/alerts (Stage) — This subfunction displays the capacity stage number. See Tables 4A-4C for compressor loading sequence. To enter the STAGE subfunction, press and press the to display the stage number. ALARM 9 First alarm/alert code Continue pressing • • • • • • for the following information: Number of requested stages. Percent of total unit capacity being utilized. Percent of each circuit capacity being utilized. Percent of total capacity available. Percent of capacity available in each circuit. Demand limit set point in effect (can be any value between 0% and 100%). • Status of each compressor relay. When a compressor is on, the number of that compressor is displayed. If a compressor is off, a 0 is displayed. For example: In a given circuit, if compressors 1 and 3 are running, and 2 and 4 are not running, 0301 is displayed for that circuit. • Load/Unload factor for compressors. This factor is an indication of when a step of capacity is added or subtracted. Its value can range from slightly less than –1.0 to slightly more than +1.0. When load/unload factor reaches +1.0, a compressor is added. When the load/unload factor reaches –1.0, a compressor is subtracted. If compressor unloaders are used, at –.6 a compressor is unloaded and at +.6, a compressor is loaded up. COOLER LEAVING FLUID THERMISTOR Explanation of alarm/alert code FAILURE Second alarm/alert code. ALARM 42 Cooler freeze protection COOLER FREEZE Explanation of alarm/alert code PROTECTION When a diagnostic (alarm or alert) code is stored in the display and the machine automatically resets, the code is deleted. Codes for safeties which do not automatically reset are not deleted until the problem is corrected and either the machine is switched to STOP position, then back to LOCAL/ ENABLE or CCN position, or by using the keypad and display module. 36 Table 10 — Operational and Mode Display Codes The operating modes are displayed by name or code number, to indicate the operating status of the unit at a given time. The modes are: (Set Point) — This subfunction displays leaving fluid temperature and leaving chilled fluid set point. If unit is programmed for dual set point, the chilled fluid set point currently in effect (either occupied or unoccupied) is displayed. If reset is in effect, the unit operates to the modified chilled fluid set point. This means the leaving fluid temperature may not equal the chilled fluid set point. The modified chilled fluid set point can also be displayed in the Status function. To enter the set point subfunction, press and press to display the set point followed by the modified leaving chilled fluid set point and actual control temperature. CODE DESCRIPTION Unit is off. LOCAL/ENABLE-STOP-CCN switch is in position, or LOCAL/ENABLE-STOP-CCN switch LOCAL OFF OFF may be in LOCAL position with external ON/OFF switch in OFF position. Unit is off due to CCN network command. LOCAL/ CCN OFF ENABLE-STOP-CCN switch is in CCN position. is off due to internal clock schedule. LOCAL/ CLOCK OFF Unit ENABLE-STOP-CCN switch is in LOCAL position. Unit is on. LOCAL/ENABLE-STOP-CCN switch is in LOCAL ON LOCAL position. If external ON/OFF switch is used, it will be in ON position. Unit is on due to CCN command. LOCAL/ENABLECCN ON STOP-CCN switch is in CCN position. Unit is on due to internal clock schedule or occuCLOCK ON pied override function. LOCAL/ENABLE-STOPCCN switch is in LOCAL/ENABLE position. Dual set point is in effect. In this mode, unit continues to run in unoccupied condition, but leaving fluid MODE 7 set point is automatically increased to a higher level (CSP2 set point is in SET function). Temperature reset is in effect. In this mode, unit is using temperature reset to adjust leaving fluid set point upward, and unit is currently controlling to the MODE 8 modified set point. The set point can be modified based on return fluid, outdoor-air temperature, or space temperature. Demand limit is in effect. This indicates that capacity of unit is being limited by demand limit control MODE 9 option. Because of this limitation, unit may not be able to produce the desired leaving fluid temperature. Flotronic™ System Manager (FSM) is controlling the MODE 10 chiller. MODE 11 Not applicable. Ramp load (pulldown) limiting is in effect. In this mode, the rate at which leaving fluid temperature is dropped is limited to a predetermined value to prevent comMODE 12 pressor overloading. See CRAMP set point in the SET function in Table 9. The pulldown limit can be modified, if desired, to any rate from .2 F to 2 F (.1° to 1° C)/minute. Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed schedule, forcMODE 13 ing unit to occupied mode. Override can be implemented with unit under LOCAL/ENABLE or CCN control. Override expires after each use. Low cooler suction protection is in effect. In this mode, circuit capacity is not allowed to increase if cooler saturated suction temperature is 20° F (11° C) for fluid or 30° F (16° C) for brine or more below leaving MODE 14 fluid temperature, and saturated suction temperature is less than 32 F (0° C). If these conditions persist beyond 10 minutes, circuit is shut down and fault code 44 or 45 is displayed. MODE 15 Water System Manager is controlling the chiller. MODE 16 Slow change override is in effect. MODE 17 X minute off-to-on delay is in effect. MODE 18 Low suction superheat protection is in effect. (Temperature) — The temperature subfunction displays the readings at temperature sensing thermistors. To read a temperature, enter , then scroll to desired temperature using the key. See Table 9 for the order of readouts. This subfunction also displays the saturated refrigerant temperatures corresponding to the suction and discharge pressures measured by the compressor transducers. (Pressure) — This subfunction displays suction, discharge, and net oil pressure at lead compressor of each circuit of unit. (Analog Inputs) — This subfunction displays analog inputs, if any. Press , then press . The transducer supply voltage, 4-20 mA reset signal can be displayed. This is useful for problem diagnosis prior to using the test function. (Discrete Inputs) — This subfunction displays status (open/closed) of discrete input switch where applicable. Status of dual set point switch and demand limit switches 1 and 2 can be displayed. This is useful for problem diagnosis prior to using the test function. (Outputs) — This function displays on/off status of alarm relay, all fan relays, and chilled water pump relay. It also displays on/off status of compressor unloaders (if used). The position of each EXV (in percent open) can be displayed. TEST FUNCTION — The test function operates the diagnostic program. To initiate test function, the LOCAL/ ENABLE-STOP-CCN switch must be in STOP position. To reach a particular test, press its subfunction number, then scroll to desired test by pressing . Press to start a test. Press or or to terminate or exit a test. Pressing the key after a test has started advances system to next test, whether current test is operating or has timed out. Once in the next step, you may start test by pressing or advance past it by pressing . While the unit is in test, you may leave test function and access another display or function by pressing appropriate keys. However, a component that is operating when another function is accessed remains operating. You must re-enter test function and press to shut down the component. Components with a timed operating limit time out normally even if another function is accessed. CCN — Carrier Comfort Network 37 Keypad entry SET POINT FUNCTION — Set points are entered through the keypad. Set points can be changed within the upper and lower limits, which are fixed. The ranges are listed below. allows the operator to make the following checks by using : • LID display check. Proper display is 8.8.8.8.8.8.8.8. • Operation of alarm relay. • Operation of condenser fans. • Operation of chilled fluid pump. • Operation of liquid line solenoids. • Operation of the hot gas bypass relays. • Operation of EXVs. To drive EXV fully open, enter Chilled Fluid Set Point Water: 38 to 86 F (3.3 to 30 C) Medium Brine: 14 to 86 F (–10 to 30 C) Pulldown Set Point 0.2 to 2.0 F (0.11 to 1.1 C)/min. (100% open). To drive EXV fully closed, enter (0% open). • Operation of each remote alarm. • Operation of Motormastert signals. Reset Set Points Maximum Reset Range: –30° to 30° F (–17° to 17° C) External Temperature Reset –40 to 240 F (–40 to 118 C) Chiller Fluid DT: 0° to 15° F (0° to 8° C) External Signal Reset 4 to 20 mA Keypad entry accesses the compressor and compressor unloader operational tests. During compressor operational tests, compressor starts and runs for 10 seconds. Compressor service valves must be open. Energize crankcase heaters 24 hours prior to performing compressor tests. Demand Limit Set Points Switch Input: Step 1 — 0 to 100% Capacity Reduction Step 2 — 0 to 100% Capacity Reduction External Signal: Maximum Demand Limit 4 to 20 mA Minimum Demand Limit 4 to 20 mA Loadshed Demand Delta: 0 to 60% Maximum Loadshed Time: 0 to 120 min. Since test function checks only certain outputs, it is good practice to also check all inputs and outputs accessible through the status function. These are located at , , and (see Table 9). If keypad is not used for 10 minutes, unit automatically leaves test function and resumes rotating display. See Example 3. Set points are grouped in subfunctions as follows: Example 3 — Using Test Function KEYPAD DISPLAY ENTRY RESPONSE Subfunction displays chiller fluid set points. COMP Factory/field test of compressors subfunction of test function CPA 1 OFF Circuit A, Compressor 1A test CPA 1 ON Pressing ENTR starts the test: when the compressor should be running the display shows CPA1 on If the test is allowed to time out (10 seconds) the display will show CPA1 off Pressing the down arrow key advances the system to Circuit A, compressor 2 test CPA 1 OFF CPA 2 OFF a. The first value shown is the occupied chilled fluid set point. b. The next value displayed depends on how the schedule function has been programmed. (See pages 4447.) If dual set point has been selected, the next set point after has been pressed is the second chilled fluid set point. If single set point or inactive schedule has been selected in the schedule function, then when is pressed, the display shows the head pressure set points, one for each circuit. These are utilized only if the set point controlled method of head pressure control is selected in . COMMENTS NOTE: Once a compressor has been run using the it is not allowed to run again for 30 seconds. function, c. The final value displayed when the is pressed is the cooling ramp loading rate. This is the maximum rate at which the leaving chilled fluid is allowed to drop, and can be field set from 0.2 to 2.0 F (.11° to 1.1° C)/minute. This value is not displayed unless the function is enabled (see Adjustable Field Configurations on page 44). accesses the transducer calibration subfunction. All transducers must be calibrated in order for the unit to operate. Refer to Pressure Transducers section on page 60 for calibration procedure. HISTORY FUNCTION — Pressing and displays total unit run time, total run time for each circuit, and total run time for each compressor. Reading and Changing Set Points — Example 4 shows how to read and change the chilled fluid set point. Other set points can be changed by following the same procedure. Refer to Table 9 for the sequence of display of set points in each subfunction. Pressing and displays total unit starts, the total starts for each circuit, and total starts for each compressor. Pressing and displays the last 10 alarms along with a description of each alarm. 38 Example 4 — Reading and Changing Chilled Fluid Set Point KEYPAD ENTRY DISPLAY RESPONSE COMMENTS SET POINT System set points CSP1 44.0 Present occupied chilled fluid set point is 44.0 F CSP1 42.0 Press the . Display shows new occupied chilled fluid set point is 42.0 F Present unoccupied chilled fluid set point is 44.0 F CSP2 44.0 CSP2 50.0 RESET configuration. Select one of the 4 choices for type of reset: Return Fluid Reset, External Temperature Reset, 4-20 mA External Signal Reset, or 4-20 mA Internal Signal Reset. If dual set point control is enabled (see Field Wiring section on page 69), the amount of reset is applied to whichever set point is in effect at the time. Examples 5A-5C demonstrate how to activate reset. Example 6 demonstrates how to change the type of reset. Assume that reset is to be based on return fluid temperature, the desired reset range is to be 0° to 10° F (0° to 5.5° C) and full load is a 10° F (5.5° C) drop across the cooler. See Fig. 5. Activating reset based on external temperature or 4-20 mA signal is done the same way, except the reference set point range is –40° to 240° F (–40° to 115° C), or 4 to 20 mA depending on which method was selected at the field configuration step. Press the . Display shows new unoccupied chilled fluid set point is 50.0 F Displays the maximum reset set point. The minimum and maximum reference reset set points can also be displayed. These set points are not accessible when reset type has been configured for NONE in the service function. Example 5A — External Reset In this example, the unit set point is reset from full load at 90 F (32 C) to a maximum reset value of 10 F (5.5 C) at 20 F (–6.7 C) outdoor ambient. NOTE: All temperatures given in this example are in F. Subfunction displays temperature reset set points. KEYPAD ENTRY Temperature Reset Based on Return Fluid Temperature — The control system is capable of providing leaving fluid temperature reset based on return fluid temperature. Because the temperature difference between leaving and return temperature is a measure of the building load, return fluid temperature reset is essentially an average building load reset method. Under normal operation, the chiller maintains a constant leaving fluid temperature approximately equal to chilled fluid set point. As building load drops from 100% down to 0%, entering cooler fluid temperature drops in proportion to load. Thus, temperature drop across the cooler drops from a typical 10 F (5.5 C) at full load to a theoretical 0° F (0° C) at no load. See Fig. 5. At partial load, leaving chilled fluid temperature may be lower than required. If this is allowed to increase (reset), the efficiency of the chiller increases. Amount of reset can be defined as a function of cooler temperature drop, as shown in Fig. 5. This is a simple linear function that requires 3 pieces of input data for the set function that will vary depending on measurement method used as follows (see Table 11): NOTE: Reset set points are not accessible unless the reset function is enabled first. This is done as a field DISPLAY RESPONSE COMMENTS FLD CFG CRTYP 0 Scroll past to reset type CRTYP 2 External reset selected ERTYP 0 Scroll past to space thermistor sensor selected ERTYP 1 OAT selected RESET CRT2F 20 Temperature reset is 0 Temperature reset is 90 Temperature reset is 0 Temperature reset is 20 CRT2D 0 Maximum reset is 0 CRT2D 10 Maximum reset is 10 CRT2N 0 CRT2N 90 CRT2F 0 for no for no for maximum for maximum Table 11 — Reset Amounts INPUT DATA DESCRIPTION Maximum Reset Amount — Allowable range for maximum amount which LWT is to be reset. Maximum Reset Reference — Temperature at which maximum reset occurs. Minimum Reset Reference — Temperature at which no reset occurs. 4-20 mA MEASUREMENT METHOD OAT/Occupied Space or Internal/External Variable Limits (F) Variable Limits (F) CRT1 –30 to 30 CRT2D — — — — LEGEND OAT — Outdoor-Air Temperature LWT — Leaving Fluid Temperature 39 Return Water Variable Limits (F) –30 to 30 CRT3D –30 to 30 CRT2F –40 to 240 CRT3F 0 to 15 CRT2N –40 to 240 CRT3N 0 to 15 Example 5B — 4 to 20 mA and Internally or Externally Powered Reset In this example, the unit set point is reset from full load at 4 mA to a maximum reset value of 10 F (5.5 C) at 20 mA. Internally powered 4 to 20 mA option is used in this example. NOTE: To use externally powered reset, when CRTYP Temperature Reset Based on External Temperature — If desired, temperature reset can be based on an external temperature, such as space or outdoor-air temperature. This requires a thermistor (T10, Part No. 30GB660002) located in the space or outdoor air and wired to terminals as follows (also see Field Wiring section on page 69 and Fig. 6): appears, press so CRTYP 4 appears in the display. The remainder of the information in the following example applies to either type of reset. At the field configuration step, enter set points as described in Examples 5A-5C on pages 39 and 40. Then KEYPAD ENTRY DISPLAY RESPONSE 4 in/4 out Module — J7-15 and J7-16. select external temperature reset by entering when CRTYP 0 appears. See Fig. 7. Temperature Reset Based on 4-20 mA Signal— If desired, temperature reset can be based on a 4-20 mA signal. For proper connections, refer to Field Wiring section on page 69 and Fig. 8. At the field configuration step, select 4-20 mA reset by entering (internally powered) or (externally powered) when CRTYP 0 appears. Then enter set points as described previously in Examples 5A-C. See Fig. 8. COMMENTS FLD CFG CRTYP 0 Scroll past to reset type CRTYP 1 Internally powered reset selected RESET CRT1 0 Reset at 20 mA is 0 CRT1 10 Reset at 20 mA is 10 Subfunction displays demand limit set points. Example 5C — Using Return Fluid Temperature Reset KEYPAD ENTRY DISPLAY RESPONSE COMMENTS FLD CFG Field configuration subfunction of service function CSPTYP X Scroll past single/dual CRTYP 0 CRTYP 3 RESET Demand Limit, 2-Stage Switch Control — This control has been designed to accept demand limit signals from a building load shedding control. The demand limit function provides for 2 capacity steps. The keypad is used to set the 2 demand limit set points, which range from 100 to 0% of capacity. Capacity steps are controlled by 2 field-supplied relay contacts connected to the designated chiller terminals. (See Field Wiring section on page 69 and Fig. 7.) Display shows no reset type has been selected Return fluid temperature is selected and activated Reset set points Fig. 5 — Cooling Return Fluid Reset 40 Fig. 6 — Cooling External Temperature Reset LEGEND COMM — Communications Bus PWR — Power SW — Switch NOTE: For specific connection points, see Fig. 25 - 29. Fig. 7 — 4 IN/4 OUT Options Module Wiring for Reset, Demand Limit, and Dual Set Point 41 Fig. 8 — 4-20 mA Cooling Temperature Reset Table 12 — Service Functions To view and modify configurations, the password must be entered under the log on subfunction. Example 6 — Changing Reset Type To change type of reset, first log on as shown in Table 12. Also refer to Set Point Function section, page 38, for information on entering reset set points using reset feature. KEYPAD ENTRY DISPLAY RESPONSE FLD CFG CSPTYP 0 CRTYP 0 CRTYP 1 CRTYP 2 CRTYP 3 CRTYP 4 CRTYP 0 SUBFUNCTION 1 Log On COMMENTS KEYPAD ENTRY DISPLAY COMMENT Password/ PASSWORD Enter Disable Password LOGGEDON Logged On Field configuration subfunction of service function Scroll past single cooling set point No reset has been selected Internally powered 4-20 mA signal reset is selected Space or outdoor-air temperature reset is selected Return fluid temperature reset is selected Externally powered 4-20 mA signal reset is selected NOTE: Configurations may be modified at this time. When finished viewing and/or modifying configurations, log out as follows: LOGGEDON — 2 Version LOG OFF Disable Password Protection EXIT LOG Logged Off/ Enable Password Protection VERSION Software Information XXXXXXXX Version No. of Software Reset is deactivated Demand Limit, 4 to 20 mA Signal — The controls can also accept a 4 to 20 mA signal for load shedding. Input for the signal are terminals shown below: Externally powered Positive lead to J7-5 - 4 In/4 Out Module Negative lead to J7-6 - 4 In/4 Out Module Internally powered Positive lead to J7-6 - 4 In/4 Out Module Negative lead to J7-7 - 4 In/4 Out Module See Field Wiring section on page 69 and Fig. 7. To use Demand Limit, first enable loadshed, then enter demand limit set points. See Example 7A. Closing the first stage demand limit contact puts unit on the first demand limit level, that is, the unit does not exceed the percentage of capacity entered as demand limit stage 1. Closing contacts on second-stage demand limit relay prevents unit from exceeding capacity entered as demand limit stage 2. The demand limit stage that is set to the lowest demand takes priority if both demand limit inputs are closed. The demand limit function must be enabled in order to function and may be turned off when its operation is not desired. The demand limit relays can, in off condition, remain connected without affecting machine operation. 42 the loadshed demand delta, which defines the percent of the load to be removed when a loadshed command is in effect. The third set point is maximum loadshed time, which defines the maximum length of time that a loadshed condition is allowed to exist. The allowable range for this entry is zero to 120 minutes. Subfunction displays date, time, and day of the week. At field configuration step, select 4 to 20 mA loadshed by entering (internally powered) or (externally powered) when the LSTYP 0 display appears. See Example 7B. Then enter set points as follows. In this example, set points are coordinates of the demand limit curve shown in Fig. 9. Example 7A — Using Demand Limit (First Log On as Shown in Table 12) KEYPAD ENTRY DISPLAY RESPONSE COMMENTS FLD CFG Field configuration subfunction of service function LSTYP 0 Loadshed is not enabled LSTYP 1 DLS1 80 Loadshed is now enabled for 2-stage switch control Demand Limit set points subfunction of set point function Loadshed 1 currently set at 80% DLS1 60 Loadshed reset to 60% DLS2 50 Loadshed 2 currently set at 50% DLS2 40 Loadshed 2 reset to 40% DEMAND Reading and Changing Time Display — Time is entered and displayed in 24-hour time. The day of the week is entered as a number. 1 = Mon, 2 = Tue, 7 = Sun, etc. Key is used as the colon when entering time. See Example 8. subfunction accesses the leaving chiller fluid alert limit (LMT) option. The value to be entered here is the number of degrees above the control set point at which an alert should be generated. For example, if the control set point is 44 F, and an alert is desired (alert 70) if the fluid temperature reaches 50 F, then enter 6 for this set point. The allowable range for this entry is between 2 and 30 (F). SERVICE FUNCTION — This function allows the technician to view and input configuration data. Factory configuration data, field configuration data, and service configuration data may be viewed or entered through the keypad and display module. See Table 9 for a complete listing of configurable items. Whenever a processor module is replaced in the field, the complete list of configuration codes must be entered. Logging On/Logging Off — The service function is password protected. Therefore, to gain entry to this function, To Disable Demand Limit: KEYPAD ENTRY DISPLAY RESPONSE COMMENTS LSTYP 1 Field configuration subfunction of service function Scroll past other elements in the subfunction Loadshed is enabled for 2-stage switch control LSTYP 0 Loadshed is now disabled FLD CFG ERTYP 0 this password must be entered. Pressing allows the technician to view, change, or enter configuration codes. To log off, perform the following keystrokes: . The service function is once again password protected. NOTES: 1. Select 2 for internally powered 4 to 20 mA signal load limiting. 2. Select 3 for Carrier Comfort Network loadshed. 3. Select 4 for externally powered 4 to 20 mA signal load limiting. Software Information — displays the version number of the software that resides in the processor module. The rized in Table 12. Example 7B — Using Demand Limit (4-20 mA) (First Log On As Shown in Table 12) KEYPAD ENTRY DISPLAY RESPONSE and subfunctions are summa- Example 8 — Setting Time of Day and Day of Week COMMENTS ERTYP 0 Field configuration subfunction of service function Scroll past other elements in the subfunction LSTYP 0 Loadshed is not enabled TIME LSTYP 2 Loadshed is now enabled for 4-20 mA internally-powered signal control MON 16.00 DEMAND Demand Limit set points TUE 13.05 DL20 100 Maximum demand limit is 100% DL20 90 Maximum demand limit is 90% FLD CFG KEYPAD ENTRY DISPLAY RESPONSE JAN 01 90 APR 15 90 Scrolling past the 4 to 20 mA demand limit set point brings up the loadshed set points. The loadshed feature is activated by a redline alert and loadshed commands from the CCN loadshed option. The first set point is the group number, established by the CCN system designer. The second option is 43 COMMENTS Time display subfunction of set point function Current setting is Monday, 4:00 p.m. New setting of Tuesday, 1:05 p.m. is entered and displayed Current date is Jan. 1, 1990 New setting April 15, 1990 is entered and displayed Fig. 9 — 4-20 mA Demand Limiting replaced in the field, the 2 groups of configuration codes must be entered through the keypad and display module. The 2 groups of configuration codes (groups 8 and 9) that apply to the unit being serviced can be found on a label diagram inside the control box cover. See Table 13 for keystroke information to enter configuration codes 8 and 9. The remaining items in this subfunction are read-only data provided to assist in service evaluations. SCHEDULE FUNCTION — This function provides a means to automatically switch chiller from an occupied mode to an unoccupied mode. When using schedule function, chilled fluid pump relay must be used to switch chilled fluid pump on and off. Connections for chilled fluid pump relay are: TB3-3 and TB3-4. The chilled fluid pump relay starts chilled fluid pump but compressors do not run until remote chilled fluid pump interlock contacts are between TB6-1 and TB6-2 are closed and leaving chilled fluid temperature is above set point. If a remote chilled fluid pump interlock is not used, the first compressor starts (upon a call for cooling) approximately one minute after chilled fluid pump is turned on. The unit can be programmed for inactive, single set point, or dual set point operation. When unit is configured for inactive, chilled fluid pump relay remains energized continuously but is not used since chiller is usually controlled by remote chilled fluid pump interlock contacts. When unit is configured for single set point operation, chilled fluid pump relay is energized whenever chiller is in occupied mode regardless of whether chiller is running. When chiller is in unoccupied mode, chilled fluid pump relay is not energized. Factory Configuration Codes — allows entry into the factory configuration subfunction. Under this subfunction, there are 7 groups of configuration codes that are downloaded at the factory. Each group is made up of 8 digits. If processor module is replaced in the field, these 7 groups of configuration codes must be entered through the keypad and display module. Factory configuration codes (groups 1 through 7) that apply to the particular Flotronic™ II chiller being serviced are found on a label diagram located inside the control box cover. See Table 13 for a summary of factory configuration subfunction keystrokes. Adjustable Field Configurations — After logging on, press to enter subfunction. The subfunction allows operation of the chiller to be customized to meet the particular needs of the application. The chiller comes from the factory preconfigured to meet the needs of most applications. Each item should be checked to determine which configuration alternative best meets the needs of a particular application. See Table 14 for factory loaded configuration codes and alternative configurations. If processor module is replaced, the replacement module is preloaded with factory default configuration codes. Each configuration code must be checked and, if necessary, reconfigured to meet needs of the application. See Table 14 for pre-loaded service replacement configuration codes. Service Configuration Codes — Press to enter the service configuration subfunction. The first 2 items under this subfunction are 2 groups (8 digits each) of configuration codes that are downloaded at the factory. If processor module is 44 Table 13 — Factory Configuration Keystrokes To change a configuration enter the new configuration and press SUBFUNCTION 3 FACTORY CFG 5 SERVICE CFG Table 14 — Adjustable Field Configurations FIELD CONFIGURATION ITEM AND CODES while on the correct configuration. KEYPAD ENTRY DISPLAY COMMENTS FACT CFG FACTORY CONFIGURATION CODES XXXXXXXX Configuration Code 1 XXXXXXXX Configuration Code 2 XXXXXXXX Configuration Code 3 XXXXXXXX Configuration Code 4 XXXXXXXX Configuration Code 5 XXXXXXXX Configuration Code 6 XXXXXXXX Configuration Code 7 SRV CFG CCN element address (Entered by CCN Technician) CCN Bus Number (Entered by CCN Technician) CCN Baud Rate (Entered by CCN Technician) Cooler Fluid Select 1 = Water (38 to 70 F [3.3 to 21 C] Set Point) 2 = Medium Brine (15 to 70 F [–9 to 21 C] Set Point) Display Unit Select 0 = English 1 = Metric SI Delay at Power Up No. Circuit A Unloaders 0 = No Unloaders 1 = One Unloader 2 = Two Unloaders No. Circuit B Unloaders 0 = No Unloaders 1 = One Unloader 2 = Two Unloaders Hot Gas Bypass Select 0 = No Valve Loading Sequence Select 1 = Equal Circuit Loading 2 = Staged Circuit Loading Lead/Lag Sequence Select 1 = Automatic 2 = Manual, Circuit A Leads 3 = Manual, Circuit B Leads Oil Pressure Switch Select 0 = Not Used 1 = Air Cooled Head Pressure Control Type 0 = Not Used 1 = Air Cooled Head Pressure Control Method 1 = EXV Controlled 2 = Set Point Control for Both Circuits 3 = Set Point Control for Circuit A; EXV Control for Circuit B 4 = Set Point Control for Circuit B; EXV Control for Circuit A MotormasterT Select 0 = None 2 = Indirect Control Cooling Set Point Control Select 0 = Single Set Point Control 1 = External Switch Controlled Set Point 2 = Clock Controlled Set Point Cooling Reset Control Select 0 = No Reset 1 = 4-20 mA, Internally Powered 2 = External Temperature Reset 3 = Return Fluid Reset 4 = 4-20 mA, Externally Powered SERVICE CONFIGURATION CODES XXXXXXXX Configuration Code 8 XXXXXXXX Configuration Code 9 REFRIG X Refrigerant Type TDTYPE X Pressure Transducer Select OPS X Oil Pressure Set Point LPS X Low Pressure Set Point FANTYP X Fan Staging Select SH X EXV Superheat Set Point MOP X EXV MOP Superheat ZM X Z Multiplier LEGEND MOP — Maximum Operating Pressure EXV — Electronic Expansion Valve FACTORY CONFIGURATION CODE SERVICE REPLACEMENT CODE 001 001 000 000 9600 9600 1 = Standard Models clock for the scheduling function. are used to program schedules for specific occupied and unoccupied periods. The schedule consists of from one to 8 occupied time periods, set by the operator. These time periods can be flagged to be in effect or not in effect on each day of the week. The day begins at 00.00 and ends at 24.00. The machine is in unoccupied mode unless a scheduled time period is in effect. If an occupied period is to extend past midnight, it must be programmed in the following manner: occupied period must end at 24:00 hours (midnight); a new occupied period must be programmed to begin at 00:00 hours. 0 0 0 0 0 = 30GN040-070, 190-210* 1 = 30GN080-170* 0 LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve 45 0 0 = 30GN190-210* 1 = 30GN040-170* External Reset Sensor Select 0 = Thermistor Connected to Options Module 1 = Obtained Through CCN Outdoor-Air Sensor Select 0 = Not Selected 1 = Selected Demand Limit Control Select 0 = No Demand Limiting 1 = Two External Switch Inputs 2 = Internal 4-20 mA Input 3 = CCN Loadshed 4 = External 4-20 mA Input Ramp Load Select (Pulldown Control) 0 = Disabled 1 = Enabled Cooler Pump Interlock Select 0 = No Interlock 1 = With Interlock Cooler Pump Control Select 0 = Not Controlled 1 = ON/OFF Controlled Remote Alarm Option Select 0 = Not Selected 1 = Selected Local/Enable-Stop-CCN Switch Usage† 0 = Not Allowed 1 = Allowed When unit is configured for dual set point, chilled liquid pump relay is energized continuously, in both occupied and unoccupied modes. Occupied mode places occupied chilled water set point into effect; unoccupied mode places unoccupied chilled water set point into effect. Scheduling — is used to override any current schedule in effect (for 0-4 hours). is used to activate a 1 2 = Brine Models 0 0 1 1 1 1 0 0 1 0 1 2 = 040,045 Brine Units 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 0 0 1 1 *And associated modular units. †For reset of alarms. Example 9 — Using the Schedule Function (cont) NOTE: This is true only if the occupied period starts at 00:00 (midnight). If the occupied period starts at a time other than midnight, then the occupied period must end at 00:00 hours (midnight) and new occupied period must be programmed to start at 00:00 in order for the chiller to stay in the occupied mode past midnight. The time schedule can be overridden to keep unit in occupied mode for one, 2, 3, or 4 hours on a one-time basis. See Example 9. All subfunctions of schedule function are password protected except the override subfunction, KEYPAD ENTRY DISPLAY PERIOD 2 Occupied time will start at 7:00 a.m. Start of unoccupied time of period). For this UNO 00.00 (end example, period 2 should end at 18:00 (6:00 p.m.) OCC 7.00 . Pass- 2 ends at 18:00 UNO 18.00 Period (6:00 p.m.) MON NO MON YES TUE NO TUE YES Example 9 — Using the Schedule Function WED YES DISPLAY COMMENT OVRD 0 No scheduled override in effect OVRD 3 3 hours override in effect OVRD 0 Override cancelled CLOCK 0 Schedule function is inactive CLOCK 1 Schedule function is enabled through local unit clock WED NO PERIOD 3 OCC 00.00 UNO 00.00 UNO 3.00 MON NO MON YES TUE YES TUE NO Monday is now flagged no for period 2. To put period 2 into effect on Monday, Monday must be flagged yes Monday is now flagged for period 2 to be in effect Tuesay is now flagged no for period 2. To put period 2 into effect on Tuesday, Tuesday must be flagged yes Tuesday is now flagged for period 2 to be in effect For this example, period 2 is to be in effect only on Monday and Tuesday. All other days must be checked to be sure that they are flagged no. If a day is flagged yes, change to no Wednesday is now flagged no for period 2 Define schedule period 3 of occupied OCC 00.00 Start time Occupied time will start at 7:00 a.m. Start of unoccupied time of period 3). For this UNO 00.00 (end example, period 3 should end at 21:30 (9:30 p.m.) 3 ends at 21:30 UNO 21.30 Period (9:30 p.m.) Check to be sure that MON NO Monday and Tuesday are flagged no for period 3 OCC 7.00 PROGRAMMING PERIOD 1: PERIOD 1 Define schedule period 2 OCC 00.00 Start of occupied time word entry into subfunctions through , is done through service function. See page 43, logging on/ logging off. Figure 10 shows a schedule for an office building with the chiller operating on a single set point schedule. The schedule is based on building occupancy with a 3-hour off-peak cool-down period from midnight to 3 a.m. following the weekend shutdown. To learn how this sample schedule would be programmed, see Example 9. NOTE: This schedule was designed to illustrate the programming of the schedule function and is not intended as a recommended schedule for chiller operation. KEYPAD ENTRY COMMENT PROGRAMMING PERIOD 2: Define schedule period 1. Start of occupied time For this example, first period should start here (at midnight) so no entry is needed Start of unoccupied time (end of period). For this example, period 1 should end at 3:00 a.m. TUE NO WED NO Wednesday is flagged no, change to yes WED YES Wednesday is now flagged yes for period 3 THUR NO Check to be sure that all other days are flagged no Period 1 ends at 3:00 a.m. Monday is now flagged no for period 1. To put period 1 into effect on Monday, Monday must be flagged yes Monday is now flagged for period 1 to be in effect For this example, period 1 is to be in effect on Monday only. All other days must be checked to be sure that they are flagged no. If any day is flagged yes, change to no Tuesday is now flagged no for period 1 FRI NO SAT NO SUN NO CCN — Carrier Comfort Network 46 Periods 4 and 5 can be programmed in the same manner, flagging Thursday and Friday yes for period 4 and Saturday yes for period 5. For this example, periods 6, 7, and 8 are not used: they should be programmed OCC 00.00, UNO 00.00. NOTE: When a day is flagged yes for 2 overlapping periods, occupied time will take precedence over unoccupied time. Occupied times can overlap in the schedule with no consequence. To extend an occupied mode beyond its normal termination for a one-time schedule override, program as shown below: OVRD 0 OVRD 3 Override is set for 0. Enter the number of hours of override desired Unit will now remain in occupied mode for an additional 3 hours Holiday Schedule — Press to schedule up to 30 holiday periods. All holidays are entered with numerical values. First, the month (01 to 12), then the day (01 to 31), then the duration of the holiday period in days. Examples: July 04 is 07.04.01. Dec 25 - 26 is 12.25.02 If any of the 30 holiday periods are not used, the display shows NEW. See Example 10. Fig. 10 — Sample Time Schedule TROUBLESHOOTING Example 10 — Holiday Schedule Function ENTER The Flotronic™ II control has many features to aid the technicians in troubleshooting a Flotronic II Chiller. By using the keypad and display module and the status function, actual operating conditions of the chiller are displayed while unit is running. Test function allows proper operation of compressors, compressor unloaders, fans, EXVs and other components to be checked while chiller is stopped. Service function displays how configurable items are configured. If an operating fault is detected, an alarm is generated and an alarm code(s) is displayed under the subfunction , along with an explanation of the fault. Up to 10 current alarm codes are stored under this subfunction. For checking specific items, see Table 9. DISPLAY HOLIDAY JAN01 02 (Includes Jan 1st and 2nd) APR17 01 (Includes April 17th) MAY21 01(Includes May 21st) JUL03 01 (Includes July 3rd) JUL04 01 (Includes July 4th) Checking Display Codes — To determine how ma- SEP07 01 (Includes Sep. 7th) chine has been programmed to operate, check diagnostic information ( ) and operating mode displays ( ). If no display appears, follow procedures in Control Modules section on page 63. If display is working, continue as follows: 1. Note all alarm codes displayed, . NOV26 02 (Includes Nov. 26th and 27th) DEC24 02 (Includes Dec. 24th and 25th) DEC30 02 (Includes Dec. 30th and 31st) 2. Note all operating mode codes displayed, . 3. Note leaving chilled water temperature set point in effect and current leaving water temperature, . If machine is running, compare the ‘‘in effect’’ leaving water temperature set point with current water temperature. Remember, if reset is in effect, the values may be different because machine is operating to the modified chilled water set point. If current temperature is equal to set point, but set point is not the one desired, remember that if dual set point has been selected in the schedule function, there are 2 set points to which the machine can be operating. Check the programming of schedule function to see if occupied or unoccupied set point should be in effect. NEW MAY25 01 (Includes May 25th) NEW NEW NEW NEW NEW (30TH HOLIDAY) NEW indicates a holiday that has not been assigned yet. 47 Unit Shutoff — To shut unit off, move LOCAL/ENABLESTOP-CCN switch to STOP position. Any refrigeration circuit operating at this time continues to complete the pumpout cycle. Lag compressors stop immediately, and lead compressors run to complete pumpout. If stoppage occurs more than once as a result of any of the above safety devices, determine and correct the cause before attempting another restart. Complete Unit Stoppage — Complete unit stoppage can 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Restart Procedure — After cause for stoppage has been corrected, restart is either automatic or manual, depending on fault. Manual reset requires that LOCAL/ENABLESTOP-CCN switch be moved to STOP position, then back to original operating position. Some typical fault conditions are described in Table 15. For a complete list of fault conditions, codes, and reset type, see Table 16. be caused by any of the following conditions: Cooling load satisfied Remote on/off contacts open Programmed schedule Emergency stop command from CCN General power failure Blown fuse in control power feed disconnect Open control circuit fuse LOCAL/ENABLE-STOP-CCN switch moved to STOP position Freeze protection trip Low flow protection trip Open contacts in chilled water flow switch (optional) Open contacts in any auxiliary interlock. Terminals that are jumpered from factory are in series with control switch. Opening the circuit between these terminals places unit in stop mode, similar to moving the control switch to STOP position. Unit cannot start if these contacts are open. If they open while unit is running, unit pumps down and stops. Cooler entering or leaving fluid thermistor failure Low transducer supply voltage Loss of communications between processor module and other control modules Low refrigerant pressure Off-to-on delay is in effect. Table 15 — Typical Stoppage Faults and Reset Types Chilled Fluid, Low Flow Chilled Fluid, Low Temperature Manual reset Auto reset first time, manual if repeated in same day Chilled Fluid Pump Interlock Manual reset Unit restarts automatically when Control Circuit Fuse Blown power is restored High-Pressure Switch Open Manual reset Auto reset first time, then Low Refrigerant Pressure manual if within same day Low Oil Pressure Manual reset Discharge Gas Thermostat Open Manual reset POWER FAILURE EXTERNAL TO THE UNIT — Unit restarts automatically when power is restored. 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 below. These code numbers are displayed on the HSIO when the subfunction is entered. A fault that affects one one circuit of the chiller will generate an alert, and a fault that affects the entire unit will generate an alarm. Following is a detailed description of each alarm and alert code error and possible cause. Manual reset is accomplished by moving LOCAL/ENABLE-STOP-CCN Switch to STOP position, then back to LOCAL or CCN position. See Table 16 for listing of each alarm and alert code. Code 0 No alarms or alerts exist Codes 1 - 8 Compressor failure If DSIO-LV or -EXV relay module control relay feedback switch or signal is sensed as open during operation of a compressor, microprocessor detects this and stops compressor, energizes alert light, and displays a code of 1, 2, 3, 4, 5, 6, 7, or 8 depending on the compressor. Compressor locks off; to reset, use manual reset method. If lead compressor in a circuit shuts down, the other compressors in the circuit stop and lock off. Only the alert mode for lead compressor is displayed. The microprocessor is also programmed to indicate compressor failure if feedback terminal on DSIO-LV or -EXV J3 terminal strip receives voltage when compressor is not supposed to be on. Single Circuit Stoppage — Single circuit stoppage can 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. be caused by the following: Low oil pressure in lead compressor Open contacts in lead compressor high-pressure switch Low refrigerant pressure Thermistor failure Transducer failure Ground fault in lead compressor indicator (indicator is field-supplied on 040-060, 070 [60 Hz], and 080-110 and associated modular units) High suction superheat Low suction superheat Lead compressor circuit breaker trip. Stoppage of one circuit by a safety device action does not affect other circuit. When a safety device trips on a lead compressor, circuit is shut down immediately and EXV closes. Ground fault for any circuit compressor (130-210 and associated modular units). Lag Compressor Stoppage — Lag compressor stoppage can be caused by the following: 1. Open contacts in high-pressure switch 2. Compressor ground fault (indicator is field-supplied on 040-060, 070 [60 Hz], and 080-110 and associated modular units) 3. Compressor circuit breaker trip 4. Not required to run to meet cooling load requirement NOTE: It takes 5 seconds for the control to generate the alarm code and lock out the compressor(s) on compressor failure code(s) 1 through 8. 48 Table 16 — Alarm and Alert Codes 0 ALARM OR DESCRIPTION ALERT — No Alarms or Alerts Exist — — 1 Compressor A1 failure Circuit A shut down No Manual Compressor A2, A3, A4 failure Compressor B1 failure Compressor B2, B3, B4 failure Compressor shut down Circuit B shut down Compressor shut down Yes No Yes Manual Manual Manual Leaving fluid thermistor failure Entering fluid thermistor failure Compressor A1 sensor failure Compressor B1 sensor failure Reset thermistor failure Unit shut down Unit shut down Circuit A shut down Circuit B shut down Normal set point used Yes Yes Yes Yes No Auto. Auto. Auto. Auto. Auto. Thermistor or transducer failure or wiring error. Circuit A shut down Circuit B shut down Circuit A shut down Circuit B shut down Circuit A shut down Circuit B shut down Yes Yes No No No No Auto. Auto. Auto. Auto. Auto. Auto. Transducer failure or wiring error. DISPLAY 2, 3, 4 5 6, 7, 8 9 10 19 20 21 Alert Alarm Alert ACTION TAKEN BY CONTROL — CIRCUIT RESET PUMPDOWN METHOD 22 23 24 25 26 27 Alert Discharge pressure transducer failure, circuit A Discharge pressure transducer failure, circuit B Suction pressure transducer failure, circuit A Suction pressure transducer failure, circuit B Oil pressure transducer failure, circuit A Oil pressure transducer failure, circuit B 28 29 Alarm Transducer supply voltage low LOCAL/ENABLE-STOP-CCN Unit shut down Unit shut down No No Auto. Manual 4-20 mA reset input failure 4-20 mA demand limit failure Loss of communication with DSIO-LV Normal set point used Demand limit ignored Unit shut down No No No Auto. Auto. Auto. Loss of communication with DSIO-EXV Loss of communication with 4 In/4 Out module Unit shut down Unit shut down No Yes Auto. Auto. 30 31 32 33 34 35 Alert Alarm — 36 37 Alert 38 39 Alert 40 41 42 43 Alert Alarm 44 45 Alert 46 47 Alert Not used — PROBABLE CAUSE — High-pressure switch trip, or wiring error. CPCS Ground Fault Protection Unit voltage low or PS1 faulty. Switch failure or wiring error. Wiring error or faulty module or improper address code. — — Low refrigerant pressure circuit A Circuit A shut down No * Low refrigerant pressure circuit B Circuit B shut down No * Failure to pump out circuit A Circuit A shut down No Manual Failure to pump out circuit B Circuit B shut down No Manual Low oil pressure circuit A Circuit A shut down No Manual Low oil pressure circuit B Circuit B shut down No Manual Cooler freeze protection Low cooler fluid flow Unit shut down Unit shut down No No * Manual Low suction temperature circuit A Circuit A shut down after 10 minutes Circuit B shut down after 10 minutes No Manual Low fluid flow or faulty thermistor. Chilled fluid pump failure or faulty thermistor. Faulty expansion valve or thermistor. No Manual Faulty expansion valve or thermistor. High suction superheat circuit A Circuit A shut down Yes Manual High suction superheat circuit B Circuit B shut down Yes Manual Low charge, faulty expansion valve or thermistor, or plugged filter drier. Low charge, faulty expansion valve or thermistor, or plugged filter drier. Low suction temperature circuit B — Low refrigerant charge, plugged filter drier, faulty expansion valve. Low refrigerant charge, plugged filter drier, faulty expansion valve. Faulty expansion valve, transducer, or thermistor. Faulty expansion valve, transducer, or thermistor. Low oil level, circuit breaker trip, faulty expansion valve, crankcase heater, or pressure transducer. Low oil level, circuit breaker trip, faulty expansion valve, crankcase heater, or pressure transducer. 48 49 Alert Low suction superheat circuit A Low suction superheat circuit B Circuit A shut down Circuit B shut down Yes Yes Manual Manual Faulty EXV or thermistor. Faulty EXV or thermistor. 50 51 52 Alarm Illegal configuration Initial configuration required Emergency stop by CCN command Unit cannot start Unit cannot start Unit shut down — — Yes Manual Manual CCN Configuration error. Configuration omitted. Network command. 53 54 55 Alarm Cooler pump interlock failure Cooler pump interlock failure Cooler pump interlock failure Unit shut down Unit shut down Cooler pump shut down No No — Manual Manual Manual Failure of cooler pump or controls Failure of cooler pump or controls Failure of cooler pump relay or interlock 56 Alert WSM communication failure WSM forces removed — Auto. discharge pressure Circuit cannot start — Auto. discharge pressure Circuit cannot start — Auto. suction pressure Circuit cannot start — Auto. Alert Calibration required for transducer, circuit A Calibration required for transducer, circuit B Calibration required for transducer, circuit A Calibration required for transducer, circuit B Calibration required for transducer, circuit A Calibration required for transducer, circuit B suction pressure Circuit cannot start — Auto. oil pressure Circuit cannot start — Auto. oil pressure Circuit cannot start — Auto. 57 58 59 60 61 62 49 Wiring fault or module failure Transducer not calibrated Table 16 — Alarm and Alert Codes (cont) DISPLAY ALARM OR ALERT 63 DESCRIPTION ACTION TAKEN BY CONTROL CIRCUIT PUMPDOWN RESET METHOD PROBABLE CAUSE Alarm Complete unit shutdown Alarm only — Auto. Check individual alarms 64 65 Alert Loss of charge, circuit A Loss of charge, circuit B Circuit cannot start Circuit cannot start — — Auto. Auto. Refrigerant leak or transducer failure 66 Alarm FSM communication loss FSM forces removed — Auto. Wiring faulty or module failure 67 Alarm Transducer calibration date code failure Unit cannot start — Auto. 68,69 — Not used — — — 70 Alert High leaving chilled fluid temperature Alarm only — Auto. CPCS FSM PS WSM — — — — Incorrect date code entered — Building load greater than unit capacity, low water/brine flow, or compressor fault. Check for other alarms or alerts. *Reset automatic first time, manual if repeated same day. LEGEND Compressor Protection Control Module Flotronic™ System Manager Power Supply Water System Manager Possible causes of failure: 1. High-Pressure Switch Open — High-pressure switch for each compressor is wired in series with 24-v power that energizes compressor control relay. If high-pressure switch opens during operation, compressor stops. This is detected by microprocessor through the feedback terminals. 2. DSIO-LV or DSIO-EXV Module Failure — If a DSIO-LV relay module relay fails open or closed, microprocessor detects this, locks compressor off, and indicates an error. 3. Wiring Errors — If a wiring error exists causing CPCS, CR, or feedback switch to not function properly, microprocessor indicates an error. 4. Processor (PSIO) Failure — If hardware that monitors feedback switch fails, or processor fails to energize relay module relay to on, an error may be indicated. NOTE: The control does not detect circuit breaker failures. If a circuit breaker trips on lead compressor in a circuit, a low oil pressure failure is indicated. On the other compressors, no failure is indicated. 5. Ground Fault Module on 130-210 and associated modular units (CGFA or CGFB) Open — Module contacts are in lead compressor circuits, but ground fault could be in any compressor in affected circuit. Ground fault of any 040-110 and associated modular unit compressor (field-supplied accessory on 040-060 and 070, 60 Hz units; standard on 070, 50 Hz and 80-110 and associated modular units) will cause a trip. 6. Checkout Procedure — Shut off main power to unit. Turn on control power, then step through subfunction to proper compressor number (i.e., failure code 5 is compressor B1). Next, energize the step. If step works correctly, then failure code is caused by: • HPS (high-pressure switch) open • Misplaced feedback wire from J4 and J5 terminals • Ground wire and 24-v feeds reversed on one or more points on J3 Compressor Alarm/Alert Circuit — For compressor A1 circuit, processor closes contacts between J4 terminals 2 and 3 to start compressor. See Fig. 11A-11C. Safeties shown to left of J4 must be closed in order for power to reach compressor control relay, and the feedback input terminals on J3. Failure of power to terminal 1 on J3, when contacts between 2 and 3 on J4 should be closed, causes a code 1 alert. Terminal 2 on J3 is the other leg of the compressor A1 feedback channel. It is connected to the 24-v common. NOTE: Similar connections for each compressor can be followed on the unit wiring diagrams located on the unit. Code 9 Leaving fluid thermistor failure (alarm) Code 10 Entering fluid thermistor failure (alarm) If temperature measured by these thermistors is outside range of –40 to 240 F (–40 to 116 C), unit shuts down after going through a normal pumpout. Reset is automatic if temperature returns to the acceptable range, and unit start-up follows normal sequence. The cause of the fault is usually a bad thermistor, wiring error, or loose connection. Code 19 Compressor A1 suction sensor failure (alert) Code 20 Compressor B1 suction sensor failure (alert) On units with thermistors, if temperature measured by these thermistors is outside the range of –40 to 240 F (–40 to 116 C), affected circuit shuts down after going through a normal pumpout. Other circuit continues to run. Reset is automatic if temperature returns to the acceptable range, and circuit start-up follows normal sequence. The cause of this fault is usually a bad thermistor, wiring error, or loose connection. On units with transducers, if the saturated suction temperature is greater than the leaving fluid temperature plus 10° F (5.5 C) for more than 5 minutes, the affected circuit shuts down (after going through normal pumpout). The reset is automatic if the saturated suction temperature returns to the acceptable range and start-up follows the normal sequence. The cause of this fault is usually a bad transducer, a wiring error, or a loose connection. 50 C CB COM, COMM CPCS — — — — CR DGT DSIO HPS LV NC NO PL PWR SNB TB TRAN U — — — — — — — — — — — — — LEGEND Contactor Circuit Breaker Communications Bus Compressor Protection Control Module Compressor Contactor Relay Discharge Gas Thermostat (Optional) Relay Module (Low Voltage) High-Pressure Switch Low Voltage Normally Closed Normally Open Plug Power Snubber Terminal Block Transformer Unloader Fig. 11A — 24-V Safety Circuit Wiring (040-070) Code 21 Reset thermistor failure (applies only to installations having external temperature reset) (alert) If temperature measured by this thermistor is outside range of –40 to 240 F (–40 to 116 C), reset function is disabled and unit controls to normal set point. If temperature returns to the acceptable range, reset function is automatically enabled. The cause of this fault is usually a bad thermistor, wiring error, or loose connection. Code 22 Compressor A1 discharge pressure transducer failure (alert) Code 23 Compressor B1 discharge pressure transducer failure (alert) Code 24 Compressor A1 suction pressure transducer failure (alert) Code 25 Compressor B1 suction pressure transducer failure (alert) Code 26 Compressor A1 oil pressure transducer failure (alert) Code 27 Compressor B1 oil pressure transducer failure (alert) If output voltage of any of these transducers is greater than 5 v, affected circuit shuts down without going through pumpout process (Alerts 24-27). Other circuit continues to run. Reset is automatic if output voltage returns to the acceptable range, and circuit start-up follows normal sequence. The cause of this fault is usually a bad transducer or a wiring error. Code 28 Low transducer supply voltage (alarm) If transducer supply voltage is less than 4.5 v or greater than 5.5 v, unit shuts down without going through pumpout process. Reset is automatic if supply voltage returns to the acceptable range, and circuit start-up follows normal sequence. The cause of this fault is usually a faulty transformer or primary voltage is out of range. 51 C CB COMM CPCS DGT DSIO HPS LV PL PWR TB TRAN U — — — — — — — — — — — — — LEGEND Contactor Circuit Breaker Communications Bus Compressor Protection Control Module Discharge Gas Thermostat (Optional) Relay Module (Low Voltage) High-Pressure Switch Low Voltage Plug Power Terminal Block Transformer Unloader *And associated modular units. Fig. 11B — 24-V Safety Circuit Wiring (080-110 and Associated Modular Units) The voltage supplied to the processor is polarized. When checking for proper voltage supply, be sure to consider this polarity. If voltage appears to be within acceptable tolerance, check to be sure the transformer supplying PS1 is not grounded. Grounding the supply transformer can result in serious damage to the control system. Code 29 LOCAL/ENABLE-STOP-CCN Switch Failure (switch resistances out of range) (alarm) This fault occurs due to the failure of the switch or due to a wiring error. Code 30 Reset input failure (4 to 20 mA) (alert) Code 31 Demand limit input failure (4 to 20 mA) (alert) These codes apply only if unit is configured for these functions. If 4 to 20 mA signal is less than 4 or more than 20 mA, reset or demand limit function is disabled and unit functions normally. If mA signal returns to the acceptable range, function is automatically enabled. Code 32 Loss of communication with compressor relay module (DISO-LV) (alarm) Code 33 Loss of communication with EXV relay module (DSIO-EXV) (alarm) If communication is lost with either of these modules, unit shuts down without pumpout. This alarm resets automatically when communication is restored. The unit starts up normally after alarm condition is reset. Probable cause of condition is a faulty or improperly connected plug, wiring error, or faulty module. Loss of communication can be attributed to a grounded transformer with a secondary voltage of 21 vac supplying the PSIO, DSIO-LV, or 4 IN/4 OUT modules; the 12.5-vac transformer supplying the DSIO-EXV module; or the 24-vac transformer supplying PS1 for the transformers. These transformers should not be grounded, or serious damage to controls can result. Check to be sure the transformers are not grounded. NOTE: If a blank PSIO module is downloaded without being connected to the modules DSIO, this alarm is energized. Code 34 Loss of communication with 4 In/4 Out module (alarm) This applies only if one or more of the following options are used: • external temperature reset • 4 to 20 mA temperature reset • external switch controlled dual set point • switch controlled demand limit • 4 to 20 mA demand limit • hot gas bypass If communication is lost with 4 IN/4 OUT module, the unit shuts off automatically, after finishing pumpout. Reset of alarm is automatic when communication is restored. Start-up after alarm is remedied follows a normal sequence. Probable cause of condition is a faulty or improperly connected plug, wiring error, or faulty module. 52 CB CGF COMM CR DSIO HPS LV PL SNB TB TRAN U LEGEND — Circuit Breaker — Ground Fault Module — Communications Bus — Compressor Contactor Relay — Relay Module (Low Voltage) — High-Pressure Switch — Low Voltage — Plug — Snubber — Terminal Block — Transformer — Unloader *And associated modular units. Fig. 11C — 24-V Safety Circuit Wiring (130-210 and Associated Modular Units) Loss of communication can be attributed to a grounded transformer with a secondary voltage of 21 vac supplying the PSIO, DSIO-LV, or 4 IN/4 OUT; the 12.5-vac transformer supplying the DSIO-EXV module, or the 24-vac transformer supplying PS1 for the transformers. These transformers should not be grounded, or serious damage to controls can result. Check to be sure the transformers are not grounded. Code 36 Low refrigerant pressure, Circuit A (alert) Code 37 Low refrigerant pressure, Circuit B (alert) If suction pressure transducer senses a pressure below set point for more than 5 minutes at start-up or more than 2 minutes during normal operation, affected circuit shuts down without going through the pumpout process. Reset is automatic when pressure reaches 10 psig above set point if there have been no previous occurrences of this fault on the same day. If this is a repeat occurrence on same day, then reset is manual, with LOCAL/ENABLE-STOP-CCN switch. Factory configured set point is 27 psig for standard chillers and 12 psig for brine chillers. Possible causes of fault are low refrigerant charge, faulty EXV, plugged filter drier, or faulty transducer. Code 38 Failure to pump out, Circuit A (alert) Code 39 Failure to pump out, Circuit B (alert) The pumpout process is terminated when saturated suction temperature is 10° F (5.6° C) below temperature at beginning of pumpout, or 10° F (5.6° C) below leaving water temperature or reaches a saturated suction temperature of –15 F (–26 C). If appropriate saturated suction temperature is not met within 3 minutes (on 2 consecutive tries), circuit shuts down without pumpout. Reset is manual with LOCAL/ ENABLE-STOP-CCN switch, and start-up follows normal sequence. Possible causes for this alarm are a bad thermistor or transducer or a faulty expansion valve. Code 40 Low oil pressure, Circuit A (alert) Code 41 Low oil pressure, Circuit B (alert) 53 Code 50 Illegal configuration (alarm) This fault indicates a configuration error. Unit is not allowed to start. Check all configuration data and set points and correct any errors. Code 51 Initial configuration required (alarm) This fault indicates factory configuration has not been done, and unit is not allowed to start. Refer to unit wiring label diagrams for factory configuration codes. There are 9 groups of 8-digit numbers that must be entered. The first 7 groups must be entered under subfunction. Groups If oil pressure differential is less than set point for more than 2 minutes at start-up, or more than one minute during normal operation, affected circuit shuts down without going through pumpout process. Reset is manual with LOCAL/ ENABLE-STOP-CCN switch, and start-up follows normal sequence. Factory configured differential oil pressure is 6 psig. Possible causes of fault are faulty compressor, expansion valve, crankcase heater or transducer, refrigerant overcharge, insufficient oil charge, or tripped circuit breaker. Code 42 Cooler freeze protection (alarm) If cooler entering or leaving water temperature is below 34° F (1.1° C) for water or more than 8° F (4.4° C) below set point for brine, unit shuts down without pumpout. Chilled water pump continues to run if controlled by chiller controls. Reset is automatic when leaving fluid temperature reaches 6° F (3° C) above set point, providing there has been no prior occurrence of this fault the same day. If fault has occurred previously the same day, reset is manual with LOCAL/ ENABLE-STOP-CCN switch. Possible causes of fault are low fluid flow or faulty thermistor. Code 43 Low fluid flow (alarm) If any compressors are operating and entering fluid temperature is 3° F (1.7° C) or more below leaving fluid temperature for more than one minute, unit shuts down without pumpout. Chilled fluid pump also shuts down. Reset is manual with LOCAL/ENABLE-STOP-CCN switch, and start-up follows normal sequence. This is a suitable method for sensing low fluid flow because entering fluid thermistor is in the cooler shell and responds more quickly to compressor operation than the leaving fluid thermistor in the leaving water nozzle. Possible causes of fault are faulty chilled fluid pump, control or thermistor. Code 44 Low cooler suction temperature, Circuit A (alert) Code 45 Low cooler suction temperature, Circuit B (alert) If saturated suction temperature is less than 32 F (0°C) and is 20° F (11° C) for water or 30° F (16° C) for brine or more below leaving fluid temperature, mode 14 is displayed. Unit continues to run, but additional compressors are not allowed to start. If condition persists for more than 10 minutes, fault code is displayed, and unit shuts down without pumpout. Reset is manual with LOCAL/ENABLE-STOPCCN switch, and start-up follows normal sequence. Possible causes of fault are low refrigerant charge, plugged filter drier, or a faulty expansion valve or thermistor. Code 46 High suction superheat, Circuit A (alert) Code 47 High suction superheat, Circuit B (alert) If expansion valve is fully open, suction superheat is greater than 75 F (42 C), and saturated evaporator temperature is less than MOP (maximum operating pressure) for more than 5 minutes, unit shuts down after normal pumpout process. Reset is manual with LOCAL/ENABLE-STOP-CCN switch, and start-up follows normal sequence. Possible causes of fault are low refrigerant charge, plugged filter drier, or a faulty expansion valve or thermistor. Code 48 Low suction superheat, Circuit A (alert) Code 49 Low suction superheat, Circuit B (alert) If EXV is at minimum position, suction superheat is less than 10° F (5.5° C) or saturated evaporator temperature is greater than MOP (maximum operating pressure) for more than 5 minutes, affected circuit shuts down after going through pumpout process. Reset is manual with LOCAL/ENABLESTOP-CCN switch, and start-up follows normal sequence. Possible causes of fault are faulty expansion valve or thermistor. 8 and 9 must be entered under subfunction. Enter each group, then press the key. Press the down arrow after each group to bring up the next empty screen. Unit should start after factory and field configurations are correctly entered. The usual cause of this fault is replacement of the processor module. Refer to instructions accompanying the replacement module. Code 52 Emergency stop by CCN command (alarm). Unit shuts down immediately without pumpout when this command is received, and goes through normal start-up when command is cancelled. Code 53 Cooler pump interlock failure — Contacts fail to close at start-up (alarm) If the unit is configured for cooler pump control and cooler pump interlock, and the interlock fails to close within one minute of starting the cooler pump, the unit is shut down without pumpout. The cooler pump is also shut down. Reset is manual with the LOCAL/ENABLE-STOP-CCN switch, and start-up follows the normal sequence. Possible causes are: 1. Interlock switch fails to close within one minute after chilled water pump starts 2. Interlock switch opens during unit operation 3. Interlock voltage is detected, but unit is not configured for interlock 4. Interlock voltage is outside its valid range If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout. Chilled fluid pump also shuts down. Reset is manual, with LOCAL/ENABLE-STOP-CCN switch. Most probable cause of this fault is shutdown or failure of chilled fluid pump to start. Other possibilities are improper configuration or wiring errors. Code 54 Cooler pump interlock failure — Contacts open during normal operation (alarm) If the unit is configured for cooler pump control and cooler pump interlock, and the interlock opens during normal operation, the unit is shut down without pumpout. The cooler pump is also shut down. Reset is manual with the LOCAL/ ENABLE-STOP-CCN switch, and startup follows the normal sequence. Possible causes are: 1. Interlock switch fails to close within one minute after chilled water pump starts 2. Interlock switch opens during unit operation 3. Interlock voltage is detected, but unit is not configured for interlock 4. Interlock voltage is outside its valid range If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout. Chilled fluid pump also shuts down. Reset is manual, with 54 15 psig. This alarm does not function in units using different part number transducers for suction and discharge pressure, since the discharge transducer in that application does not function below 20 psig. Code 66 Flotronic™ System Manager loss of communications (alarm) If the FSM has established communication with the control, and the communication is subsequently lost for more than 20 seconds, the control will remove all forces on the chiller variables. Control of the unit will revert to standalone basis, and reset is automatic upon re-establishment of communication. Code 67 Transducer calibration failure due to incorrect date code (alarm) This applies to units having pressure transducers with the same part number for both suction and discharge pressures. If the transducer calibration is attempted and the factory default date code (Jan. 1, 1980) is in the date variable, then the unit will not start. Reset is automatic when the proper date code is entered upon calibration. Code 70 High leaving chilled fluid temperature (alert) If the leaving chilled fluid temperature is rising and is higher than the limit established in the subfunction and the unit is at full capacity then alert 70 will be activated. The unit will continue to function normally, and reset will be automatic upon leaving chilled fluid temperature dropping to 5° F below the limit or less than control set point. LOCAL/ENABLE-STOP-CCN switch. Most probable cause of this fault is shutdown or failure of chilled fluid pump to start. Other possibilities are improper configuration or wiring errors. Code 55 Cooler pump interlock failure — Contacts closed when pump is off (alarm) If the unit is configured for cooler pump control and cooler pump interlock, and the interlock is closed when the cooler pump relay is off, the cooler pump shall be shut down and the unit prevented from starting. Reset is manual with the LOCAL/ENABLE-STOP-CCN switch. Possible causes are: 1. Interlock switch fails to close within one minute after chilled water pump starts 2. Interlock switch opens during unit operation 3. Interlock voltage is detected, but unit is not configured for interlock 4. Interlock voltage is outside its valid range If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout. Chilled fluid pump also shuts down. Reset is manual, with LOCAL/ENABLE-STOP-CCN switch. Most probable cause of this fault is shutdown or failure of chilled fluid pump to start. Other possibilities are improper configuration or wiring errors. Code 56 Water System Manager (WSM) communication failure (alert) If the WSM has previously established communications with the control and the WSM is not disabled and has not communicated with the control within the last 5 minutes, the control will remove all WSM forces from the chillers variables. The chiller will continue to operate on a stand-alone basis. Reset is automatic when the WSM re-establishes communication with the unit. Code 57 Calibration required for discharge pressure transducer, circuit A (alert) Code 58 Calibration required for discharge pressure transducer, circuit B (alert) If the discharge pressure transducer has not been successfully calibrated, the circuit will not start. Reset is automatic upon successful calibration of the transducer. Code 59 Calibration required for suction pressure transducer, circuit A (alert) Code 60 Calibration required for suction pressure transducer, circuit B (alert If the suction pressure transducer has not been successfully calibrated, the circuit will not start. Reset is automatic upon successful calibration of the transducer. Code 61 Calibration required for oil pressure transducer, circuit A (alert) Code 62 Calibration required for oil pressure transducer, circuit B (alert) If the oil pressure transducer has not been successfully calibrated, the circuit will not start. Reset is automatic upon successful calibration of the transducer. Code 63 Complete unit shutdown due to failure (alarm) This alarm alerts the user that the unit is totally shut down due to one or more fault conditions. Reset is automatic when all alarms causing complete unit shutdown are reset. Code 64 Loss of charge, circuit A (alert) Code 65 Loss of charge, circuit B (alert) If the unit uses suction and discharge transducers with the same part number, and the discharge pressure is below 10 psig when the unit is shut down, the circuit will not start. Reset is automatic when the discharge pressure rises above Electronic Expansion Valve (EXV) NOTE: This applies to all units except 30GN040 and 045 with optional brine. The 040 and 045 units with optional brine have TXVs. EXV OPERATION — These valves control the flow of liquid refrigerant into the cooler. They are operated by the processor to maintain a specified superheat at lead compressor entering gas thermistor (located between compressor motor and cylinders). There is one EXV per circuit. See Fig. 12. High-pressure liquid refrigerant enters valve through bottom. A series of calibrated slots are located in side of orifice assembly. As refrigerant passes through orifice, pressure drops and refrigerant changes to a 2-phase condition (liquid and Fig. 12 — Electronic Expansion Valve (EXV) 55 vapor). To control refrigerant flow for different operating conditions, sleeve moves up and down over orifice, thereby changing orifice size. Sleeve is moved by a linear stepper motor. Stepper motor moves in increments and is controlled directly by the processor module. As stepper motor rotates, motion is transferred into linear movement by lead screw. Through stepper motor and lead screws, 1500 discrete steps of motion are obtained. The large number of steps and long stroke result in very accurate control of refrigerant flow. The subfunction shows EXV valve position as a percent of full open. Position should change constantly while unit operates. If a valve stops moving for any reason (mechanical or electrical) other than a processor or thermistor failure, the processor continues to attempt to open or close the valve to correct the superheat. Once the calculated valve position reaches 120 (fully closed) or 1500 (fully open), it remains there. If EXV position reading remains at 120 or 1500, and the thermistors and pressure transducers are reading correctly, the EXV is not moving. Follow EXV checkout procedure below to determine cause. The EXV is also used to limit cooler suction temperature to 50 F (10 C). This makes it possible for chiller to start at higher cooler fluid temperatures without overloading compressor. This is commonly referred to as MOP (maximum operating pressure), and serves as a load limiting device to prevent compressor motor overloading. This MOP or load limiting feature enables the 30G Flotronic™ II chillers to operate with up to 95 F (35 C) entering fluid temperatures during start-up and subsequent pull-down. CHECKOUT PROCEDURE — Follow steps below to diagnose and correct EXV problems. 1. Check EXV driver outputs. Check EXV output signals at appropriate terminals on EXV driver module (see Fig. 13) as follows: Connect positive test lead to terminal 1 on EXV driver. Set meter for approximately 20 vdc. Enter outputs subfunction of test function by pressing EXV — Electronic Expansion Valve Fig. 13 — EXV Cable Connections to EXV Driver Module, DSIO (EXV) Control of valve is by microprocessor. A thermistor and a pressure transducer located in lead compressor are used to determine superheat. The thermistor measures temperature of the superheated gas entering the compressor cylinders. The pressure transducer measures refrigerant pressure in the suction manifold. The microprocessor converts pressure reading to a saturation temperature. The difference between temperature of superheated gas and saturation temperature is the superheat. Because the EXVs are controlled by the processor module, it is possible to track valve position. During initial start-up, EXV is fully closed. After start-up, valve position is tracked by processor by constantly observing amount of valve movement. The processor keeps track of EXV position by counting the number of open and closed steps it has sent to each valve. It has no direct physical feedback of valve position. Whenever unit is switched from STOP to RUN position, both valves are initialized, allowing the processor to send enough closing pulses to the valve to move it from fully open to fully closed, then reset the position counter to zero. 4. The EXV test can be used to drive EXV to any desired position. When EXV opens, the metering slots begin to provide enough refrigerant for operation at step 120. This is fully closed position when circuit is operating. The fully open position is 1500 steps. 5. Check thermistors and pressure transducers that control EXV. Check thermistors and pressure transducers that control processor output voltage pulses to EXVs. See Fig. 14 for locations. Circuit A — Thermistor T7, Suction Pressure Transducer SPTA Circuit B — Thermistor T8, Suction Pressure Transducer SPTB a. Use temperature subfunction of the status function ( ) to determine if thermistors are reading correctly. b. Check thermistor calibration at known temperature by measuring actual resistance and comparing value measured with values listed in Tables 17 and 18. c. Make sure thermistor leads are connected to proper pin terminals at J7 terminal strip on processor module and that thermistor probes are located in proper position in refrigerant circuit. See Fig. 15 and 16. d. Use the pressure subfunction of the Status function ( ) to determine if pressure transducers are , then advance to EXVA test by pressing 10 times. Press . The driver should drive the circuit A EXV fully open. During next several seconds connect negative test lead to pins 2, 3, 4, and 5 in succession. Voltage should rise and fall at each pin. If it remains constant at a voltage or at zero v, remove connector to valve and recheck. Press to close circuit A EXV. If a problem still exists, replace EXV driver module. If voltage reading is correct, expansion valve should be checked. Next, test EXVB. Connect positive test lead to pin 7 and the negative test lead to pin 8, 9, 10, and 11 in succession during EXVB test. 2. Check EXV wiring. Check wiring to electronic expansion valves from terminal strip on EXV driver. See Fig. 13. a. Check color coding and wire connections. Make sure they are connected to correct terminals at driver and EXV plug connections. b. Check for continuity and tight connection at all pin terminals. c. Check plug connections at driver and at EXVs to be sure EXV cables are not crossed. 3. Check resistance of EXV motor windings. Remove plug at J4 terminal strip and check resistance between common lead (red wire, terminal D) and remaining leads, A, B, C, and E (see Fig. 13). Resistance should be 25 ohms 6 2 ohms. 56 Other possible causes of improper refrigerant flow control could be restrictions in liquid line. Check for plugged filter drier(s) or restricted metering slots in the EXV. Formation of ice or frost on lower body of electronic expansion valve is one symptom of restricted metering slots. However, frost or ice formation is normally expected when leaving fluid temperature from the cooler is below 40 F. Clean or replace valve if necessary. NOTE: Frosting of valve is normal during compressor test steps and at initial start-up. Frost should dissipate after 5 to 10 minutes operation in a system that is operating properly. If valve is to be replaced, wrap valve with a wet cloth to prevent excessive heat from damaging internal components. reading correctly. Connect a calibrated gage to lead compressor suction or discharge pressure connection to check transducer reading. e. Make sure transducer leads are properly connected in junction box and at processor board. Check transformer 5 output. Check voltage transducer 5 vdc 6 .2 v. When above checks have been completed, check actual operation of EXV by using procedures outlined in this step. 6. Check operation of EXV. a. Close liquid line service valve of circuit to be checked, and run through the test step ( ) for lead compressor in that circuit to pump down low side of system. Repeat test step 3 times to ensure all refrigerant has been pumped from low side. NOTE: Be sure to allow compressors to run for the full pumpout period. b. Turn off compressor circuit breaker(s). Close compressor discharge service valves and remove any remaining refrigerant from low side of system. c. Remove screws holding top cover of EXV. Carefully remove top cover. If EXV plug was disconnected during this process, reconnect it after cover is removed. Thermostatic Expansion Valve (TXV) — Refer to base unit Installation Instructions for TXV information (30GN040,045 with optional brine only). Thermistors — All thermistors are identical in their temperature vs. resistance performance. Resistance at various temperatures are listed in Tables 17 and 18. LOCATION — General location of thermistor sensors are shown in Fig. 14. Cooler Leaving Fluid Thermistor (T1) — T1 is located in leaving fluid nozzle. The probe is immersed directly in the fluid. All thermistor connections are made through a 1⁄4-in. coupling. See Fig. 16. Actual location is shown in Fig. 14 and 15. Cooler Entering Fluid Thermistor (T2) — T2 is located in cooler shell in first baffle space near tube bundle. Thermistor connection is made through a 1⁄4-in. coupling. See Fig. 16. Actual location is shown in Fig. 14 and 15. Compressor Suction Gas Temperature Thermistors (T7 and T8) — T7 and T8 are located in lead compressor in each circuit in suction passage between motor and cylinders, above oil pump. They are well-type thermistors. See Fig. 14 and 15. When removing top cover, be careful to avoid damaging motor leads. d. Enter appropriate EXV test step for EXVA or EXVB in the outputs subfunction of the test function ( ). Press to initiate test. With cover lifted off EXV valve body, observe operation of valve motor and lead screw. The motor should turn counterclockwise, and the lead screw should move up out of motor hub until valve is fully open. Lead screw movement should be smooth and uniform from fully closed to fully open position. Press to check open to closed operation. If valve is properly connected to processor and receiving correct signals, yet does not operate as described above, valve should be replaced. Operation of EXV valve can also be checked without removing top cover. This method depends on operator’s skill in determining whether or not valve is moving. To use this method, initiate EXV test and open valve. Immediately grasp EXV valve body. As valve drives open, a soft, smooth pulse is felt for approximately 26 seconds as valve travels from fully closed to fully open. When valve reaches end of its opening stroke, a hard pulse is felt momentarily. Drive valve closed and a soft, smooth pulse is felt for the 52 seconds necessary for valve to travel from fully open to fully closed. When valve reaches end of its stroke, a hard pulse is again felt as valve overdrives by 50 steps. Valve should be driven through at least 2 complete cycles to be sure it is operating properly. If a hard pulse is felt for the 26-second duration, valve is not moving and should be replaced. The EXV test can be repeated as required by entering any percentage from 0 ( ) to 100 to initiate movement. If operating problems persist after reassembly, they may be due to out-of-calibration thermistor(s) or intermittent connections between processor board terminals and EXV plug. Recheck all wiring connections and voltage signals. THERMISTOR REPLACEMENT (T1, T2, T7, T8) Thermistors are installed directly in fluid Relieve all pressure using standard practices or drain fluid before removing. Proceed as follows (see Fig. 16): To replace thermistor sensor T2: 1. Remove and discard original thermistor and coupling. IMPORTANT: Do not disassemble new coupling. Install as received. 2. Apply pipe sealant to 1⁄4-in. NPT threads on replacement coupling and install in place of original. Do not use packing nut to tighten coupling. This damages ferrules (see Fig. 16). 3. Insert new thermistor in coupling body to its full depth. If thermistor bottoms out before full depth is reached, pull thermistor back out 1⁄8 in. before tightening packing nut. Hand tighten packing nut to position ferrules, then finish tightening 11⁄4 turns with a suitable tool. Ferrules are now attached to thermistor which can be withdrawn from coupling for unit servicing. To replace thermistors T1, T7, and T8: Add a small amount of thermal conductive grease to thermistor well. Thermistors are friction-fit thermistors, which must be slipped into well located in the compressor pump end. 57 Table 17 — Thermistor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ II TEMPERATURE (F) −25.0 −24.0 −23.0 −22.0 −21.0 −20.0 −19.0 −18.0 −17.0 −16.0 −15.0 −14.0 −13.0 −12.0 −11.0 −10.0 −9.0 −8.0 −7.0 −6.0 −5.0 −4.0 −3.0 −2.0 −1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0 51.0 52.0 53.0 54.0 55.0 56.0 57.0 58.0 59.0 60.0 61.0 62.0 63.0 64.0 65.0 66.0 67.0 68.0 69.0 70.0 VOLTAGE DROP (V) 4.821 4.818 4.814 4.806 4.800 4.793 4.786 4.779 4.772 4.764 4.757 4.749 4.740 4.734 4.724 4.715 4.705 4.696 4.688 4.676 4.666 4.657 4.648 4.636 4.624 4.613 4.602 4.592 4.579 4.567 4.554 4.540 4.527 4.514 4.501 4.487 4.472 4.457 4.442 4.427 4.413 4.397 4.381 4.366 4.348 4.330 4.313 4.295 4.278 4.258 4.241 4.223 4.202 4.184 4.165 4.145 4.125 4.103 4.082 4.059 4.037 4.017 3.994 3.968 3.948 3.927 3.902 3.878 3.854 3.828 3.805 3.781 3.757 3.729 3.705 3.679 3.653 3.627 3.600 3.575 3.547 3.520 3.493 3.464 3.437 3.409 3.382 3.353 3.323 3.295 3.267 3.238 3.210 3.181 3.152 3.123 RESISTANCE (OHMS) 98010 94707 91522 88449 85486 82627 79871 77212 74648 72175 69790 67490 65272 63133 61070 59081 57162 55311 53526 51804 50143 48541 46996 45505 44066 42679 41339 40047 38800 37596 36435 35313 34231 33185 32176 31202 30260 29351 28473 27624 26804 26011 25245 24505 23789 23096 22427 21779 21153 20547 19960 19393 18843 18311 17796 17297 16814 16346 15892 15453 15027 14614 14214 13826 13449 13084 12730 12387 12053 11730 11416 11112 10816 10529 10250 9979 9717 9461 9213 8973 8739 8511 8291 8076 7868 7665 7468 7277 7091 6911 6735 6564 6399 6238 6081 5929 TEMPERATURE (F) 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 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 VOLTAGE DROP (V) 3.093 3.064 3.034 3.005 2.977 2.947 2.917 2.884 2.857 2.827 2.797 2.766 2.738 2.708 2.679 2.650 2.622 2.593 2.563 2.533 2.505 2.476 2.447 2.417 2.388 2.360 2.332 2.305 2.277 2.251 2.217 2.189 2.162 2.136 2.107 2.080 2.053 2.028 2.001 1.973 1.946 1.919 1.897 1.870 1.846 1.822 1.792 1.771 1.748 1.724 1.702 1.676 1.653 1.630 1.607 1.585 1.562 1.538 1.517 1.496 1.474 1.453 1.431 1.408 1.389 1.369 1.348 1.327 1.308 1.291 1.289 1.269 1.250 1.230 1.211 1.192 1.173 1.155 1.136 1.118 1.100 1.082 1.064 1.047 1.029 1.012 0.995 0.978 0.962 0.945 0.929 0.914 0.898 0.883 0.868 0.853 58 RESISTANCE (OHMS) 5781 5637 5497 5361 5229 5101 4976 4855 4737 4622 4511 4403 4298 4196 4096 4000 3906 3814 3726 3640 3556 3474 3395 3318 3243 3170 3099 3031 2964 2898 2835 2773 2713 2655 2597 2542 2488 2436 2385 2335 2286 2239 2192 2147 2103 2060 2018 1977 1937 1898 1860 1822 1786 1750 1715 1680 1647 1614 1582 1550 1519 1489 1459 1430 1401 1373 1345 1318 1291 1265 1240 1214 1190 1165 1141 1118 1095 1072 1050 1029 1007 986 965 945 925 906 887 868 850 832 815 798 782 765 750 734 TEMPERATURE (F) 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) 0.838 0.824 0.810 0.797 0.783 0.770 0.758 0.745 0.734 0.722 0.710 0.700 0.689 0.678 0.668 0.659 0.649 0.640 0.632 0.623 0.615 0.607 0.600 0.592 0.585 0.579 0.572 0.566 0.560 0.554 0.548 0.542 0.537 0.531 0.526 0.520 0.515 0.510 0.505 0.499 0.494 0.488 0.483 0.477 0.471 0.465 0.459 0.453 0.446 0.439 0.432 0.425 0.417 0.409 0.401 0.393 0.384 0.375 0.366 RESISTANCE (OHMS) 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 18 — Thermistor Temperature (°C) vs Resistance/Voltage Drop; Flotronic™ II TEMPERATURE (C) −40 −39 −38 −37 −36 −35 −34 −33 −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 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 VOLTAGE DROP (V) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.657 4.639 4.619 4.598 4.577 4.554 4.531 4.507 4.482 4.456 4.428 4.400 4.371 4.341 4.310 4.278 4.245 4.211 4.176 4.140 4.103 4.065 4.026 3.986 3.945 3.903 3.860 3.816 3.771 3.726 3.680 3.633 3.585 3.537 3.487 3.438 3.387 3.337 3.285 3.234 3.181 3.129 3.076 3.023 2.970 2.917 2.864 2.810 2.757 2.704 2.651 2.598 2.545 2.493 2.441 2.389 2.337 2.286 2.236 2.186 2.137 2.087 2.039 1.991 RESISTANCE (Ohms) 168 230 157 440 147 410 138 090 129 410 121 330 113 810 106 880 100 260 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 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 TEMPERATURE (C) 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 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 59 VOLTAGE DROP (V) 1.944 1.898 1.852 1.807 1.763 1.719 1.677 1.635 1.594 1.553 1.513 1.474 1.436 1.399 1.363 1.327 1.291 1.258 1.225 1.192 1.160 1.129 1.099 1.069 1.040 1.012 0.984 0.949 0.920 0.892 0.865 0.838 0.813 0.789 0.765 0.743 0.722 0.702 0.683 0.665 0.648 0.632 0.617 0.603 0.590 0.577 0.566 0.555 0.545 0.535 0.525 0.515 0.506 0.496 0.486 0.476 0.466 0.454 0.442 0.429 0.416 0.401 0.386 0.370 RESISTANCE (Ohms) 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 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 DPT EXV OPT SPT T — — — — — LEGEND Discharge Pressure Transducer Electronic Expansion Valve Oil Pressure Transducer Suction Pressure Transducer Thermistor Number Fig. 14 — Thermistor and Pressure Transducer Locations Pressure Transducers — A single style of pressure transducer is used for both high- and low-pressure sensing on Flotronic™ II chillers. However, this transducer must be calibrated before the unit will operate. On new units, this will have been done at the factory in order to test run the unit. If a transducer or PSIO is replaced in the field, however, the transducer will have to be field calibrated as follows: 1. Disconnect transducer from the system. 2. Hang the transducer in the atmosphere. 3. Press on the HSIO keypad, and Read the pressure. Pressures before calibration must be within the range of 6 5 psig. If the pressure is outside the range of 6 5 psig, the HSIO display will read ---. If this is the case, replace the transducer or PSIO or check for a wiring error. If the value of the atmospheric pressure is greater than 5 psig or less than –5 psig, the transducer will be considered out of range and will not calibrate. 4. Press on the HSIO keypad. This automatically applies the proper correction factor to all future inputs from the transducer. Three pressure transducers are mounted on each lead compressor: 2 low-pressure transducers to monitor compressor suction pressure and oil pressure, and a high-pressure transducer to monitor compressor discharge pressure (see Fig. 17 for exact locations on compressor). Each transducer is supplied with 5 vdc power from a rectifier which changes 24 vac to 5 vdc. TROUBLESHOOTING — If transducer is suspected of being faulty, first check supply voltage to transducer. Supply voltage should be 5 vdc ± .2 v. If supply voltage is correct, compare pressure reading displayed on keypad and display module against pressure shown on a calibrated pressure gage. If the 2 pressure readings are not reasonably close, replace pressure transducer. 60 Fig. 15 — Thermistor Locations (Circuits A and B, Lead Compressor Only) COMPRESSOR SUCTION GAS TEMPERATURE THERMISTORS T7 AND T8 (ALL UNITS) AND FLUID-SIDE TEMPERATURE THERMISTOR T1 (ALL UNITS) FLUID-SIDE TEMPERATURE THERMISTOR T2 (ALL UNITS) Fig. 16 — Thermistors 61 Fig. 17 — Lead Compressor Transducer and Thermistor Locations 3. Unscrew transducer from 1⁄4-in. male flare fitting. When installing new pressure transducer, do not use thread sealer. Thread sealer can plug transducer and render it inoperative. 4. Insert weathertight wiring plug into end of transducer until locking tab snaps in place. 5. Check for refrigerant leaks. TRANSDUCER REPLACEMENT Transducers are installed directly in the refrigerant circuit. Relieve all refrigerant pressure using standard refrigeration practices before removing. 1. Relieve refrigerant pressure using standard refrigeration practices. 2. Disconnect transducer wiring at transducer by pulling up on locking tab while pulling weathertight connection plug from end of transducer. Do not pull on transducer wires. 62 Control Modules Turn controller power off before servicing controls. This ensures safety and prevents damage to controller. PROCESSOR MODULE (PSIO), 4 IN/4 OUT MODULE (SIO), LOW-VOLTAGE RELAY MODULE (DSIO-LV), AND EXV DRIVER MODULE (DSIO-EXV) — The PSIO, DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware. Proper operation of these modules is indicated by LEDs (light-emitting diodes) on the front surface of the DSIOs, and on the top horizontal surface of the PSIO and SIO. RED LED — Blinking continuously at a 3- to 5-second rate indicates proper operation. Lighted continuously indicates a problem requiring replacement of module. Off continuously indicates power should be checked. If there is no input power, check fuses. If fuse is bad, check for shorted secondary of transformer or for bad module. On the PSIO module, if the light is blinking at a rate of twice per second, the module should be replaced. GREEN LED — On a PSIO and an SIO, this is the green LED closest to COMM connectors. The other green LED on module indicates external communications, when used. Green LED should always be blinking when power is on. It indicates modules are communicating properly. If green LED is not blinking, check red LED. If red LED is normal, check module address switches. See Fig. 18. Proper addresses are: PSIO (Processor Module) — 01 (different when CCN connected) DSIO (Relay Module) — 19 DSIO (EXV Driver Module) — 31 SIO (4 In/4 Out Module) — 59 If all modules indicate communication failure, check COMM plug on PSIO module for proper seating. If a good connection is assured and condition persists, replace PSIO module. If only DSIO or SIO module indicates communication failure, check COMM plug on that mode for proper seating. If a good connection is assured and condition persists, replace DSIO or SIO module. All system operating intelligence rests in PSIO module, the module that controls unit. This module monitors conditions through input and output ports and through DSIO modules (low-voltage relay module and EXV driver module). The machine operator communicates with microprocessor through keypad and display module. Communication between PSIO and other modules is accomplished by a 3-wire sensor bus. These 3 wires run in parallel from module to module. On sensor bus terminal strips, terminal 1 of PSIO module is connected to terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner. See Fig. 19. If a terminal 2 wire is connected to terminal 1, system does not work. In Flotronic™ II chillers, processor module, low-voltage relay module, and keypad and display module are all powered from a common 21-vac power source which connects to terminals 1 and 2 of power input strip on each module. A separate source of 21-vac power is used to power options module through terminals 1 and 2 on power input strip. A separate source of 12.5 vac power is used to power EXV driver module through terminals 1 and 2 on power input strip. Fig. 18 — Module Address Selector Switch Locations 63 Fig. 19 — Sensor Bus Wiring (Communications) PROCESSOR MODULE (PSIO) (Fig. 20) Inputs — Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are used. Always refer to individual unit wiring for terminal numbers. Outputs — Output is 24 vdc. There are 3 terminals, only 2 of which are used, depending on application. Refer to unit wiring diagram. NOTE: Address switches (see Fig. 20) must be set at 01 (different when CCN connected). LOW VOLTAGE RELAY MODULE (DSIO-LV) (Fig. 21) Inputs — Inputs on strip J3 are discrete inputs (ON/OFF). When 24-vac power is applied across the 2 terminals in a channel it reads as on signal. Zero v reads as an off signal. Outputs — Terminal strips J4 and J5 are internal relays whose coils are powered-up and powered-off by a signal from microprocessor. The relays switch the circuit to which they are connected. No power is supplied to these connections by DSIO module. 4 IN/4 OUT MODULE (SIO) (Fig. 22) — 4 In/4 Out module allows the following features to be utilized: 1. Temperature Reset by outdoor air or space temperature. A remote thermistor (Part No. 30GB660002) is also required. NOTE: This accessory is not required for return water temperature reset. 2. Temperature Reset by remote 4 to 20 mA signal. 3. Demand Limit by remote 2-stage switch. 4. Demand Limit by remote 4 to 20 mA signal 5. Dual Set Point by remote switch. The options module is standard. Remember to reconfigure the chiller for each feature selected (see Table 14). For temperature reset, demand limit, and dual set point, desired set points must be entered through keypad and display module (see Set Point Function section on page 38). See Table 19 for overall troubleshooting information. PWR — Power Fig. 20 — Processor Module (PSIO) ACCESSORY UNLOADER INSTALLATION Some of the 30G Flotronic™ II units come standard with unloader(s), and many permit additional unloader(s) to be added if desired. See Table 20. IMPORTANT: The following combinations ARE NOT permitted (combinations are per circuit): 1. Two unloaders and hot gas bypass 2. Four compressors and 2 unloaders. 3. Four compressors, 1 unloader, and hot gas bypass. LEGEND COMM — Communications Bus NC — Normally Closed NO — Normally Open PWR — Power Fig. 21 — Low-Voltage Relay Module (DSIO) 64 3. Install the additional unloader cylinder head on the lead compressor, A1 or B1, according to instructions provided by the compressor manufacturer in the accessory package. 4. Continue installation per either 040-110, 130 (60 Hz) units or 130 (50 Hz), 150-210 units section as appropriate. 040-110, 130 (60 Hz) UNITS (And Associated Modular Units) 1. Wire the solenoid before any field wiring begins. Wiring between components and control box must be enclosed in conduit. All local electrical codes and National Electrical Code (NEC) must be followed. Factory wires are provided in the compressor harness to connect the solenoid. These wires are in the compressor control box. 2. Wire the control side. Open the left side control box door and remove inner panel. Using the holes provided and field-supplied screws, install field-supplied transformer above the DSIO-LV on the control panel. Wire the primary side of the transformer in parallel with TRAN4. See Fig. 23. This supplies transformer with proper line voltage. Be sure to connect proper tap of the transformer to ensure supply of proper secondary voltage. Wire the secondary side of transformer to DSIO-LV - J5-9, and a jumper from DSIO-LV - J5-9 to DSIO-LV - J4-9. Wire the secondary common to TB7-2. Connect the transformer ground to ground hole supplied near the transformer. These connections provide DSIO with necessary power to energize the solenoid coils. 3. When all connections are made, check for proper wiring and tight connections. Replace and secure inner panel. Restore power to unit. 4. Configure the processor. With the addition of extra unloaders, the unit configuration has changed. To change the configuration of the processor, enter the service function using the keypad and display module. Before any changes can be made, the LOCAL/ENABLE-STOPCCN switch must be in the STOP position, and the servicer must log on to the processor. LEGEND COMM — Communications Bus PWR — Power a. Press . Keypad LCD displays the word PASSWORD. b. Enter . Keypad LCD displays LOGGEDON. c. To change configuration, press . Keypad LCD displays FLD CFG. d. If an additional unloader was added to compressor A1, press until NULA 1 appears in keypad dis- Fig. 22 — 4 In/4 Out Module (SIO) If accessory unloaders are desired, an accessory unloader package is used. Package includes a suction cutoff unloader head package. The 24-v coil in the package can be used for 040-110, 130 (60 Hz), and associated modular units (Table 1). A 115 v or 230 v coil must be used for 130 (50 Hz), 150-210, and associated modular units (Table 1). Coil voltage depends on control circuit voltage. Consult current Carrier price pages for appropriate part numbers. NOTE: The accessory package will include all necessary components and wiring with the following exceptions: The field must provide screws, and on the 130-210, and associated modular units, the field must also supply a 20 vdc (part number HK35AB001) unloader relay and wire (90° C or equivalent). play. Press for the number of unloaders on circuit A. Keypad display now reads NULA 2. e. If an additional unloader was added to compressor B1, press until NULB 1 appears in keypad display. Press for the number of unloaders on circuit B. Keypad display now reads NULB 2. f. When configuration is complete, press . Key- Installation 1. Be sure all electrical disconnects are open and tagged before any work begins. Inspect the package contents for any damage during shipping. File a claim with the shipper if damage has occurred. 2. For ease of installation, factory-supplied wiring for the additional unloader is provided in the compressor harness. pad display reads LOGGEDON. Press pad display reads LOG OFF. Press play reads EXIT LOG. 65 until key. Keypad dis- Table 19 — Troubleshooting SYMPTOMS COMPRESSOR DOES NOT RUN CAUSE Power line open Control fuse open High-Pressure Switch (HPS) tripped Tripped power breaker Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective COMPRESSOR CYCLES OFF ON LOW PRESSURE COMPRESSOR SHUTS DOWN ON HIGH PRESSURE CONTROL UNIT OPERATES LONG OR CONTINUOUSLY SYSTEM NOISES Seized compressor Loss of charge Bad transducer Low refrigerant charge High-pressure control erratic in action Compressor discharge valve partially closed Condenser fan(s) not operating Condenser coil plugged or dirty Low refrigerant charge Control contacts fused Partially plugged or plugged expansion valve or filter driver Defective insulation Service load Inefficient compressor Piping vibration Expansion valve hissing Compressor noisy COMPRESSOR LOSES OIL FROSTED SUCTION LINE HOT LIQUID LINE FROSTED LIQUID LINE COMPRESSOR DOES NOT UNLOAD COMPRESSOR DOES NOT LOAD Leak in system Mechanical damage (blown piston or broken discharge valve) Crankcase heaters not energized during shutdown Expansion valve admitting either too much or too little refrigerant Shortage of refrigerant due to leak Shutoff valve partially closed or restricted Burned out coil Defective capacity control valve Miswired solenoid Weak, broken, or wrong valve body spring Miswired solenoid Defective capacity control valve Plugged strainer (high side) Stuck or damaged unloader piston or piston ring(s) REMEDY Reset circuit breaker. Check control circuit for ground or short. Replace fuse. Move LOCAL/ENABLE-STOP-CCN switch to STOP position then back to RUN or CCN position. Check the controls. Find cause of trip and reset breaker. Check connections. Check wiring and rewire. Check line voltage. Determine location of voltage drop and remedy deficiency. Check motor winding for open or short. Replace compressor if necessary. Replace compressor. Repair leak and recharge. Replace transducer. Add refrigerant. Replace control. Open valve or replace if defective. Check wiring. Repair or replace motor(s) if defective. Clean coil. Add refrigerant. Replace control. Clean or replace. Replace or repair. Keep doors and windows closed. Check valves. Replace if necessary. Support piping as required. Add refrigerant. Check for plugged liquid line filter drier. Check valve plates for valve noise. Replace compressor (worn bearings). Check for loose compressor holddown bolts. Repair leak. Repair damage or replace compressor. Replace heaters, check wiring and crankcase heater relay contacts. Check cooler and compressor thermistors. Test EXV. Repair leak and recharge. Open valve or remove restriction. Replace coil. Replace valve. Rewire correctly. Replace spring Rewire correctly. Replace valve. Clean or replace strainer. Clean or replace the necessary parts. EXV — Electronic Expansion Valve Table 20 — Standard and Accessory Unloaders UNIT NO. OF STANDARD UNLOADER(s) 30GN040-070 30GN080-170* 30GN190-210* 1 2 0 *And associated modular units. 66 NO. OF ACCESSORY UNLOADERS PERMITTED Circuit A Circuit B 1 1 or 2 1 1 1 1 5. Using test function, check unloaders. Press pad display reads OUTPUTS. Press reads UNA2 OFF. Press b. Log into the processor and enter the service function using the keypad and display module. . Keyuntil display Press . Relay energizes. Press and relay deenergizes. Press . The keypad LCD will display ‘‘PASSWORD.’’ Enter , and the keypad LCD will display ‘‘LOGGEDON.’’ c. To change the configuration, press , and the keypad LCD will display ‘‘FLD CFG.’’ Press until either ‘‘NULA 0’’ or ‘‘NULA 1’’ is displayed (depending on the number of unloaders provided as until display reads UNB2 OFF. Press . Relay energizes. Press and relay deenergizes. 6. When unloader check has been performed, return LOCAL/ ENABLE-STOP-CCN to proper position. Close and secure control box door. 130 (50 Hz), 150-210 UNITS (And Associated Modular Units) 1. Install control wiring. The minimum wire size for installation is 16 AWG (American Wire Gage). Refer to Fig. 23 and 24 for proper wiring. Open the control box door. Locate unloader relays A and B (UA, UB) in place of the hot gas bypass relays as shown on the component arrangement diagram on the unit. Mount the relays with the field-supplied screws. Be careful not to damage the components and wiring in the area when mounting the relays. 2. Wire the control side. Wire the UA coil in series between J6-18 and J6-19 of the 4 IN/4 OUT module with the wires provided. Wire the UB coil in series between J6-21 and J6-22 of the same module with the wires provided. Locate the black wire in the control harness originating from TRAN5 labeled HGBPR-A-COM. Connect this wire to the UA terminal COM. Connect the wire labeled HGBPRA-NO to UA-NO. Connect the wire from UA-NO to TB3-5. For an extra unloader on circuit B, connect the wire labeled HGBPR-B-COM to UR-B-COM, and the wire labeled HGBPR-B-NO to UB-NO. Connect the wire from UB-NO to TB3-6. 3. Wire in the solenoid valves. NOTE: Wires external to the control box must be run in conduit. Terminal blocks are provided for easy field wiring. Use one of the isolated 7⁄8-in. (22-mm) holes in the side of the compressor electrical box with a strain relief to run the wires to the solenoid coil. Connect UA between TB3-5 and TB3-8. Connect UB between TB3-6 and TB3-8. Check all of the electrical connections for proper location and tightness, and replace and secure the electrical box of the compressor. 4. Configure the microprocessor. Once the relays are mounted in the control box, the microprocessor must be configured for the unloader option. To do so: a. Be sure the LOCAL/ENABLE-STOP-CCN switch is in the STOP position. standard). Then press (for 1 unloader on A1) or (for 2 unloaders on compressor A1). The display will now read either ‘‘NULA 1’’ or ‘‘NULA 2,’’ as appropriate. Press to get to the NULB display, and change this setting in the same manner as with circuit A. d. Once the configuration is complete, press , and the keypad LCD will display ‘‘LOGGEDON,’’ Press until the keypad LCD display reads ‘‘LOG OFF.’’ Press and the keypad LCD will display ‘‘EXIT LOG.’’ 5. Once the unloader heads are installed, the unit is checked for leaks, and the system is prepared for operation per the instructions for the compressor unloader head installation, check the output of the relays using the test function as follows: a. Press , and the display will read ‘‘COMP.’’ b. Press the to scroll down until the display reads ‘‘CPA1 OFF.’’ c. Press , and the compressor should start. d. Press , and the compressor should stop. e. Press f. Press until the display reads ‘‘UNA1 OFF.’’ , and the solenoid should energize. g. Press and the solenoid should deenergize. h. Use the and keys to check the remainder of the unloader coils. 6. Once the check has been performed, return the LOCAL/ ENABLE-STOP-CCN switch to the proper position. 7. Close and secure the control box door. 8. Start the unit and confirm that the chiller operates properly. 67 *Or HGBPR-A. †Or HGBPR-B. LEGEND C CB COMM HGBPR — — — — Contactor Circuit Breaker Communications Bus Hot Gas Bypass Relay PWR SW TRAN U — — — — Power Switch Transformer Unloader Fig. 23 — Accessory Unloader Control Wiring, All Units COM HGBPR NO SNB — — — — LEGEND Communications Bus TB — Terminal Block Hot Gas Bypass Relay TRAN — Transformer Normally Open U — Unloader Snubber Fig. 24 — Flotronic™ II 115/230-V (Unloader Wiring, 130 (50 Hz), 150-210 and Associated Modular Units (See Table 1) 68 FIELD WIRING Refer to Fig. 25-35 for field wiring. NOTE: Contacts must be rated for dry circuit application, capable of reliably switching a 5 vdc, 1 mA to 20 mA load. Fig. 25 — Demand Limit — Two External Switch Inputs Fig. 26 − Demand Limit — 4-20 mA Signal (Externally Powered) Fig. 30 — Remote Reset from 4-20 mA Signal (Internally Powered) TB — Terminal Block NOTE: Contacts must be rated for dry circuit application, capable of reliably switching a 5 vdc, 1 mA to 20 mA load. Fig. 27 — Demand Limit — 4-20 mA Signal (Internally Powered) Fig. 31 — Remote On/Off Fig. 28 — Remote Reset from Space or Outdoor-Air Temperature Fig. 32 — Remote Dual Set Point Control Fig. 29 — Remote Reset from 4-20 mA Signal (Externally Powered) CWP — Chilled Water (Fluid) Pump TB — Terminal Block Fig. 33 — Chilled Fluid Pump 69 TB — Terminal Block Fig. 34 — Remote Alarm CWP1 — Chilled Water (Fluid) Pump Interlock CWFS — Chilled Water (Fluid) Flow Switch (not required — low flow protection is provided by Flotronic™ II controls) TB — Terminal Block Fig. 35 — Interlocks REPLACING DEFECTIVE PROCESSOR MODULE The replacement part number is printed on a small label on the front of the PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior corner post. The proper software and unit configuration data is factory installed by Carrier in the replacement module. Therefore, when ordering a replacement processor module (PSIO), specify complete replacement part number, full unit model number, and serial number. If these numbers are not provided, the replacement module order is configured instead as a generic Flotronic II replacement module. This requires reconfiguration of the module by the installer. 4. Remove defective PSIO by removing its mounting screws with a Phillips screwdriver, and removing the module from the control box. Save the screws for later use. 5. Use a small screwdriver to set address switches S1 and S2 on the new PSIO module to exactly match the settings on the defective module. 6. Package the defective module in the carton of the new module for return to Carrier. 7. Mount the new module in the unit control box using a Phillips screwdriver and the screws saved in Step 4 above. 8. Reinstall all 6 wire connectors and the green ground wire. 9. Carefully check all wiring connections before restoring power. 10. Verify the LOCAL/ENABLE-STOP-CCN switch is in STOP position. 11. Restore control power. Verify the red and green lights on top of PSIO and front of each DSIO module respond as described in Control Modules section on page 63. The keypad and display module should also begin its rotating display. 12. Using the keypad and display module, press to verify that the software version number matches the ER (engineering requirement) number shown on the PSIO label. 13. Press to verify that the 7 factory configuration codes (CODE 1 through CODE 7) exactly match the codes listed for this unit model on the component arrangement label diagram on the control box door. If they are different or are all zeros, reenter the 7 codes. If any changes are required, the PSIO display becomes blank and reconfigures itself after pressing the key while displaying CODE 7. The display returns in approximately 15 seconds. NOTE: Codes with leading zeros in the configuration will be displayed starting with the first number greater than zero. 14. Press to verify each item is configured as needed Electrical shock can cause personal injury. Disconnect all electrical power before servicing. for this particular installation. Table 14 shows the factory configuration code default settings. Table 14 also shows the service replacement code default settings which are used if no model number was specified when ordering the replacement PSIO module. It is strongly suggested that the Start-Up Checklist for Flotronic II Chiller Systems (completed at time of original start-up) be used at this time to verify and/or reprogram the various options and configurations required for this job. 15. Press to verify that the 2 field configuration codes (codes 8 and 9) match exactly the codes listed on the label diagram on the control box door. If they are different, or are all zeros, reenter the 2 codes. 16. After completing the configuration steps outlined above, restore main power and perform a unit test as described in and sections on page 38. 17. Complete this procedure and restore chiller to normal operation by returning the LOCAL/ENABLE-STOPCCN switch to desired position. Installation 1. Verify the existing PSIO module is defective by using the procedure described in the Control Modules section on page 63. 2. Refer to Start-Up Checklist for Flotronic II Chiller Systems (completed at time of original start-up) found in job folder. This information is needed later in this procedure. If checklist does not exist, fill out the and configuration code sections on a new checklist. Tailor the various options and configurations as needed for this particular installation. 3. Check that all power to unit is off. Carefully disconnect all wires from defective module by unplugging the 6 connectors. It is not necessary to remove any of the individual wires from the connectors. Remove the green ground wire. 70 Copyright 1995 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. 563-079 Printed in U.S.A. Form 30GN-3T Pg 72 7-95 Replaces: 30G-1T Tab 5c

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