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Carrier 30GT060

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2. 1 INTRODUCTION 2 INSTALLATION 2 9 Step 1 Rig and Place the Unit 2 DOMESTIC UNITS EXPORT UNITS AND DOMESTIC UNITS WITH SKIDS PLACING UNIT Step 2 Check Compressor Mounting 2 Step 3 Cooler Fluid and Drain Piping Connections 0 0 0 0 cece eee 2 PREPARATION FOR YEAR ROUND OPERATION PREPARATION FOR WINTER SHUTDOWN Step 4 Make Electrical Connections 8 FIELD POWER CONNECTIONS FIELD CONTROL POWER CONNECTIONS 30GT040 070 Flotronic Reciprocating Liquid Chillers 50 60 Hz Page Step 5 Install Accessories 9 ELECTRICAL LOW AMBIENT OPERATION HOT GAS BYPASS MISCELLANEOUS ACCESSORIES PRE START UP 9 18 System Check uuuuuuus 9 QUICK Test ess te it aero ee eo cases 13 QUICK TEST STEPS 1 15 UNIT CONFIGURATION QUICK TEST STEPS 16 30 THERMISTORS AND SET POINT POTENTIOMETERS QUICK TEST STEPS 31 42 OUTPUT RELAYS START UP AND OPERATION 19 21 Digital Display Action 19 Actual Start Up 19 Operating Limitations 19 TEMPERATURES VOLTAGE MINIMUM FLUID LOOP VOLUME FLOW RATE REQUIREMENTS Operation Sequence 20 UNITS WITH EXV UNITS WITH STANDARD TXV LOAD SHED TEMPERATURE RESET HEAD PRES
3. in Cooler Inlet and Outlet Victaulic Type Inlet and Outlet 3 4 4 Drain 34 NPT T 30GT UNIT SIZE 070 C AL oo Les _ oso geo 68 2473 APPROX OPERATING WEIGHT kg Gc 1759 1825 1972 2357 2758 REFRIGERANT CHARGE pst kg 17 7 5 4 18 1 5 4 21 8 5 4 23 6 6 3 32 2 16 8 dixe Ck B Total Over Clear Glass 21 8 5 4 20 9 5 4 27 2 54 24 5 6 3 31 3 16 8 COMPRESSORS Type r s Reciprocating Semi Hermetic 24 2 06E No Ckt A 1 2250 1 6265 1 6275 1 6299 1 6265 F265 No Ckt B 1 F265 1 F275 1 F299 1 F299 1 F299 Oil Charge Compressor L 250 6 6 265 9 0 275 9 0 299 9 0 Capacity Control Steps 4 4 4 4 6 Ca Ckt A 42 4 47 6 43 3 50 0 58 0 Sap Ckt B 57 6 52 4 56 7 50 0 42 0 Minimum Step Capacity 21 2 31 7 28 8 33 3 19 3 CONDENSER FANS Type Propeller Direct Drive Standard Fan Speed r s 15 8 15 8 15 8 15 8 15 8 No Blades Diameter mm 6 762 6 762 6 762 6 762 6 762 No Fans Total kW 4 6 2 4 6 2 4 6 2 6 9 3 6 9 3 Total Airflow L s 16 517 16 517 16 045 24 540 24 068 High Static Fan Speed r s 24 24 24 24 24 No Blades Diameter mm 12 762 12 762 12 762 12 762 12 762 No Fans Total kW 4 14 8 4 14 8 4 14 8 6 22 2 6 22 2 Total Airflow L st 18 876 18 876 18 876 28 314 28 314 CONDENSER COILS Type Vertical and Horizontal Plate Fin Enhanced Tubing Tubes Copper OD mm 9 53 9 53 9 53 9 53 9 53 Fins m 669 669 669 669 669 No Rows Ckt A or B 2 2 3
4. Installation Start Up and COMMERCIAL UNITARY aia Service Instructions SAFETY CONSIDERATIONS Installing starting up and servicing this equipment can be hazardous due to system pressures electrical compo nents and equipment location roofs elevated structures etc Only trained qualified installers and service mechanics should install start up and service this equipment Untrained personnel can perform basic maintenance func tions such as cleaning coils All other operations should be performed by trained service personnel When working on the equipment observe precautions in the literature and on tags stickers and labels attached to the equipment Follow all safety codes Wear safety glasses and work gloves Use care in handling rigging and setting bulky equipment ELECTRIC SHOCK HAZARD Open all remote disconnects before servic ing this equipment IMPORTANT This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with these instructions may cause radio interference This equipment has been tested and found to comply with the limits of a Class A comput ing device as defined by FCC Federal Communica tions Commission U S A regulations Subpart J of Part 15 which are designed to provide reasonable pro tection against such interference when operated in a commercial environment CONTENTS Page SAFETY CONSIDERATIONS
5. C DROP V OHMS 32 0 100 049 16 0 7507 64 0 1090 31 5 97 006 16 5 7334 64 5 1070 31 0 94 061 17 0 7165 65 0 1050 30 5 91 209 17 5 7000 65 5 1030 30 0 88 449 18 0 6840 66 0 1011 29 5 85 777 18 5 6683 66 5 992 29 0 83 191 19 0 6531 67 0 973 28 5 80 687 19 5 6382 67 5 955 28 0 78 264 20 0 6237 68 0 937 27 5 75 918 20 5 6096 68 5 919 27 0 73 648 21 0 5959 69 0 902 26 5 71 451 21 5 5825 69 5 885 26 0 69 324 22 0 5694 70 0 868 25 5 67 265 22 5 5566 70 5 852 25 0 65 272 23 0 5442 71 0 836 24 5 63 344 23 5 5321 71 5 820 24 0 61 477 24 0 5203 72 0 805 23 5 59 670 24 5 5088 72 5 790 23 0 57 921 25 0 4976 73 0 775 22 5 56 228 25 5 4867 73 5 761 22 0 54 589 26 0 4760 74 0 746 21 5 53 003 26 5 4656 74 5 733 21 0 51 467 27 0 4555 75 0 719 20 5 49 980 27 5 4457 75 5 706 20 0 48 541 28 0 4360 76 0 693 19 5 47 148 28 5 4267 76 5 681 19 0 45 799 29 0 4175 77 0 669 18 5 44 492 29 5 4086 77 5 657 18 0 43 228 30 0 4000 78 0 645 17 5 42 003 30 5 3915 78 5 634 17 0 40 817 31 0 3832 79 0 623 16 5 39 668 31 5 3752 79 5 613 16 0 38 556 32 0 3674 80 0 602 15 5 37 478 32 5 3597 80 5 592 15 0 36 435 33 0 3523 81 0 583 14 5 35 424 33 5 3450 81 5 573 14 0 34 444 34 0 3379 82 0 564 13 5 33 495 34 5 3310 82 5 556 13 0 32 576 35 0 3243 83 0 547 12 5 31 685 35 5 3177 83 5 539 12 0 30 821 36 0 3113 84 0 531 11 5 29 984 36 5 3051 84 5 524 11 0 29 173 37 0 2990 85 0 516 10 5 28 386 37 5 2931 85 5 509 10 0 27 624 38
6. LI COOLER SIDE STD 3 VICTAULIC TYPE CONNECTION ELUID OUT STD 3 VICTAULIC TYPE CONNECTION TOP_VIEW CONDENSER COIL TOP OF FAN DECK 6 3 11 16 1922 31 6 13 16 1172 31 2 88 816 9 13 51 17 32 DIA 8 MTG HOLES 3 4 NPT COOLER DRAIN 040 655 51 1 3 4 ey 1489 0 TET 323 0 COOLER DRAIN 045 050 87 703 3 4 NPT 4 RIGGING HOLES 1117 1 2 5 8 66 7 DIA _ 8 3 5 16 2523 03 SIDE VIEW LEGEND a E C _ Copper Fins Copper Tubing Mtg Mounting NOTES 1 Unit must have clearances for airflow as follows TOP Do not restrict in any way ENDS 1524 5 ft SIDES 1829 6 ft 2 00 dia holes are recommended for parallel conductors on 040 and 045 208 230 V units 3 dia hole is recommended for single entry power on 050 208 230 V units Mounting holes may be used to mount unit to concrete pad They are not recommended for spring isolator location If spring isolators are used a perimeter support channel between the unit NO 0 RO N S 16 2319 33 OPTIONAL SOURD REDUCTION STACK 22 2 7 8 DIA 2 FIELO POWER SUPPLY CONTROL 4 3 5 16 0303 11 VIEW A A TOP VIEW OF CONTROL BOX SHELF WITH FIELD POWER SUPPLY CONNECTIONS tS y v2 7 1 1 2 38 1 2171 0 MOUNTING HOLES 7 4 1 27 2247 01 END VIEW FIELD POWER SUPPLY CONNECTIONS FIELD POWER SUPPLY 1 OR see NOTES 2 AND 3 AND F
7. Refrigerant Circuits 2 2 2 2 2 Net Fluid Volume Gal includes nozzles 10 9 13 5 13 5 18 0 18 0 Max Working Pressure Refrigerant Side Fluid Side psig Standard Cooler 278 300 Australian Code Cooler 207 150 FLUID CONNECTIONS in Cooler Inlet and Outlet Victaulic Type Inlet and Outlet 3 3 4 4 Drain 34 NPT a 30GT UNIT SIZE 070 C AL oo 610 Les 669 oso 749 EN NM 50 2280 APPROX OPERATING WEIGHT kg C C 1741 1800 1945 2339 2565 REFRIGERANT ORANGE kg kt A 17 7 5 4 18 1 5 4 21 8 5 4 23 6 6 3 31 7 6 8 Bee Ckt B Totalover Clear Glass 21 8 5 4 20 9 5 4 272 54 24 5 6 3 31 3 6 8 COMPRESSORS Type r s Reciprocating Semi Hermetic 29 2 06E No Ckt A 1 2250 1 2250 i 6265 E 6275 1 6299 No Ckt B 1 A250 1 F265 F275 F299 1 F299 Oil Charge Compressor L 250 6 6 AS 275 9 0 aa Capacity Control Steps 4 4 4 4 4 Ca Ck i 50 0 42 4 47 6 43 3 50 0 EE Ckt 50 0 57 6 52 4 56 7 50 0 Minimum Step Capacity 9 25 0 21 2 31 7 28 8 33 3 CONDENSER FANS Type Propeller Direct Drive Standard Fan Speed r s 19 19 19 19 19 No Blades Diameter mm 4 762 4 762 4 762 4 762 4 762 No Fans Total kW 4 6 2 4 6 2 4 6 2 6 9 3 6 9 3 Total Airflow L s 16 517 16 517 16 045 24 540 24 068 High Static Fan Speed r s 29 29 29 29 29 No Blades Diameter mm 12 762 12 762 12 762 12 762 12 762 No Fans Total kW 4 14 8 4 14 8 4 14 8 6 22 2 6 22 2 Total Airflow L st 18 876 18 876
8. to 216 ohms Normal display code for good sensors and po tentiometers is DI Display code indicates a faulty FAN ARRANGEMENT 30GT040 050 QUICK TEST DISPLAY NUMBER potentiometer thermistor or wiring A display indi cates a particular option is not being used i e demand limit not installed Tables 7 and 9 show set point potentiometer function lo cation and quick test display codes QUICK TEST STEPS 31 42 OUTPUT RELAYS These quick test steps allow microprocessor to check output sig nals from relay boards in unit control system In addition operation of all condenser fans and compressors is checked at each step Normal display code for steps En through ES is il In steps EG through when appropriate each compressor is started and allowed to run for approxi mately 10 seconds At start up will appear fol lowed by a EH in a few seconds At end of 10 second test code returns to display indicating that test step has been successfully completed Code EH in dicates that CPCS compressor protection circuit was tested Fan and compressor operating sequence for quick test steps En through are shown in Table 7 and Fig 10 If quick test steps do not operate as described a defect exists in one or more of the following Relay being tested electronic control and or unit wiring Refer to Controls and Troubleshooting publication for additional information Table 8 DIP Switch Functions DIP SWI
9. 0 2873 86 0 502 9 5 26 884 38 5 2816 86 5 496 9 0 26 168 39 0 2761 87 0 489 8 5 25 472 39 5 2707 87 5 483 8 0 24 798 40 0 2655 88 0 477 7 5 24 144 40 5 2603 88 5 472 7 0 23 509 41 0 2553 89 0 466 6 5 22 893 41 5 2504 89 5 461 6 0 22 296 42 0 2457 90 0 456 5 5 21 716 42 5 2410 90 5 451 5 0 21 153 43 0 2364 91 0 446 4 5 20 606 43 5 2320 91 5 441 4 0 20 076 44 0 2276 92 0 436 3 5 19 561 44 5 2234 92 5 432 3 0 19 061 45 0 2192 93 0 427 2 5 18 575 45 5 2152 93 5 423 2 0 18 103 46 0 2112 94 0 419 1 5 17 645 46 5 2073 94 5 415 1 0 17 199 47 0 2035 95 0 410 0 5 16 766 47 5 1997 95 5 406 0 0 16 346 48 0 1961 96 0 402 0 5 15 937 48 5 1925 96 5 398 1 0 15 539 49 0 1890 97 0 393 1 5 15 153 49 5 1856 97 5 389 2 0 14 777 50 0 1822 98 0 385 2 5 14 412 50 5 1789 98 5 380 3 0 14 057 51 0 1757 99 0 376 3 5 13 711 51 5 1725 99 5 371 4 0 13 375 52 0 1694 100 0 367 4 5 13 048 52 5 1663 100 5 362 5 0 12 730 53 0 1634 101 0 357 5 5 12 420 53 5 1604 101 5 352 6 0 12 119 54 0 1575 102 0 346 6 5 11 826 54 5 1547 102 5 341 7 0 11 541 55 0 1519 103 0 335 7 5 11 263 55 5 1492 103 5 330 8 0 10 992 56 0 1465 104 0 324 8 5 10 729 56 5 1438 104 5 318 9 0 10 472 57 0 1412 105 0 312 9 5 10 223 57 5 1387 105 5 305 10 0 9 979 58 0 1362 106 0 299 10 5 9 742 58 5 1337 106 5 292 11 0 9 512 59 0 1313 107 0 285 11 5 9 287 59 5 1289 12 0 9 068 60 0 1265 12 5 8 855 60 5 1242 13 0 8 647 61 0 1219 13 5 8 444 61 5 1197 14 0 8 247 62 0 1
10. 045 60 Hz Alt 040 50 Hz 045 60 Hz Att B1 045 50 Hz 050 60 Hz Att 045 50 Hz 050 60 Hz Att B1 050 50 Hz 060 60 Hz At 050 50 Hz 060 60 Hz Att B1 060 50 Hz 070 60 Hz Att 060 50 Hz 070 60 Hz Att B1 070 50 Hz Alt 070 50 Hz Ait B1 A1 A2 B1 A1 A2 B1 CONTROL STI 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 Compressor unloaded TCompressor unloader standard Compressor unloader accessory NOTES 1 The microprocessor has a random number generator that selects loading sequence A or B which in turn determines the compressor circuit that is energized first This balances operating hours on each circuit over an ex tended period of time 2 If unit operation is anticipated with system load below minimum unloaded capacity of chiller a Consider using 2 smaller units in place of the larger unit b Increase fluid loop volume to ensure adequate run time see Applica tion Data in Product Data literature c Consider adding accessory hot gas bypass package Microprocessor control also cycles condenser fans on and off to maintain an adequate pressure differential across ex pansion valves Fans are controlled by position of EXV and saturated condensing temperature thermistors T3 and T4 When expansion valve is fully open and superheat i
11. 2 3 Face Area m Ckt A and B Total 7 48 7 48 7 48 10 84 10 84 Max Working Pressure Refrigerant kPa 3103 COOLER No Type One Direct Expansion Shell and Tube No Refrigerant Circuits 2 2 2 2 2 Net Fluid Volume L includes nozzles 41 3 51 2 51 2 68 3 68 3 Max Working Pressure Refrigerant Side Fluid Side kPa Standard Cooler 1916 2068 Australian Code Cooler 1430 1034 FLUID CONNECTIONS in Cooler Inlet and Outlet Victaulic Type Inlet and Outlet 3 3 3 4 Drain 34 NPT LEGEND C AL Copper Tubing Aluminum Fins Condenser Coil C C Copper Tubing Copper Fins Condenser Coil OD Outside Diameter 06E250 compressors have 4 cylinders all others have 6 TBased on rated external static pressure of 0 4 or 1 0 in wg 100 Pa or 250 Pa as appropriate NOTE Facing the compressors Circuit A is on the right and Circuit B is on the left BOLT FLAT WASHER Fig 4 Compressor Mounting View FLAT PAN WASHER BOLT Fig 5 Compressor Mounting Bolt PREPARATION FOR WINTER SHUTDOWN Do not shut off control power disconnect during off season shut down At end of cooling season Drain the water from the system Replace the drain plug and add 2 gal 8 L of ethylene glycol to the cooler to prevent freezing of any remaining water in system Glycol can be added through the vent on top of cooler 3 Open one of the thermistor connections to allow air to escape the ves
12. 346 3 50 power supply require a separate 230 1 50 control power source For control circuit current draw see Table 4 Control circuit power draw includes the compressor crank case heaters at 180 watts each the cooler heaters if equipped at 210 watts each and the electronic board heater at 120 watts Sizes 040 050 have 2 cooler heaters sizes 060 and 070 have 4 cooler heaters CAUTION Crankcase and cooler heaters are all wired into the con trol circuit ahead of the control circuit switch There fore they are always active even if the control circuit switch is OFF An interlock circuit for external safeties such as the Chilled Water Fluid Flow Switch CWFS Remote On Off and Chilled Water Fluid Pump Interlock CWPI is provided between terminals TB6 3 and TB6 4 for field use To use this circuit remove the factory jumper and install the switches 00 nd ai B CONTROL WIRING SIDE POWER WIRING SIDE Fig 6 Control Box Step 5 Install Accessories ELECTRICAL Several electrical accessories are avail able to provide the following optional features for details refer to the Controls and Troubleshooting book Accessory temperature reset board and accessory therm istor used for any of the following types of temperature reset Return fluid temperature reset Space temperature reset r
13. 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 See Legend and Notes on page 11 Table 5 Compressor Electrical Data 12 COMPRESSOR NUMBERS Table 6 Condenser Fan Electrical Data 30GT UNIT HIGH STATIC CONDENSER FAN FLA ea LRA ea 208 230 60 460 60 575 60 380 60 346 50 380 415 50 208 230 60 460 60 575 60 380 60 346 50 380 415 50 208 230 60 460 60 575 60 E os oo CROOK o EH MM anal STIA PISTOIA S C GOL REEE Oi to V9 0 to IX on s to NN os co I9 m co I NS 346 50 380 415 50 208 230 60 460 60 575 60 380 60 346 50 380 415 50 208 230 60 460 60 575 60 380 60 346 50 380 415 50 See Legend and Notes on page 11 BESS A ESEE HA El R ica ea ea TL 00d En cde A FLO ONO WNANMWO WNAMWO WNANMWO WNAMDWO WN KM 9999 to 5 Check tightness of all electrical connections 6 Oil should be visible in the compressor sight glasses IMPORTANT Do not allow unit control circuit to See Fig 8 An acceptable oil level in the compressor is remain energized with showing in display for from Vs to s of sight glass Adjust the oil level as re more than 2 minutes If display button is not pressed quired No oil should be removed unless the crankcase within this time control will attempt to start unit heater has be
14. Close liquid line service valve before charging Weigh in charge shown on unit nameplate also in Tables 1 and 2 Open liquid line ser vice valve start unit and allow it to run several minutes fully loaded Check for a clear sight glass Be sure clear condition is liquid and not vapor DPT EXV OPT SPT T TXV CONDENSER CIRCUIT A CONDENSER CIRCUIT B COMPRESSORS FILTER LEGEND Discharge Pressure Transducer Ckt A or B Electronic Expansion Valve Oil Pressure Transducer Ckt A or B Suction Pressure Transducer Ckt A or B Thermistor Number Thermostatic Expansion Valve Not used with TXV Fig 11 Thermistor and Transducer Locations YE JT JT JE LLL TE TE dat LUI mil d man la aa aaa DE laman man T4 LA pasa had Im I eee Hi T4 SUPR E LPR LR OO T T T 9 TS TL mm LE ie ERES LLL HU DE 4 E G E IE E A Ear nu a T4 T3 Fig 12 Thermistor T3 and T4 Locations 22 Charging with Unit Running If charge is to be added while unit is operating all condenser fans and compressors must be operating It may be necessary to block condenser coils at low ambient temperatures to raise condensing pressure to approximately 280 psig 1931 kPa to turn all condenser fans on Do not totally block a coil to do this Partially block all coils in uniform pattern Charge each circuit until sight g
15. OFF AURA sum lt x ra no SEE NOTE 3 o Lr SEE NOTE cd Co T O UTI ci 1 eee cui curs lo 1 fespaceso a dr oe 380 VOLT 60HZ 346 380 415 VOLT S0HZ SHAFT 208 230 VOLT B0HZ 040 045 Se L A A ME 460 575 VOLT 60 HZ ALL UNITS E I GND NEUTRAL mp ap op a H TO 200 amp 400 AMP DISCONNECT OPTION 380 415 VOLT SOHZ 460 VOLT 60 HZ I t i mE H TT TT DEN H EXCEPT 050 346 280 415 VOLT 63 5 2 172 DIA HOLE d o a oh d ERN 1 1 JAEN OEC ME er e a SD no I LIED e 2 SEE NOTE 2 SEE NOTE 2 208 230 VOLT 60HZ 050 080 AND 070 UNITS TN POWER SIDE OF BOX 1 Factory wiring is in accordance with NEC Field modifica tions or additions must be in compliance with all applicable codes 2 Wiring for main field power supply must be rated 75 C mini mum Use copper copper clad aluminum or aluminum con ductors for all units 3 Power for control circuit should be supplied from a separate Source through a field supplied fused disconnect with 30 amp maximum protection for 115 v control circuits 15 amp maxi mum protection for 230 v control circuit for a unit with cooler heaters and 5 amp maximum for a unit without cooler heat ers Connect control circuit power to terminals 1 and 2 of TB4 Connect neutral side of supply to terminal 2 of TB4 Control circuit conductors for all units must be copper only tot Vr LIO 91 4 Terminals 3 and 4 of TB6 are for field
16. bal ancing Locate valves in return and supply cooler fluid lines as close to the chiller as possible Upon completion of the field piping installation in areas where the piping is exposed to 32 F 0 C or lower ambient temperatures freeze up protection is recommended using in hibited ethylene glycol or other suitable corrosion inhibitive antifreeze and electric heater tapes Heater tapes should have a rating for area ambient temperatures and should be cov ered with a suitable thickness of closed cell insulation Route power for the heater tapes from a separate fused disconnect Mount the disconnect within sight from the unit as pre scribed by local or NEC codes Identify disconnect as heater tape power source with warning that power must not be turned off except when servicing the unit IMPORTANT Before starting unit be sure all of the air has been purged from the system A drain connection is located at leaving fluid supply end of cooler See Fig 1 and 2 PREPARATION FOR YEAR ROUND OPERATION If unit is to operate all year round add sufficient inhibited eth ylene glycol or other suitable corrosion inhibitive anti freeze to the cooler water to prevent freeze up under cold operating conditions Consult local water authority on char acteristics of area water and a recommended inhibitor for the cooler fluid loop CENTER OF GRAVITY COMPRESSOR SIDE B CONTROL BOX END CENTER OF GRAVITY EOS COOLER
17. end of the compressor is from the inside of the unit All compressors can be removed from the com pressor side of the unit IMPORTANT All compressor mounting hardware and support brackets removed during servicing must be re installed prior to start up Following the installation of the new compressor Tighten discharge and suction service valves to Compressor s 20 25 ft lb 27 34 N m 06E250 80 90 ft Ib 109 122 N m 06E265 275 299 Tighten suction valves to 80 90 ft Ib 109 122 N m 06E250 90 120 ft Ib 122 163 N m 06E265 275 299 Tighten the following fittings to 120 in Ib 13 5 N m High Pressure Switch 120 in Ib 13 5 N m Loss of Charge Switch OIL CHARGE Refer to Table 13 All units are factory charged with oil Acceptable oil level for each compressor is from Vs to 8 of sight glass see Fig 8 When additional oil or a complete charge is required use only Carrier approved compressor oil Approved oils are as follows Petroleum Specialties Inc Cryol 150 factory oil charge Texaco Inc Capella WF 32 Witco Chemical Co Suniso 3GS 23 Table 13 Oil Charge COMPRESSOR OIL REQUIRED 06E250 6 6 06E265 9 0 06E275 9 0 06E299 9 0 Do not reuse drained oil and do not use any oil that has been exposed to atmosphere Cooler The cooler is easily accessible from the cooler side of the unit The refrigerant feed components are acces sible from the c
18. or other equip ment to which the chiller supplies liquid Consult manu facturer s instructions If the unit has field installed ac cessories be sure all are properly installed and wired correctly Refer to unit wiring diagrams 2 Backseat open compressor suction and discharge shut off valves Close valves one turn to allow refrigerant pres sure to reach the test gages Open liquid line service valves 4 Fill the chiller fluid circuit with clean water with rec ommended inhibitor added or other noncorrosive fluid to be cooled Bleed all air out of high points of system An air vent is included with the cooler If outdoor tem peratures are expected to be below 32 F 0 C suffi cient inhibited ethylene glycol or other suitable corrosion inhibitive antifreeze should be added to the chiller fluid circuit to prevent possible freeze up Uo TAG LEGEND A Alarm CWFS Chilled Water Fluid Flow madai RI MICROPROCESSOR Switch PORT Chilled Water Fluid Pump oe CWPI interlock X GND Ground NEC National Electrical Code U S A SS O A Outdoor Air PELLE TB Terminal Block CONTROL SIDE OF BOX enove siston X Sea Fed Power Wir E Field Control Wiring PT BRU X Factory Installed Wiring _ WE bye i A 460 VOLT 60 HZ TG JUMPER 1 1 i I FIELD CONTROL N POWER SUPPLY U U 122 2 7 8 DIA HOLE 22 2 7 8 DIA HOLE ALARM SHUT OFF SWITCH SEE NOTE REMOTE ON
19. point and rate of change of leaving fluid temperature If fluid temperature is very warm and pull down option is being used microprocessor limits rate of temperature drop of leaving fluid to 1 F 0 56 C per minute to avoid high peak kW charges If the capacity is being lim ited by pulldown the control display shows when the display button is pressed Once capacity has been sat isfied the unit starts to shut down Lag compressor will be shut down and lead compressor continues to run for 10 seconds to purge cooler of any refrigerant LOAD SHED If load shed option is being used control limits maximum capacity to load shed input value Refer to Controls and Troubleshooting publication for details If ca pacity is limited by a load shed signal display shows when display button is pressed TEMPERATURE RESET If temperature reset is being used microprocessor adjusts leaving fluid temperature to ob tain greater part load efficiency Refer to Controls and Trouble shooting book for details If leaving fluid temperature is being reset display shows EN when the display button is pressed HEAD PRESSURE CONTROL Units with EXV Microprocessor also controls EXV to main tain a superheat of 24 to 30 F 13 3 to 16 7 C entering compressor cylinders Table 12 Capacity Control Steps SEQUENCE A 30GT SEQUENCE B UNIT SIZE m v o g 3 2s o 040 60 Hz Alt 040 60 Hz Att B1 040 50 Hz
20. to obtain lower or higher temperature rises Minimum flow rates must be exceeded to assure turbulent flow and proper heat transfer in the cooler A CAUTION Operation below minimum flow could subject tubes to frost pinching in tube sheet resulting in failure of cooler Consult application data and job design requirements to determine flow rate requirements for particular installation Table 11 Nominal and Minimum Cooler Fluid Flow Rates MINIMUM FLOW RATE See Notes LEGEND ARI Air Conditioning and Refrigeration Institute U S A N Liters per kW V Gallons per ton Nominal flow rates required at ARI conditions 44 F 7 C leaving fluid temperature 54 F 12 C entering fluid temperature 95 F 35 C ambient Fouling factor 00025 ft hr F Btu 000044 m K W NOTES 1 Minimum flow based on 1 0 fps 0 30 m s velocity in cooler with out special cooler baffling 2 Minimum Loop Volumes Gallons V x ARI Cap tons Liters N x ARI Cap kW APPLICATION Normal Air Conditioning Process Type Cooling Low Ambient Unit Operation 20 Operation Sequence During unit off cycle crank case heaters are energized If ambient temperature is below 36 F 2 C cooler heaters and a microprocessor board heater are also energized When control ON OFF switch is turned to ON position control first goes through a 2 minute initialization period during which the display continuously shows
21. 175 14 5 8 055 62 5 1153 15 0 7 868 63 0 1132 15 5 7 685 63 5 1111 Other possible causes of improper refrigerant flow con trol could be restrictions in liquid line plugged filter dri er s stuck liquid line solenoid valve s or restricted meter ing slots in the EXV Formation of ice or frost on lower body of EXV is one symptom of restricted metering slots Clean or replace valve if necessary NOTE Frosting of valve is normal during quick test steps 3 5 and 3 9 and at initial start up Frost should dissipate after a 5 to 10 minute operation of a system that is oper ating properly If valve is to be replaced wrap valve with a wet cloth to prevent excessive heat from damaging internal components Superheat control built into valve is not adjustable NOTE The EXV orifice is a screw in type and may be re moved for inspection and cleaning Once the top cover has been removed the EXV motor may be taken out by remov ing the 2 cap screws securing motor to valve body Pull mo tor lead screw and the slide assembly up off the orifice as sembly A slot has been cut in top of orifice assembly to facilitate removal using a large screwdriver Turn orifice assembly coun terclockwise to remove When cleaning or reinstalling orifice assembly be careful not to damage orifice assembly seals The bottom seal acts as a liquid shut off replacing a liquid line solenoid valve Reassembly of valve is made easier by screwing the slide and
22. 18 876 28 314 28 314 CONDENSER COILS Type Vertical and Horizontal Plate Fin Enhanced Tubing Tubes Copper OD mm 9 53 9 53 9 53 9 53 9 53 Fins m 669 669 669 669 669 No Rows Ckt A or B 2 2 3 2 3 Face Area m Ckt A and B Total 7 48 7 48 7 48 10 84 10 84 Max Working Pressure Refrigerant kPa 3103 COOLER No Type One Direct Expansion Shell and Tube No Refrigerant Circuits 2 2 2 2 2 Net Fluid Volume L includes nozzles 41 3 51 2 51 2 68 3 68 3 Max Working Pressure Refrigerant Side Fluid Side kPa Standard Cooler 1916 2068 Australian Code Cooler 1430 1034 FLUID CONNECTIONS in Cooler Inlet and Outlet Victaulic Type Inlet and Outlet 3 3 3 4 4 Drain 34 NPT LEGEND 06E250 compressors have 4 cylinders all others have 6 TBased on rated external static pressure of 0 4 or 1 0 in wg 100 Pa or 250 Pa C AL Copper Tubing Aluminum Fins Condenser Coil C C Copper Tubing Copper Fins Condenser Coil OD Outside Diameter as appropriate NOTE Facing the compressors Circuit Ais on the right and Circuit B is on the left Table 2 Physical Data 50 Hz ENGLISH 30GT UNIT SIZE 040 os 050 060 070 C AL 3550 3736 3916 4780 5453 APPROX OPERATING WEIGHT Ib CC 3878 4024 4349 5197 6081 SETUP A so aona seno sona Ckt A 39 12 40 12 48 12 52 14 71 15 jas Ckt B TOotalOver clear Glass 48 12 46 12 60 12 54 14 69 15 COMPRESSORS Type rpm Reciprocat
23. 191 473 15 26 804 103 2 713 192 467 16 26 011 104 2 655 193 461 17 25 245 105 2 598 194 456 18 24 505 106 2 542 195 450 19 23 789 107 2 488 196 444 20 23 096 108 2 436 197 439 21 22 427 109 2 385 198 434 22 21 779 110 2 335 199 429 23 21 153 111 2 286 200 424 24 20 547 112 2 238 201 419 25 19 960 113 2 192 202 415 26 19 392 114 2 147 203 410 27 18 843 115 2 103 204 405 28 18 311 116 2 060 205 401 29 17 796 117 2 018 206 396 30 17 297 118 1 977 207 391 31 16 814 119 1 937 208 386 32 16 346 120 1 898 209 382 33 15 892 121 1 860 210 377 34 15 453 122 1 822 211 372 35 15 027 123 1 786 212 366 36 14 614 124 1 750 213 361 37 14 214 125 1 715 214 356 38 13 826 126 1 680 215 350 39 13 449 127 1 647 216 344 40 13 084 128 1 614 217 338 41 12 730 129 1 582 218 332 42 12 387 130 1 550 219 325 43 12 053 131 1 519 220 318 44 11 730 132 1 489 221 311 45 11 416 133 1 459 222 304 46 11 111 134 1 430 223 297 47 10 816 135 1 401 224 289 48 10 529 136 1 373 225 282 49 10 250 137 1 345 50 9 979 138 1 318 51 9 717 139 1 291 52 9 461 140 1 265 53 9 213 141 1 239 54 8 973 142 1 214 55 8 739 143 1 189 56 8 511 144 1 165 57 8 291 145 1 141 58 8 076 146 1 118 59 7 868 147 1 095 60 7 665 148 1 072 61 7 468 149 1 050 62 7 277 151 1 007 28 Table 16 Sensor Temperature C vs Resistance Voltage Drop TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE C DROP V OHMS C DROP V OHMS
24. 6 4740 5028 APPROX OPERATING WEIGHT Ib CC 3838 3969 4289 5157 5656 PAT ena sone sono sana Ckt A 39 12 40 12 48 12 52 14 70 15 tes Ckt B Total Ov r Clear Glass 48 12 46 12 60 12 54 14 69 15 COMPRESSORS Type rpm Reciprocating Semi Hermetic 1750 06E No Ckt A 2250 5 2250 z 6265 A 6275 1 6299 No Ckt B A250 F265 F275 F299 1 F299 Oil Charge Compressor pt 250 14 bara 275 19 sot Capacity Control Steps 4 4 4 4 4 G Ckt A 50 0 42 4 47 6 43 3 50 0 S ap Ckt B 50 0 57 6 52 4 56 7 50 0 Minimum Step Capacity 25 0 21 2 31 7 28 8 33 3 CONDENSER FANS Type Propeller Direct Drive Standard Fan Speed rpm 1140 1140 1140 1140 1140 No Blades Diameter in 4 30 4 30 4 30 4 30 4 30 No Fans Total kW 4 6 2 4 6 2 4 6 2 6 9 3 6 9 3 Total Airflow cfm 35 000 35 000 34 000 52 000 51 000 High Static Fan Speed rpm 1750 1750 1750 1750 1750 No Blades Diameter in 12 30 12 30 12 30 12 30 12 30 No Fans Total kW 4 14 8 4 14 8 4 14 8 6 22 2 6 22 2 Total Airflow cfmt 40 000 40 000 40 000 60 000 60 000 CONDENSER COILS Type Vertical and Horizontal Plate Fin Enhanced Tubing Tubes Copper OD in 0 375 0 375 7 0 375 Fins in 17 17 17 17 17 No Rows Ckt A or B 2 2 3 2 3 Face Area sq ft Ckt A and B Total 80 5 80 5 80 5 116 7 116 7 Max Working Pressure Refrigerant psig 450 COOLER No Type One Direct Expansion Shell and Tube No
25. Accessory Not used on units with thermostatic expansion valve All thermistors are identical in their temperature vs re sistance and voltage drop performance Resistances at vari ous temperatures are listed in Table 15 or 16 LOCATION General locations of thermistor sensors are shown in Fig 11 Cooler Leaving Fluid Sensor T1 Sensor TI is located in the leaving fluid nozzle The probe is in a well immersed in the fluid Actual location is shown in Fig 11 and 13 Cooler Entering Fluid Sensor T2 Sensor T2 is located in the cooler shell in first baffle space in close proximity to tube bundle The 4 in coupling is used Fig 21 Actual location is shown in Fig 11 and 13 Saturated Condensing Temperature Sensors T3 and T4 Sensors T3 and T4 are each clamped to outside of a return bend on condenser coil Exact locations for all units are shown in Fig 11 and 12 Evaporator Refrigerant Sensors T5 and T6 Sensors T5 and T6 are located next to refrigerant inlet in cooler head Thermistors are well type thermistors Typical location is Shown in Fig 11 and 13 Not used on units with TXV Compressor Return Gas Temperature Sensors T7 and T8 Sensors T7 and T8 are located in lead compressor in each circuit in a suction passage between motor and cylinders above oil pump They are well type thermistors Location is shown in Fig 11 Not used on units with TXV Remote Sensor T10 Sensor T10 is a
26. C below leaving temperature unit stops and is locked off Loss of Charge A pressure switch connected to high side of each refrigerant circuit protects against total loss of charge Switch settings are listed in Table 18 If switch is open unit cannot start if it opens during operation unit locks out and cannot restart until switch is closed Low charge is also monitored by the processor when an EXV is used A low charge is detected by monitoring EXV position and superheat entering the compressor If EXV is wide open su perheat is greater than 50 F 28 C and saturated cooler suction is less than 55 F 13 C circuit is stopped and locked off Relief Devices Fusible plugs are located in each cir cuit to protect against damage from excessive pressures HIGH SIDE PROTECTION One device is located be tween condenser and filter drier a second is on filter drier These are both designed to relieve on a temperature rise to approximately 210 F 99 C LOW SIDE PROTECTION A device is located on suc tion line designed to relieve on a temperature rise to ap proximately 170 F 77 C COMPRESSOR PROTECTION Pressure Relief Valves Valves for unit sizes 040 070 60 Hz and 040 060 50 Hz are installed in compressors A1 and B1 Valves for unit size 070 50 Hz are installed in com pressors A2 and B1 These valves are designed to relieve at 450 psig 3103 kPa These valves should not be capped If a valve relieves
27. HINGED ACCESS HINGED ACCESS OPTIONAL SOUND We PANEL REDUCTICN STACK POWER SIDE CONDENSER col PANEL KCONTROL SIDE 7 3 3 8 2918 81 LA 13 5 17 32 DIA 8 MTG HOLES T STE 3 3 0 PAIR a 85 8 2 U 67 8 lo 1 8 3 4 Ol Par 173 1 528 51 AB LN 1 2 13118 4 376 3 ener TT m 1345 01 1528 5 lt 11 176 COOLER E g Y 2 V4 280 9 DRAIN 362 0 4 x Lu Tt COUNTING HOLES 7 1 9 18 1 6 3 4 38 11 t2171 01 2173 0 RIGGING HOLES 476 1 R 2 2 5 8 65 7 DIA 7 4 1 2 107 3 2247 0 3125 01 EE SIDE VIEW END VIEW LEGEND Copper Fins Copper Tubing Mtg Mounting NOTES 1 2 Dimensions in are millimeters Unit must have clearances for airflow as follows T Do not restrict in any way FIELD POWER SUPPLY CONNECTIONS ENDS 1524 5 ft SIDES 1826 6 ft Unit 30GT Voltage Hz Diameter Qty Mounting holes may be used to mount unit to concrete pad They are not DIS recommended for spring isolator location 060 208 230 60 63 5 2 If spring isolators are used a perimeter support channel between the unit EZ and the isolators is recommended 070 208 230 60 3 2 Thru the door handles for non fused disconnect option on 380 415 v and 92 0 460 v units only When unit has non fused disconnect option power side 060 460 2v 1 door opens from r
28. IELI WER SUPPLY CONNECTIONS 5 7 1 4 2012 7 and the isolators is recommended Unit 30GT Voltage Diameter Qty Dimensions in are millimeters Thru the door handles for non fused disconnect option on 380 415 v and 040 045 208 230 1 460 v units only When unit has non fused disconnect option power side door opens from right side NOT left side as shown for standard units 050 208 230 2 040 3 5 Ae 3 1013Ae 4 51 0 1 11v8 040 050 575 1 1059 1189 1359 587 5 040C 3 57 3 11 4 512 1 11 040 050 380 1 1064 1194 1359 587 5 045 3 6 16 3 1013Ae 5 51 2 1 534e 040 045 50 1 1069 1189 1663 436 6 045C 3 63Ae 3 11 51 512 1 534e 050 50 1 1072 1194 1663 436 6 050 3 57 3 11 5 51 2 1 534e 040 045 380 415 50 1 1064 1194 1663 436 6 050C 3 6 3 113Ae 5 51 2 1 534e 050 380 415 50 1 1067 1199 1663 436 6 Fig 1 Dimensions 30GT040 050 3 C FIELD POWER SUPPLY 1 OR 2 COMPRESSOR SIDE mv ge gi CENTER OF GRAVITY 22 21 7 8 DIA 2 FIELD POWER SUPPLY CONTROL SEE FIELD POWER SUPPLY Nl TABLE 4 5 8 117 3 2 A 1 21 32 CONTROL 42 2 OUTSIDE OF Box BASERAIL CENTER OF GRAVITY SIDE 4 3 3 8 x 1305 2 COOLER VIEW A A TOP VIEW OF CONTROL 80X SHELF WITH FIELD POWER SUPPLY CONNECTIONS S 5 1651 0 ELUID QUI STD VICTAULIC TYPE CONNECTION STD 4 VICTAULIC TYPE CONNECTION TOP VIEW L 8 3 7 16 i 2525 0
29. Ninety 90 seconds after EM leaves display control begins to bring on compressors Rate at which compressors are started depends on leaving chilled fluid temperature and rate of change of leaving fluid temperature On all units an automatic lead lag feature in control sys tem determines by random selection either circuit A or B to start first At first call for cooling microprocessor starts first com pressor deenergizes crankcase heater and starts one con denser fan UNITS WITH EXV The EXV remains closed for 10 sec onds to purge cooler and suction line of any liquid refrig erant that may have migrated to these areas during off pe riod After 10 seconds EXV starts to open As more cooling is required control brings on additional stages of capacity Loading sequence for compressors is shown in Table 12 Lag compressor will shut down and lead compressor will continue to run After lag compressor has shut down the EXV is signaled to close Lead compressor remains on until EXV is less than 600 steps open and either the saturated suction temperature is less than 25 F 4 C as sensed by thermistor T5 or T6 or one minute has elapsed UNITS WITH STANDARD TXV Liquid line solenoid valve is not energized for first 10 seconds of compressor op eration This is called pumpout cycle Microprocessor determines how rapidly capacity stages are added or subtracted based on deviation from leaving chilled fluid temperature set
30. RS COOLER PROTECTION Relief Devices RA REREer iS 32 HIGH SIDE PROTECTION LOW SIDE PROTECTION COMPRESSOR PROTECTION Other Safeties 32 START UP CHECKLIST CL 1 to CL 4 INTRODUCTION These instructions cover installation start up and service of 30GT040 070 Flotronic liquid chillers with electronic controls and units with factory installed options FIOPs Standard chillers are equipped with electronic expansion valves EXVs and FIOP units have conventional thermo static expansion valves TXVs and liquid line solenoid valves LLSVs Differences in quick test procedures and operation sequence should be carefully noted when following these instructions Inspect the unit upon arrival for damage If damage is found file a claim right away with the shipping company When considering location for the unit be sure to consult National Electrical Code NEC U S A and local code requirements Allow sufficient space for airflow wiring piping and ser vice See Fig 1 and 2 Be sure surface beneath the unit is level and is capable of supporting the operating weight of the unit See Fig 3 and Tables 1 and 2 INSTALLATION Step 1 Rig and Place the Unit These units are designed for overhead rigging Lifting holes are provided in frame base channels see rigging label on unit Use spreader bars or frame to keep cables or chains clear of unit sides Run cables to a central s
31. SURE CONTROL REMOTE ON OFF REMOTE ALARM SERVICE aE RE A RA mop tts 21 32 Diagnostics and Troubleshooting 21 Refrigerant Circuit 21 LEAK TESTING e REFRIGERANT CHARGE Electronic Components 23 CONTROL COMPONENTS UNIT CONTROL BOX Compressors 23 COMPRESSOR REMOVAL OIL CHARGE Cooler ln ur Re RE UNUS 23 COOLER REMOVAL REPLACING COOLER SERVICING COOLER Condenser Coils 25 COIL CLEANING Condenser Fans 26 STANDARD CONDENSER FANS HIGH STATIC CONDENSER FANS Refrigerant Feed Components 26 ELECTRONIC EXPANSION VALVE EXV THERMOSTATIC EXPANSION VALVE TXV MOISTURE LIQUID INDICATOR FILTER DRIER LIQUID LINE SOLENOID VALVE LIQUID LINE SERVICE VALVE Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 002 Book 2 PC 903 Tab 5c Printed in U S A Form 30GT 49SI Pg 1 12 96 Replaces 30GT 41SI CONTENTS cont Thermistors i cole VERE 30 e LOCATION e REPLACING THERMISTOR T2 e REPLACING THERMISTORS T1 T5 T6 T7 AND T8 THERMISTORS T3 AND T4 THERMISTOR TEMPERATURE SENSOR CHECK Safety Devices 31 COMPRESSOR PROTECTION LOW OIL PRESSURE PROTECTION CRANKCASE HEATE
32. TCH NO SELECTED FUNCTION Type of Reset Reset Pulldown Limit Not Used Demand Limit 1 Unloader 2 Unloaders Brine ON OURO DIP Dual In Line Package Refer to Table 7 quick test steps 3 through 1 0 Table 9 Potentiometer Locations POTENTIOMETER P1 Leaving Fluid Set Point P3 Reset Limit Set Point P4 Demand Limit P5 Reset Ratio Set Point P6 Reset Temp Set Point LOCATION Set Point Board Standard Accessory Board Option Accessory Board Option Accessory Board Option Accessory Board Option CONTROLLED BY Compressor No A1 Ex 22 o o E Ex 59 3 4 Z 9 5 6 During quick test only Compressor No B1 First Stage of Condenser Fans wo N Second Stage of Condenser Fans wo oa Compressor No A1 Compressor No B1 First Stage of Condenser Fans m Second Stage of Condenser Fans Fig 10 Condenser Fan Sequence START UP AND OPERATION NOTE Complete Start Up Checklist at center of publica tion pages CL 1 to CL 4 prior to starting unit Digital Display Action The electronic control system uses a 2 digit LED light emitting diode display lo cated on display set point board see Fig 9 to show opera tional information and diagnostic codes When control ON OFF switch is turned to ON position display shows EH for 2 minutes to indicate control is in initialization mode Electronic expansion val
33. built into the microprocessor control See the following sec tions and Controls and Troubleshooting literature for more details STEPPER MOTOR 12 VDC LEAD SCREW PISTON SLEEVE ORIFICE ASSEMBLY INSIDE PISTON SLEEVE Fig 19 Electronic Expansion Valve EXV Follow steps below to diagnose and correct EXV problems Step 1 Check Processor EXV Outputs Check EXV out put signals at appropriate terminals on J7 terminal strip as follows 1 Turn power off 2 Connect positive test lead of meter to terminal 8 on con nector J7 see Fig 20 3 Set meter for approximately 20 vdc 4 Turn power on but do not enter quick test mode For the first 50 seconds valve motor windings are alternately en ergized to close valve in circuit 1 5 During this time connect negative test lead to terminals 9 10 11 and 12 in succession Voltage should rise and fall at each pin If it remains constant at a voltage or at 0 v remove connector and recheck If problem still ex ists replace processor board If problem no longer exists check EXV 6 Turn power off and connect positive lead to terminal on connector J7 7 Turn power on After 50 seconds motor windings in cir cuit 2 valve will begin to be energized 8 During this time connect negative test lead to terminals 2 3 4 and 5 Voltage should rise and fall at each pin If it remains constant at a voltage or at 0 v remove con nector and rech
34. connection of remote 63 51 2 1 27 DIA HOLE awe de ke ke lele 4 ON OFF control CWPI and CWFS The contacts must be peer om ws 52 1 S DIA WAE LANES FUSED DISCOWECT 1 rated for dry circuit application capable of reliably switching GEE NOTE 2 a 5 vdc 5 mA load Remove jumper between 3 and 4 of TB6 if remote ON OFF is installed 5 The maximum load allowed for the remote alarm circuit is 75 va sealed 360 va inrush at 115 or 230 v depending on model Remove resistor across terminals 1 and 2 of TB5 when using remote alarm 6 Dimensions in are millimeters Fig 7 Field Wiring 10 Table 3 Unit Electrical Data STANDARD CONDENSER FAN Rec Supplied S LT N Pw xt rw xe ew xe ew VOLTAGE 30GT UNIT SIZE MCA Nameplate 208 230 60 806 60 040 380 60 346 50 380 415 50 208 230 60 806 60 045 380 60 346 50 380 415 50 HIGH STATIC CONDENSER FAN 208 230 60 806 60 050 380 60 346 50 380 415 50 208 230 60 060 380 60 346 50 380 415 50 208 230 60 806 60 070 380 60 346 50 380 415 50 UNIT POWER V Ph Hz V Ph Hz 208 230 3 60 460 3 60 5753 60 380 360 346 350 380 415 3 50 230 1 50 AMPS U L 30 30 30 15 5t 15 5t 15 5t LEGEND AND NOTES FOR ELECTRICAL DATA FOR TABLES 3 6 LEGEND FLA Full Load Amps Fan Motors ICF Maximum Instantaneous Current Flow during starting the point in the starting sequence where the sum of the LRA for th
35. e start ing compressor plus the total RLA for all running compressors lus the total FLA for all running fan motors is maximum kW Total condenser fan motor power input LRA Locked Rotor Amps MCA Minimum Circuit Amps for wire sizing complies with NEC Section 430 24 MOCP Maximum Overcurrent Protective Device Amps NEC National Electrical Code U S A PW Part Wind Start Rec Fuse Recommended dual element fuse amps 150 of largest com Size pressor RLA plus 100 of sum of remaining compressor RLAs Size up to the next larger standard fuse size RLA Rated Load Amps Compressors XL Across the Line Start Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits Maximum allowable phase imbalance is voltage 2 amps 10 TFirst value is for chiller with cooler heater Second value if applicable is for chiller without cooler heater Numbers in indicate quantity NOTES 1 All units have single point primary power connection Main power must be supplied from a field supplied disconnect 11 2 The unit control circuit power 115 v 1 ph for 208 230 460 and 575 v units 230 v 1 ph for all other voltages must be supplied from a separate source through a field supplied disconnect The control circuit transformer accessory may be applied to power from primary unit power 3 Crankcase a
36. eck If problem still exists replace pro cessor board If there is no longer a problem check EXV Step 2 Check EXV Wiring Check wiring to EXVs from J7 terminal strip on processor board see Fig 20 1 Check color coding and wire connections Make sure wires are connected to correct terminals at J7 and EXV plug connections 2 Check for continuity and tight connection at all pin terminals 3 Check plug connections at J7 and at EXVs Be sure EXV connections are not crossed Step 3 Check Resistance of EXV Motor Windings Re move plug at J7 terminal strip and check resistance between common lead red wire terminal D and remaining leads A B C and E Resistance should be 25 ohms 2 ohms Step 4 Check Thermistors that Control EXV Check thermistors that control processor output voltage pulses to EXVs Circuit A thermistors are T5 and T7 and circuit B thermistors are T6 and T8 Refer to Fig 11 for location PROCESSOR BOARD EXV Electronic Expansion Valve Fig 20 Processor Board Connections 27 ra Use quick test steps 2 0 through 2 3 to determine if ther mistors are shorted or open 2 Check thermistor calibration at a known temperature by measuring actual resistance and comparing value mea sured with values listed in Tables 15 and 16 3 Make sure that thermistor leads are connected to proper pin terminals at J1 terminal strip on processor board and that therm
37. efer to separate installation instructions for low ambient operation Motormaster III con trol Contact your Carrier representative for details High Cooler LWT leaving fluid temperature During start up with leaving fluid temperatures above approximately 60 F 16 C expansion valves EXV and optional factory installed TXV will limit suction pressure to approximately 90 psig 620 kPa to avoid overloading compressor Low Cooler LWT Application of chillers within 39 9 F to 34 F 4 4 C to 1 1 C temperature range is possible in some situations with proper field change of control configuration This requires that DIP switch no 8 brine switch of S1 on the processor board be set to ON position See Tables 7 and 8 DIP switch requires modification below this A WARNING Do not operate with leaving water temperature below 34 F 1 1 C Application in the range 34 F to 15 F 1 C to 9 4 C requires chiller with factory modifica tion for brine duty Contact your Carrier representative for details VOLTAGE Main Power Supply Minimum and maximum acceptable supply voltages are listed in Table 3 Unbalanced 3 Phase Supply Voltage Never operate a mo tor where a phase imbalance between phases is greater than 2 To determine percentage of voltage imbalance max voltage deviation from avg voltage Voltage Imbalance 100 x average voltage The maximum voltage deviation is the largest difference be tween a vo
38. en energized for at least 24 hours See Oil Charge section on page 23 for Carrier approved oils 7 Electrical power source must agree with unit nameplate 8 Crankcase heaters must be firmly locked into compres o i S HIGH PRESSURE SWITCH THERMISTOR sors and must be on for 24 hours prior to start up EACH COMPRESSOR REFRIGERANT TEMPERATURE 9 Fan motors are 3 phase Check rotation of fans during ENTERING CYLINDERS the quick test Fan rotation is clockwise as viewed from top of unit If fan is not turning clockwise reverse 2 of the power wires 10 Check compressor suspension Snubber washers for noise suppression can be moved with finger pressure 11 Perform quick test to verify proper settings See Con trols and Troubleshooting literature for more details Quick Test See Fig 9 and Table 7 Both main HIGH SIDE OIL power and control circuit power must be on PRESSURE i m MN CONNECTION The quick test program utilizes a 2 digit LED display Fig 9 on set point board to show status of all input and output signals to microprocessor control Display action and LOW BERGE quick test procedure are described as follows PRESSURE The quick test is a 42 step program that provides a means CONNECTION of checking all input and output signals of microprocessor control prior to unit start up Check ensures that all control options thermistors and status switches are in proper work SE ing order e To initiate the q
39. equires accessory thermistor Outdoor air temperature reset requires accessory thermistor Chilled fluid flow switch LOW AMBIENT OPERATION If operating tempera tures below 0 F 18 C are expected refer to separate in stallation instructions for low ambient operation Motormaster III control HOT GAS BYPASS Hot gas bypass usually is not rec ommended because it results in application of equipment out of its normal design application range However if its use is required the appropriate hot gas bypass package may be used For installation details refer to separate instructions sup plied with the accessory package MISCELLANEOUS ACCESSORIES For applications re quiring special accessories the following packages are avail able Condenser Hail Guard Gage Panel Security Grille Package Condenser Fan Sound Reduction Kit and CPCS Compressor Protection Control System packages PRE START UP IMPORTANT Before beginning Pre Start Up or Start Up complete Start Up Checklist for Flotronic Chiller Systems at center of this publication The Checklist assures proper start up of a unit and provides a record of unit condition application requirements system in formation and operation at initial start up Do not attempt to start the chiller until following checks have been completed System Check 1 Check all auxiliary components such as the chilled fluid circulating pump air handling equipment
40. ermittent con nections between processor board terminals and EXV plug Recheck all wiring connections and voltage signals Table 15 Sensor Temperature F vs Resistance Voltage Drop TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE F DROP V OHMS F DROP V OHMS F DROP V OHMS 25 98 010 63 7 091 152 986 24 94 707 64 6 911 153 965 23 91 522 65 6 735 154 945 22 88 449 66 6 564 155 925 21 85 485 67 6 399 156 906 20 82 627 68 6 237 157 887 19 79 871 69 6 081 158 868 18 77 212 70 5 929 159 850 17 74 648 71 5 781 160 832 16 72 175 72 5 637 161 815 15 69 790 73 5 497 162 798 14 67 490 74 5 361 163 782 13 65 272 75 5 229 164 765 12 63 133 76 5 101 165 749 11 61 070 77 4 976 166 734 10 59 081 78 4 855 167 719 9 57 162 79 4 737 168 705 8 55 311 80 4 622 169 690 7 53 526 81 4 511 170 677 6 51 804 82 4 403 171 663 5 50 143 83 4 298 172 650 4 48 541 84 4 195 173 638 3 46 996 85 4 096 174 626 22 45 505 86 4 000 175 614 1 44 066 87 3 906 176 602 0 42 678 88 3 814 177 591 1 41 339 89 3 726 178 581 2 40 047 90 3 640 179 570 3 38 800 91 3 556 180 560 4 37 596 92 3 474 181 551 5 36 435 93 3 395 182 542 6 35 313 94 3 318 183 533 7 34 231 95 3 243 184 524 8 33 185 96 3 170 185 516 9 32 176 97 3 099 186 508 10 31 201 98 3 031 187 501 11 30 260 99 2 964 188 494 12 29 351 100 2 898 189 487 13 28 472 101 2 835 190 480 14 27 624 102 2 773
41. errules are now at tached to the sensor which can be withdrawn from cou pling for service REPLACING THERMISTORS T1 T5 T6 T7 AND T8 Add a small amount of thermal conductive grease to ther mistor well Thermistors are friction fit thermistors which must be slipped into receivers located in the cooler leaving fluid nozzle for T1 in the cooler head for T5 and T6 EXV units only and in the compressor pump end for T7 and T8 EXV units only THERMISTORS T3 AND T4 These thermistors are lo cated on header end of condenser coil They are clamped on a return bend THERMISTOR TEMPERATURE SENSOR CHECK A high quality digital volt ohmmeter is required to perform this check 1 Connect the digital voltmeter across the appropriate thermistor terminals at the J1 terminal strip on the pro cessor board see Fig 22 and Fig 9 Using the voltage reading obtained read the sensor temperature from Table 15 or 16 To check thermistor accuracy measure temperature at probe location with an accurate thermocouple type temperature measuring instrument Insulate thermo couple to avoid ambient temperatures from influencing reading Temperature measured by thermocouple and tem perature determined from thermistor voltage reading should be close 5 F 3 C if care was taken in applying ther mocouple and taking readings 2 If a more accurate check is required unit must be shut down and thermistor removed and checked at a known tempe
42. evel and strong enough to support operating weight of unit see Fig 3 and Tables 1 and 2 Weights at unit sup port points are shown in Fig 3 Bolt unit securely to pad when unit is positioned and leveled Fasteners for mounting unit are field supplied Check that unit is mounted levelly to ensure proper oil return to compressors If vibration isola tors field supplied are required for a particular installation refer to unit weight distribution in Fig 3 to aid in proper selection of isolators Step 2 Check Compressor Mounting All compressors on 30GT040 070 units are mounted on pans and are held down by 4 bolts during shipment After unit is in stalled loosen each of these bolts until the flat washer can be moved with finger pressure See Fig 4 and 5 Step 3 Cooler Fluid and Drain Piping Con nections When facing cooler side of unit inlet re turn fluid connection is on the right nearest the control box Outlet supply fluid connection is on the left The cooler has fluid side victaulic type connections follow connection directions as provided by the coupling manufacturer If ac cessory grilles have been added holes must be cut in grilles for field piping and insulation Although cooler has an air vent it is recommended that field supplied air vents be installed at the highest point in the system to facilitate servicing Field supplied shut off valves should also be installed to facilitate servicing and flow
43. first sign of moisture in system IMPORTANT Unit must be in operation at least 12 hours before moisture indicator can give an accu rate reading With unit running indicating element must be in contact with liquid refrigerant to give true reading FILTER DRIER Whenever moisture liquid indicator shows presence of moisture replace filter driers There is one filter drier on each circuit LIQUID LINE SOLENOID VALVE All units have a liq uid line solenoid valve to prevent liquid refrigerant migra tion to low side of system during the off cycle 30 LIQUID LINE SERVICE VALVE This valve is located immediately ahead of filter drier and has a 4 in Schrader connection for field charging In combination with compres sor discharge service valve each circuit can be pumped down into the high side for servicing Thermistors Electronic control uses 4 to 9 ther mistors to sense temperatures used to control the operation of chiller See Table 17 for thermistors used Table 17 Temperature Sensors Thermistors SENSOR TEMPERATURE T1 Cooler Leaving Fluid T2 Cooler Entering Fluid T3 Saturated Condensing Temperature Circuit A T4 Saturated Condensing Temperature Circuit B T5 Evaporator Refrigerant Temperature Circuit A T6 Evaporator Refrigerant Temperature Circuit B T7 Compressor Return Gas Temperature Circuit A T8 Compressor Return Gas Temperature Circuit B T10 Remote Temperature Sensor
44. ge the fluid of all air before start ing unit 9 Open the discharge service valves close the circuit break ers and open the liquid line service valves for the compressors SERVICING COOLER When cooler heads and partition plates are removed tube sheets are exposed showing ends of tubes A CAUTION Certain tubes in the 10HB coolers cannot be removed Eight tubes in the bundle are secured inside the cooler to the baffles and cannot be removed These tubes are marked by a dimple on the tube sheet See Fig 14 If any of these tubes have developed a leak plug the tube s as described under Tube Plugging section below Tube Plugging A leaky tube can be plugged until retub ing can be done The number of tubes plugged determines how soon cooler must be retubed Tubes plugged in the area of thermistor T2 particularly the tube that thermistor T2 is adjacent to will affect unit reliability and performance Ther mistor T2 is used in the freeze protection algorithm for the controller If several tubes require plugging check with your local Carrier representative to find out how number and lo cation can affect unit capacity Figure 15 shows an Elliott tube plug and a cross sectional view of a plug in place CAUTION Use extreme care when installing plugs to prevent dam age to the tube sheet section between the holes Fig 14 Typical Tube Sheets Cover Off Non Removable Tubes Fig 15 El
45. held OFF by the remote ON OFF switch ap pears in the display when the display button is pressed REMOTE ALARM See Fig 7 for remote alarm field wiring Remove the resistor across terminals and on TB5 when remote alarm is being used SERVICE ELECTRIC SHOCK HAZARD Turn off all power to unit before servicing The ON OFF switch on control panel does not shut off control power use field disconnect Diagnostics and Troubleshooting Refer to Con trols and Troubleshooting book For field service use a field installed Ground Fault Inter rupter GFI convenience outlet is available as an accessory for the 208 230 460 and 575 v units The GFI outlet is rated for 15 amps However in units with active cooler heat ers only 8 amps are available Refrigerant Circuit LEAK TESTING Units are shipped with complete op erating charge of refrigerant R 22 see Tables 1 and 2 and should be under sufficient pressure to conduct a leak test If there is no pressure in the system introduce enough nitro gen to search for the leak Repair the leak using good re frigeration practices After leaks are repaired system must be evacuated and dehydrated REFRIGERANT CHARGE Refer to Tables 1 and 2 Im mediately ahead of filter drier in each circuit is a factory installed liquid line service valve Each valve has a Va in Schrader connection for charging liquid refrigerant Charging with Unit Off and Evacuated
46. iewed from above If necessary to reverse fan rotation direction switch any 2 power leads TOP OF VENTURI TOP OF VENTURI ON FAN DECK ON FAN DECK 1 27 7 9 13mm m m HUB HUB ALL 50 Hz ALL 60 Hz UNITS UNITS VENTURI NOTE Fan rotation is clockwise as viewed from top of unit Fig 17 Condenser Fan Adjustment for Units with Standard Condenser Fans TOP OF FAN DECK 54 6mm 2 15 in ORIFICE 3mm 0 12 in Units with High Static Fan Option 26 Refrigerant Feed Components Each circuit has all necessary refrigerant controls ELECTRONIC EXPANSION VALVE EXV A cutaway drawing of valve is shown in Fig 19 High pressure liquid refrigerant enters valve through bot tom A series of calibrated slots have been machined in side of orifice assembly As refrigerant passes through orifice pres sure drops and refrigerant changes to a 2 phase condition liquid and vapor To control refrigerant flow for different operating conditions sleeve moves up and down over ori fice and modulates orifice size Sleeve is moved by a linear stepper motor Stepper motor moves in increments and is con trolled directly by processor board As stepper motor rotates motion is transferred into linear movement by lead screw Through stepper motor and lead screw 1500 discrete steps of motion are obtained The large number of steps and long stroke results in very accurate control of refrigerant flow The valve orifice begi
47. ight side NOT left side as shown for standard units 63 5 070 460 60 1 UNIT 30GT DIMENSIONS B 060 070 575 60 1 060 3 67 4 10 6 3 7 4 109A6 on 1092 1488 060 070 346 50 1 070 3 6 4 1012 m al T m 060 070 380 415 50 1 694g A078 070C 1072 1496 Fig 2 Dimensions 30GT060 070 CONTROL BOX MOUNTING WEIGHTS 60 Hz UNITS 30GT CONDENSER SIZE i ae ae WD oec uj D id 895 406 968 439 dE 943 428 1015 460 Tn 976 443 492 m 562 1344 560 552 609 537 590 070 6 60 66 50 Hz UNITS 30GT cONDENSER m 410 443 nie 420 452 hse 447 496 neo 561 609 mo 612 684 LEGEND Points A B C and D are located in the corners of the unit See Fig 1 and 2 for dimensions C AL Copper Tubing Aluminum Fins TContact your local Carrier representative for more information on Epoxy coated and pre coated C C Copper Tubing Copper Fins aluminum fins NOTE If spring isolators are used a perimeter support channel between the unit and the isolators is recommended RIGGING CENTER OF GRAVITY 30GT 070 UNIT SIZE im mm in mm in mm i mm in mm Dimension 46 346 1189 461 6 1189 47 1194 58 6 1481 5812 1486 FEN 4116 1059 424416 1069 4178 1064 42 1090 42 1067 Fig 3 Mounting Weights Approximate Table 1 Physical Data 60 Hz ENGLISH 30GT UNIT SIZE 090 045 oso oo 070 C AL 3550 3681 385
48. ing Semi Hermetic 1450 06E No Ckt A 2250 5 6265 5 6275 5 6299 1 6265 1 F265 No Ckt B F265 F275 F299 F299 1 F299 Oil Charge Compressor pt ani C SIERO 299 19 Capacity Control Steps 4 4 4 4 6 C C 42 4 47 6 43 3 50 0 58 0 Sap Ckt B 57 6 52 4 56 7 50 0 42 0 Minimum Step Capacity 21 2 31 7 28 8 33 3 19 3 CONDENSER FANS Type Propeller Direct Drive Standard Fan Speed rpm 950 950 950 950 950 No Blades Diameter in 6 30 6 30 6 30 6 30 6 30 No Fans Total kW 4 6 2 4 6 2 4 6 2 6 9 3 6 9 3 Total Airflow cfm 35 000 35 000 34 000 52 000 51 000 High Static Fan Speed rpm 1445 1445 1445 1445 1445 No Blades Diameter in 12 30 12 30 12 30 12 30 12 30 No Fans Total kW 4 14 8 4 14 8 4 14 8 6 22 2 6 22 2 Total Airflow cfmt 40 000 40 000 40 000 60 000 60 000 CONDENSER COILS Type Vertical and Horizontal Plate Fin Enhanced Tubing Tubes Copper OD in 0 375 0 375 0 375 0 375 375 Fins in 17 17 17 17 17 No Rows Ckt A or B 2 2 3 2 3 Face Area sq ft Ckt A and B Total 80 5 80 5 80 5 116 7 116 7 Max Working Pressure Refrigerant psig 450 COOLER No Type One Direct Expansion Shell and Tube No Refrigerant Circuits 2 2 2 2 2 Net Fluid Volume Gal includes nozzles 10 9 18 5 18 5 18 0 18 0 Max Working Pressure Refrigerant Side Fluid Side psig Standard Cooler 278 300 Australian Code Cooler 207 150 FLUID CONNECTIONS
49. istor probes are located in proper position in refrigerant circuit Fig 11 and 13 When above checks have been completed actual opera tion of EXV can be checked by using procedures outlined in Step 5 Check Operation of the EXV section below Dur ing quick test steps 3 5 and 3 9 each EXV is opened ap proximately 500 steps by processor This quick test feature along with initialization mode can be used to verify proper valve operation Step 5 Check Operation of the EXV Use following procedure to check actual operation of EXVs 1 Close liquid line service valve for circuit to be checked and run through appropriate quick test step 3 5 or 3 9 to pump down low side of system Repeat quick test step 3 times to ensure all refrigerant has been pumped from low side and that EXV has been driven fully open 1500 steps open NOTE Do not use control ON OFF switch to recycle con trol during this step and be sure to allow compressors to run full 10 seconds at each step 2 Turn OFF control circuit switch and compressor circuit breaker s Close compressor service valves and remove any remaining refrigerant from low side of system 3 Remove screws holding top cover of EXV Carefully re move top cover using caution to avoid damage to the O ring seal and motor leads If EXV plug was disconnected dur ing this process reconnect it after the cover is removed 4 Note position of lead screw see Fig 19 If valve has re
50. it should be replaced If valve is not re placed it may relieve at a lower pressure or leak due to trapped dirt from the system which may prevent resealing The pressure relief valves are equipped with a in SAE Society of Automotive Engineers U S A flare for field con nection Some local building codes require that relieved gases be removed This connection will allow conformance to this requirement Other Safeties There are several other safeties that are provided by microprocessor control For details refer to Controls and Troubleshooting literature Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 002 Printed in U S A Book 2 PC 903 Tab 5c Form 30GT 49SI Pg 32 12 96 Replaces 30GT 41SI
51. lass shows clear liquid then weigh in amount over a clear sight glass as listed in Tables 1 and 2 IMPORTANT When adjusting refrigerant charge cir culate fluid through cooler continuously to prevent freez ing and possible damage to the cooler Do not over charge and never charge liquid into low pressure side of system Electronic Components CONTROL COMPONENTS Unit uses an advanced elec tronic control system that normally does not require service For details on controls refer to Controls and Troubleshoot ing book UNIT CONTROL BOX Viewed facing compressors con trol box is at left end of unit All incoming power enters through box Control box contains power components and electronic controls Outer panels are hinged and latched for easy open ing Remove screws to remove inner panels Outer panels can be held open for service and inspection by using door retainer on each panel Remove bottom pin from door re tainer assembly swing retainer out horizontally and engage pin in one of the retainer ears and the hinge assembly Compressors If lead compressor on either refriger ant circuit becomes inoperative for any reason circuit is locked off and cannot be operated due to features built into the elec tronic control system Do not attempt to bypass controls to force compressors to run COMPRESSOR REMOVAL Access to the pump end of the compressor is from the compressor side of the unit Ac cess to the motor
52. lay button twice for each step until step to be rechecked is reached The quick test program is divided into 3 sections as described below and shown in Table 7 For more detailed information refer to Controls and Troubleshooting publication QUICK TEST STEPS 1 15 UNIT CONFIGURATION Microprocessor in unit control system is programmed by 2 switch assemblies located on processor board Fig 9 Con figuration header is factory set and cannot be changed in the field The DIP dual in line package switch assembly con tains 8 microswitches that must be set in accordance with various options and accessories selected As shipped from factory all DIP switches except those controlling pulldown option switch no 3 and compressor unloaders on com pressor B1 switch no 7 are in OFF position Switch no 8 is in OFF position for water units and in ON position for brine units All DIP switches should be checked and set to proper position for options selected during quick test The DIP switch assembly functions and display codes are shown in Fig 9 and in Table 8 Refer to Controls and Trouble shooting publication for details QUICK TEST STEPS 16 30 THERMISTORS AND SET POINT POTENTIOMETERS In these steps micropro cessor checks resistance values of all sensors and set point potentiometers to ensure they are functional and set within proper range for unit configuration Nominal resistance values for all sensors range from 363 000
53. lead screw assembly out of the motor Align hole in top of slide with the guide pin in orifice assembly and gently push slide and lead screw onto orifice assembly about half way Screw motor onto lead screw and secure EXV motor with cap screws Be careful not to twist or pull on wires from EXV motor to valve cover pin connections Check EXV op eration in test steps outlined on page 27 THERMOSTATIC EXPANSION VALVE TXV The FIOP chiller is equipped with conventional TXV one per circuit This control system necessitates use of a liquid line solenoid valve TXV is factory set to maintain 8 to 10 F 4 4 to 5 6 C superheat of vapor leaving cooler by controlling flow of refrigerant into cooler Superheat can be reset but should be done only if absolutely necessary When TXV is used thermistors T5 T6 T7 and T8 are eliminated see Fig 11 TXV also incorporates an MOP feature to limit cooler suc tion to 55 F 13 C making it possible for com pressor to start at higher cooler fluid temperatures without overloading MOISTURE LIQUID INDICATOR Clear flow of liquid refrigerant indicates sufficient charge in system Bubbles in the sight glass indicate undercharged system or presence of noncondensables Moisture in system measured in parts per million ppm changes color of indicator Green moisture is below 45 ppm Yellow green chartreuse 45 to 130 ppm caution Yellow wet above 130 ppm Change filter drier at
54. liott Tube Plug Retubing See Table 14 When retubing is to be done obtain service of qualified personnel experienced in boiler maintenance and repair Most standard procedures can be fol lowed when retubing the 10HB coolers An 846 crush is rec ommended when rolling replacement tubes into the tube sheet An 896 crush can be achieved by setting the torque on the gun at 48 to 50 in Ib 5 4 to 5 6 N m The following Elliott Co tube rolling tools are required B3400 Expander Assembly B3401 Cage B3405 Mandrel B3408 Rolls Place one drop of Loctite No 675 or equivalent on top of tube prior to rolling This material is intended to wick into the area of the tube that is not rolled into the tube sheet and prevent fluid from accumulating between the tube and the tube sheet Table 14 Plugs COMPONENTS FOR PART NUMBER PLUGGING For Tubes Brass Pin 853103 500 Brass Ring 853002 570 For Holes without Tubes Brass Pin 853103 1 Brass Ring 853002 631 Loctite No 675t Locquic NT Order directly from Elliott Tube Company Dayton Ohio TCan be obtained locally Tube information e Tube sheet hole diameter 0 631 16 03 Tube OD ott Satie a 0 625 15 87 e Tube ID after rolling 0 581 14 76 includes expansion due to to to clearance 0 588 14 94 NOTE Tubes next to gasket webs must be flush with tube sheet both ends Tightening Cooler Head Bolts Gasket Prepara
55. ltage measurement across 2 legs and the average across all 3 legs Example Supply voltage is 240 3 60 A B C AB 243 v BC 236 v AC 238 v 1 Determine average voltage 243 236 238 Average voltage 3 717 3 239 v 2 Determine maximum deviation from average voltage AB 243 239 4 v BC 239 236 3 v AC 239 238 1 v Maximum deviation is 4 v 3 Determine voltage imbalance Voltage Imbalance 100 x pus 239 1 7 This voltage imbalance is satisfactory as it is below the maximum allowable of 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility com pany immediately Do not operate unit until imbalance condition is corrected Control Circuit Power Electronic control includes logic to detect low control circuit voltage Acceptable voltage range is shown in Table 4 MINIMUM FLUID LOOP VOLUME To obtain proper temperature control loop fluid volume must be at least 3 gallons per ton 3 25 L per kW of chiller nominal capac ity for air conditioning and at least 6 gallons per ton 6 5 L per kW for process applications or systems that must op erate in low ambients below 32 F 0 C Refer to appli cation information in Product Data literature for details FLOW RATE REQUIREMENTS Standard chillers should be applied with nominal flow rates approximating those listed in Table 11 Higher or lower flow rates are permissible
56. n Motor down and hold machine in standby This feature makes remote TB Terminal block shutdown of chiller easier TXV Thermostatic Expansion Valve Do not change select switch to brine on units that do not have modifications for brine Special factory modifications are required Contact Carrier for details N is always displayed if oil pressure switch is not installed Display is il for Flotronic EXV units only Display is IE for Flotronic FIOP units with TXV ttCompressors will be energized for 10 seconds indicates open CPCS module contacts EH indicates closed CPCS module contacts 17 For each step of the 42 step program display button must be pressed twice On first press step number is displayed second press initiates required action and code as shown in Table 7 NOTE Step number is a numeral followed by a decimal point a 2 digit number has a decimal point after each numeral Action code number is one or 2 digits with no decimal point s IMPORTANT Once quick test is initiated display but ton must be pressed at least once every 10 minutes for control to remain in quick test mode If button is not pressed within this time control will attempt to start unit To recheck any step in quick test control must be re cycled by turning unit control circuit switch off for a few seconds then on again Restart quick test program as de scribed above and proceed through quick test steps Press disp
57. n accessory sensor and is mounted remotely from unit It is used for outdoor air or space temperature reset CAUTION Sensor T2 is installed directly in the fluid circuit Re lieve all pressure or drain fluid before removing To troubleshoot a sensor refer to separate Controls and Troubleshooting literature REPLACING THERMISTOR T2 Remove and discard original sensor and coupling Do not disassemble new coupling Install assembly as received 2 Apply pipe sealant to 4 in NPT threads on replacement coupling and install in place of original Do not use the packing nut to tighten coupling Damage to ferrules will result JACKETED SENSOR THERMISTOR CABLE TUBE WELL ga e ee L m vr NOTE BEND SLIGHTLY p 8 16 FOR INSERTION 76 4 8 INTO WELL FLUID SIDE TEMPERATURE SENSOR T1 AND REFRIGERANT TEMPERATURE SENSOR 15 T6 T7 T8 COUPLING JACKETED ACCESSORY 3i CABLE x v8 Mes C EL FERRULES 3 16 4 8 DIA 1 4 6 4 INSIDE OD COUPLING FLUID SIDE TEMPERATURE SENSOR T2 NOTE Dimensions in Fig 21 Thermistors Temperature Sensors are in millimeters 3 Thermistor T2 entering fluid temperature should not be touching an internal refrigerant tube but should be close enough to sense a freeze condition Recommended distance is Lx in 3 2 mm from cooler tube Tighten pack ing nut finger tight to position ferrules then tighten 11 4 turns more using a back up wrench F
58. nd cooler heaters are wired into the control circuit so they are always operable as long as the control circuit power supply disconnect is on even if any safety device is open or the unit ON OFF circuit switch is off 4 Units have the following power wiring terminal blocks and parallel conductors 30GT TERMINAL PARALLEL UNIT size VOLTAGE BLocks CONDUCTORS 3 040 045 6 050 070 460 3 040 3 do 3 E es 3 3 589415 1 5 Maximum incoming wire size for each terminal block is 500 kcmil 6 Power draw of control circuits includes both crankcase heaters where used and cooler heaters Each compressor has a crankcase heater which draws 180 watts of power Units ordered with cooler heater option have 2 cooler heaters 040 050 or 4 cooler heaters 060 070 210 w each and a 120 w circuit board heater 30GT UNIT SIZE 040 XL 040 PW 045 XL 045 PW 050 XL 050 PW 060 XL 060 PW 070 XL 070 PW NAMEPLATE VOLTAGE 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3 60 380 3 60 346 3 50 380 415 3 50 208 230 3 60 460 3 60 575 3
59. nge bolts to 70 to 90 ft lb 94 to 122 N m NOTE The suction flange is a 4 bolt pattern See Carrier specified parts for replacement part number if necessary 4 Use adhesive and reinstall the cooler insulation on the refrigerant connection end of the cooler 5 Reinstall the thermistors Refer to Thermistors section on page 30 and install as follows a Apply pipe sealant to the 4 in NPT threads on the replacement coupling for the fluid side and install it in place of the original A CAUTION Do not use the packing nut to tighten the coupling Damage to the ferrules will result b Reinstall thermistor T1 well and insert thermistor T1 into well c Install thermistor T2 entering fluid temperature so that it is not touching an internal refrigerant tube but so that it is close enough to sense a freeze condition The recommended distance is Vs in 3 2 mm from the cooler tube Tighten the packing nut finger tight and then tighten 1 turns more using a back up wrench 6 Install the cooler heater and conduit if equipped con necting the wires as shown in the unit wiring schematic located on the unit 24 7 Close the air vent at the top of the cooler and close the drain on the bottom of the cooler near the leaving fluid outlet Both the drain and the air vent are located on the leaving fluid end of the cooler See Fig 13 8 Reconnect the cooler fluid piping and open the shutoff valves if installed Pur
60. ns to be exposed at 320 steps Since there is not a tight seal with the orifice and the sleeve the mini mum position for operation is 120 steps The microprocessor controls the valve Two thermistor tem perature sensors are used to determine superheat One ther mistor is located in the cooler and other is located in the passage between compressor motor and cylinders The dif ference between the 2 temperatures controls superheat On a normal TXV or EXV system superheat leaving evaporator is 10 F 5 6 C Motor then adds approximately 15 to 20 F 8 to 11 C resulting in approximately 30 F 16 7 C superheat entering cylinders Because EXVs are controlled by processor board it is pos sible to track valve position By this means head pressure is controlled and unit is protected against loss of charge and a faulty valve During initial start up EXV is fully closed Af ter initialization period valve position is tracked by proces sor by constantly observing amount of valve movement The EXV is also used to limit cooler saturated suction tem perature to 55 F 13 C This makes it possible for chiller to start at higher cooler fluid temperatures without overloading compressor This is commonly referred to as MOP maxi mum operating pressure If it appears that EXV is not properly controlling operat ing suction pressure or superheat there are a number of checks that can be made using quick test and initialization features
61. ontrol box end of the unit COOLER REMOVAL Cooler can be removed from the cooler side of the unit as follows 1 To ensure the refrigerant is in the condenser follow this procedure a For 30GT070 50 Hz only open the circuit breaker and close the discharge valve for the lag compressor A2 A WARNING Do not close the discharge valve of an operating com pressor Severe damage to the compressor can result b Close the liquid line service valve for one circuit Al low the lead compressor to pump down that circuit until it reaches approximately 10 to 15 psig 68 8 to 103 2 kPa c As soon as the system reaches that pressure shut down the lead compressor by opening the compressor cir cuit breaker then quickly close the discharge service valve for that compressor d Repeat the procedure for the other circuit A CAUTION Open and tag all electrical disconnects before any work begins Keep in mind that cooler is heavy and both fluid side and refrigerant side may be under pressure 2 Close the shutoff valves if installed in the cooler fluid lines and remove the cooler fluid piping 3 Open the air vent at the top of the cooler and open the drain on the bottom of the cooler near the leaving fluid outlet to drain the cooler Both the drain and the air vent are located on the leaving fluid end of cooler See Fig 13 4 Disconnect the conduit and cooler heater wires if equipped Remove all thermist
62. ors from the cooler being sure to la bel all thermistors as they are removed Thermistor T2 is immersed directly in the fluid Thermistors T1 T5 and T6 are friction fit well type thermistors See Fig 13 5 Remove the insulation on the refrigerant connection end of the cooler 6 Unbolt the suction flanges from the cooler head Save the bolts 7 Remove the liquid lines by breaking the silver soldered joints at the cooler liquid line nozzles 8 Remove the screws in the cooler feet Slide the cooler slightly to the left to clear the refrigerant tubing Save all screws Remove the cooler carefully LEAVING WATER BRINE THERMISTOR T1 COOLER AIR FLUID VENT BAFFLE EVAPORATOR REFRIGERANT WATERIBRINE THERMISTORS CONNECTION SUCTION EACH NY EXV CONNECTION DRAIN LEAVING COOLER WATER BRINE TUBE CONNECTION TYPICAL LEGEND EXV Electronic Expansion Valve ENTERING WATER BRINE lt a 7 THERMISTOR T2 Fig 13 Cooler Thermistor Locations REPLACING COOLER To replace the cooler 1 Insert new cooler carefully into place Reattach the screws into the cooler feet using saved screws 2 Replace the liquid lines and solder at the cooler liquid line nozzles 3 Rebolt the suction flanges onto the cooler head using bolts saved during removal Use new gaskets for the suction line flanges Use compressor oil to aid in gasket sealing and tighten the suction fla
63. otentiometer s OK P4 Accessory Demand Potentiometer s Faulty or Option Not Used Gue i Potentiometer OK P5 Accessory Reset Potentiometer Faulty or Option Not Used Ratio Potentiometer 2 4 NN Potentiometer OK P6 Accessory Reset Set Potentiometer Faulty or Option Not Used Pomi ROtenueMneter 16 Table 7 Quick Test EEZ cont SECTION C Output Relay Check QUICK NORMAL DISPLAY RELAY STEP DESCRIPTION NO TEST STEP NO Energize First Stage of Condenser Fans 040 050 OFM3 K11 060 070 OFM3 OFM4 Energize Second Stage of Condenser Fans 040 050 OFM4 K12 060 070 OFM5 OFM6 Energize Liquid Line Solenoid Valve TXV only K9 Circuit A Energize Liquid Line Solenoid Valve TXV only K10 Circuit B Energize Compressor A1 and OFM1 K1 E Mu B tn Energize Compressor A2 K2 No action 040 060 50 Hz 040 070 60 Hz No Action K3 Energize Unloader A1 K4 Energize Compressor B1 and OFM2 K5 No Action K6 CG No Action K7 Energize Unloader B1 K8 LEGEND G IMPORTANT If TB6 3 and TB6 4 jumper is not installed chiller CPCS Compressor pe Control System remains in standby mode No compressors or fans start and Code EXV Electronic Expansion Valve 26 is displayed This is not a fault code If circuit between TB6 3 FIOP Factory Installed Option and TB6 4 is open processor is programmed to initiate a shut OFM Outdoor Condenser Fa
64. pplied by 6 parallel con ductors for these units FIELD CONTROL POWER CONNECTIONS See Fig 7 For 208 230 460 and 575 3 60 units If the accessory transformer is not used provide a single phase power source for the control circuit through a field supplied fused discon nect per NEC or local code This conductor must be cop per only Control power enters the control box through a 7 s in 22 2 mm conduit connection located on the right side of the control section For 380 3 60 and 380 415 3 50 units Control circuit volt age is taken from the line voltage therefore no additional power supply is required for the unit If a separate power source is required for a particular application disconnect the wires between the control and power terminal blocks For 346 3 50 Units Provide a 230 1 50 power source for the control circuit through a field supplied fused disconnect per NEC or local code This conductor must be copper only Control power enters the control box through a 7 in 22 mm conduit connection located on the right side of the control section Units with a power supply of 208 230 460 and 575 3 60 require 115 1 60 control circuit power Units with a power supply of 380 3 60 have 230 1 60 control circuit power which is taken from the unit s power supply voltage Units with a power supply of 380 415 3 50 have 230 1 50 control circuit power which is also taken from the unit s power supply volt age Units with a
65. r fin damage can result 5 8 11 BOLTS A J 1 2 FLANGE BOLTS 5 8 11 BOLTS A N SIZES 040 050 SIZES 060 070 Fig 16 Cooler Head Bolt Tightening Sequence Typical Tube Sheet Condenser Fans Each fan is supported by a formed wire mount bolted to fan deck and covered with a wire guard The exposed end of fan motor shaft is protected from weather by grease If fan motor must be removed for service or re placement be sure to regrease fan shaft and reinstall fan guard STANDARD CONDENSER FANS For proper perfor mance top of fan propeller center should be 7 in 22 mm below top of venturi on the fan deck for 60 Hz units For 50 Hz units distance between top of venturi and top of fan hub should be in 13 mm Tighten set screws to 15 1 ft lb 20 1 3 N m Figure 17 shows proper position of mounted fan IMPORTANT Check for proper fan rotation clock wise viewed from above If necessary to reverse fan rotation direction switch any 2 power leads HIGH STATIC CONDENSER FANS If the unit is equipped with the high static fan option the fan must be set from the top of the fan deck to the plastic ring or center of the fan to a distance of 2 15 in 0 12 in 54 6 3 mm This is dif ferent from standard fans since there is no area available to measure from the top of the orifice ring to the fan hub itself See Fig 18 IMPORTANT Check for proper fan rotation clock wise v
66. r to Controls and Troubleshooting book for details 4 Start chilled fluid pump 5 Turn ON OFF switch to ON position The display will read EB The machine checks all potentiometers and thermistors for valid readings In approximately 2 min utes the EB reading is no longer displayed and the machine is operational Allow the unit to operate and confirm that everything is functioning properly Check the leaving fluid tempera ture and be sure that it agrees with the set point poten tiometer P1 If the temperature setting does not agree the set point can be compensated by shifting the control point slightly If temperature reset is in effect the leaving fluid temperature may not agree with the set point Operating Limitations TEMPERATURES See Table 10 If unit is to be used in an area with high solar radiation mounted position should be such that control box is not exposed to direct solar 19 radiation Exposure to direct solar radiation could affect the temperature switch controlling cooler heaters Table 10 Temperature Limits TEMPERATURES C Maximum Ambient Temp 52 Minimum Ambient Temp 18 Maximum Cooler EWT 35 Maximum Cooler LWT 21 Minimum Cooler LWTYt 4 5 EWT Entering Fluid Temp LWT Leaving Fluid Temp For sustained operation it is recommended that EWT NOT exceed 85 F 29 4 C TUnit and or temperature Low Ambient Operation If operating temperatures be low 0 F 18 C are expected r
67. rature freezing point or boiling point of water us ing either voltage drop measured across thermistor at the J1 terminals with unit in quick test mode BEIM or by determining the resistance with chiller shut down and thermistor disconnected from J1 Safety Devices Chillers contain many safety de vices and protection logic built into electronic control Fol lowing is a brief summary of major safeties For complete details refer to Controls and Troubleshooting literature 31 PROCESSOR BOARD J1 COOLER LEAVING FLUID TEMP COOLER ENTERING FLUID TEMP SATURATED CONDENSING TEMP CIRCUIT A SATURATED CONDENSING TEMP CIRCUIT B AT8 COOLER SATURATION TEMP o AWWA CIRCUIT B 2 COMPR RETURN GAS TEMP 1 CIRCUIT A 2 E COMPR RETURN GAS TEMP 9 o _M RESET TEMP SENSOR ACCESSORY RESET ay Accessory T1 T8 T10 THERMISTORS COMPR Compressor Not used on FIOP Factory Installed Option unit with TXV Thermostatic Expansion Valve Fig 22 Thermistor Connections to J1 Processor Board COMPRESSOR PROTECTION Circuit Breaker One manual reset calibrated trip mag netic circuit breaker for each compressor protects against over current Do not bypass or increase size of a breaker to cor rect problems Determine cause for trouble and correct before resetting breaker Circuit breaker must trip amps MTA are listed on individual circuit breakers and on unit label diagrams Compre
68. rotated 90 degrees counterclockwise from position shown when installed in unit 3 Do not remove label covering EPROM Removal causes program to be erased Fig 9 Center of Flotronic Control System 14 Table 7 Quick Test SECTION A Configuration and Switch Check STEP DESCRIPTION Type Unit Air Cooled Chiller No of Compressors 040 060 50 Hz 040 070 60 Hz BE 070 50 Hz No of Unloaders WI Switch 6 On Switch 7 Off Switch 6 Off Switch 7 On Water i Brine an xv E IXV ENIM 50 Hz 8 60 Hz a External Reset Bl Return Fluid Reset Reset Disabled Bl Reset Enabled Pulldown Disabled Bl Pulldown Enabled Demand Limit Disabled Bl Demand Limit Enabled Remote On Off Switch Jumper Open Mi Remote On Off Switch Jumper Closed Loss of Charge Switch A Open mi Loss of Charge Switch A Closed Loss of Charge Switch B Open Ei Loss of Charge Switch B Closed Low Oil Pressure Switch A Open Mi Low Oil Pressure Switch A Closed Low Oil Pressure Switch B Open Mi Low Oil Pressure Switch B Closed HEADER POSITION OR CONTROL SWITCH Configuration Header 1 and 2 Configuration Header 3 4 and 5 DIP Switches 6 and 7 DIP Switch 8 Configuration Header 6 Configuration Header 7 DIP Switch 1 DIP Switch 2 DIP Switch 3 DIP Switch 5 TB6 3 and TB6 4 Circuit A Loss of Charge Switch Circ
69. s greater than 40 F 22 C fan stages are removed when the valve is approximately half open fan stages are added This al lows unit to run at very low condensing temperatures at part load Thus chiller has very high part load EERs energy ef ficiency ratios Fan sequence is shown in Fig 10 21 Units with TXV Thermostatic expansion valves one for each refrigerant circuit are factory set to maintain 8 to 10 F 5 to 6 C superheat of vapor leaving cooler to con trol flow of liquid refrigerant into cooler Superheat can be reset but should be done only if necessary Logic to cycle microprocessor controlled fans is based on saturated condensing temperature only This temperature is sensed by thermistors T3 and T4 Fig 11 and 12 The mi croprocessor will turn on an additional stage of fans when either of coil thermistors T3 or T4 is greater than 113 F 45 C and will turn off a fan stage when T3 and T4 are both below 73 F 23 C Between each change in fan stage control will wait one minute to allow head pressure to sta bilize unless either T3 or T4 is greater than 125 F 52 C in which case all microprocessor controlled fans will come on immediately Condenser fan sequence is shown in Fig 10 REMOTE ON OFF When it is required to control the starting and stopping of the chiller from a remote location such as a timeclock the remote ON OFF feature is used See Fig 7 for wiring information If the chiller is being
70. sel and the glycol to enter 4 For units with optional cooler heaters remove fuse no 1 FUIL 5 At the beginning of the next cooling season replace FU1 if removed refill cooler and add recommended inhibitor Ne Step 4 Make Electrical Connections The electrical characteristics of the available power supply must agree with the unit nameplate rating Supply voltage must be within the limits shown The control box is divided into field power side on the right and control power supply on the left See Fig 6 FIELD POWER CONNECTIONS See Fig 7 All power wiring must comply with applicable local and national codes Install field supplied branch circuit fused disconnect s of a type that can be locked off or open Disconnect s must be located within sight from and readily accessible from unit in compliance with NEC Article 440 14 or local codes See Tables 3 6 for unit electrical data All field main power enters the unit through the control box at the left end when facing the compressors An access hole is under the control box All units have a single location for power connection except size 050 070 208 230 units to simplify the field power wiring For all sizes maxi mum wire size that the unit terminal block will accept is 500 kcmil Unit may use copper copper clad aluminum or aluminum conductors at all voltages For 208 230 3 60 units sizes 050 070 parallel conduc tors are required Power must be su
71. size 070 50 Hz only if lead com pressor in either circuit is shut down by high pressure switch ground current protection loss of charge switch or oil pres sure switch both compressors in the circuit if applicable are locked off LOW OIL PRESSURE PROTECTION Lead compressor in each circuit is equipped with a switch to detect low oil pressure Switch is connected directly to processor board Switch is set to open at approximately 5 psig 35 kPa and to close at 9 psig 62 kPa maximum If switch opens when compressor is running CR or processor board stops all com pressors in circuit During start up switch is bypassed for 2 minutes CRANKCASE HEATERS Each compressor has a 180 w crankcase heater to prevent absorption of liquid re frigerant by oil in crankcase when compressor is not run ning Heater power source is auxiliary control power inde pendent of main unit power This assures compressor protection even when main unit power disconnect switch is off IMPORTANT Never open any switch or disconnect that deenergizes crankcase heaters unless unit is being serviced or is to be shut down for a prolonged period After a prolonged shutdown or service energize crank case heaters for 24 hours before starting unit COOLER PROTECTION Freeze Protection Cooler can be wrapped with heater cables optional as shown in Fig 23 which are wired through an ambient temperature switch set at 36 F 2 C Entire cooler is co
72. sponded properly to processor signals in Step 5 1 above valve should be fully open and lead screw should pro trude approximately 4 in 6 mm to in 19 mm above top of motor 5 Recycle control by turning control circuit switch to ON position This puts control in initialization mode During first 100 seconds of initialization mode each valve is driven to fully closed position zero steps open by pro cessor With cover lifted off EXV valve body observe operation of valve motor and lead screw The motor should turn in the counterclockwise CCW direction and lead screw should move down into motor hub until valve is fully closed Lead screw movement should be smooth and uniform from fully open to fully closed position 6 When test has been completed carefully reassemble EXV Be careful not to damage motor or O ring when reassembling valve Open compressor service valves and close compressor circuit breakers Open liquid line ser vice valve Turn control circuit switch to ON position and allow unit to operate Verify proper operation of unit This process of opening and closing EXV can be repeated by repeating quick test steps 3 5 or 3 9 and recycling con trol as described in proceeding steps If valve does not op erate as described when properly connected to processor and receiving correct signals it should be replaced If operating problems persist after reassembly they may be due to out of calibration thermistor s or int
73. ssor Protection Board CPCS or Control Relay CR The CPCS or CR is used to control and protect compres sors and crankcase heaters Each provides following features Compressor contactor control Crankcase heater control Ground current protection CPCS only Status communication to processor board High pressure protection One large relay located on CPCS board or unit CR con trols crankcase heater and compressor contactor In addi tion relay provides a set of contacts that microprocessor monitors to determine operating status of compressor If pro cessor board determines that compressor is not operating prop erly through signal contacts control locks compressor off The CPCS contains logic that can detect if current to ground of any winding exceeds 2 5 amps if so compressor shuts down A high pressure switch with a trip pressure of 426 7 psig 2936 48 kPa is mounted on each compressor switch setting is shown in Table 18 Switch is wired in series with the CPCS or control relay If switch opens CPCS relay or CR opens processor detects it through signal contacts and compressor locks off Table 18 Pressure Switch Settings psig kPa SWITCH CUTOUT CUT IN 426 7 320 20 RESTE 2936 x 48 2205 x 138 Loss of Charge 7 48 2 22 151 6 If any of these switches opens during operation the com pressor stops and the failure is detected by processor when signal contacts open On
74. tion When reassembling cooler heads al ways use new gaskets Gaskets are neoprene based and are brushed with a light film of compressor oil Do not soak gas ket Use new gaskets within 30 minutes to prevent deterio ration Reassemble cooler nozzle end or plain end cover of the cooler with the gaskets Torque all cooler bolts to the following specifications and sequence S in Diameter Perimeter Bolts 150 to 170 ft Ib 201 to 228 N m Y in Diameter Flange Bolts 70 to 90 ft Ib 94 to 121 N m pad Install all bolts finger tight Bolt tightening sequence is outlined in Fig 16 Follow the numbering sequence so that pressure is evenly ap plied to gasket 3 Apply torque in one third steps until required torque is reached Load all bolts to each one third step before pro ceeding to next one third step 4 No less than one hour later retighten all bolts to required torque values 5 After refrigerant is restored to system check for refrig erant leaks with soap solution or Halide device 6 Replace cooler insulation n Condenser Coils COIL CLEANING Clean coils with a vacuum cleaner fresh water compressed air or a bristle brush not wire Units installed in corrosive environments should have coil clean ing as part of a planned maintenance schedule In this type of application all accumulations of dirt should be cleaned off the coil CAUTION Do not use high pressure water or ai
75. uick test program first turn unit control switch to the ON position When a EM appears in dis play immediately press display button once An Rif will appear in display and alarm light will be energized this in SIGHT GLASS EQUALIZER dicates that microprocessor in control system is ready to run Bre test proram Lead compressor only Fig 8 Compressor Connections Lead Compressor Shown 13 D G9 23456 Oz ou LWT LED DISPLAY BUTTON SET POINT DISPLAY AO FUSE 1 lt Q FUSE 2 GFI CO 8 AMP MAX G DIP SWITCH CONFIGURATION amp ASSEMBLY HEADER DISPLAY GROUND FAULT CONTROL CIRCUIT BOARD INTERRUPTER SWITCH DISPLAY TP19 BOARD RELAY BOARD CONNECTOR J10 CONNECTOR J7 CONNECTOR J9 14 J9 sesel CONVENIENCE OUTLET GFI CO ACCESSORY TP15 TP14 100 o e os o U JL e 10000 00007 ln I 1 u4 Fa 3 T Ci oui US A aa e lt lo ol o 6 3 cas 3 TE lo 9 b lo E o o lo b z4 o 2 E oL jo 250 e G o ce 9 ca cio c5 JIO p E3 oo Da oo BS A lo S o g lo Uri UIZ uia x E o 00000000 fu v 00906 Oy a 900000008 _ di 6 o 9 0008 o oo s oo 000000000 s 0000000908 0600066000060
76. uit B Loss of Charge Switch Circuit A Low Oil Pressure Switch Circuit B Low Oil Pressure Switch Quick test continued on page 16 see page 17 for legend and notes 15 Table 7 Quick Test FE cont SECTION B Thermistor and Potentiometer Checkout ween THERMISTOR OR STEP NO POTENTIOMETER m BE Thermistor OK T1 Cooler Leaving Fluid Thermistor Faulty Thermistor EH i Thermistor OK T2 Cooler Entering Fluid Thermistor Faulty Thermistor LH i Thermistor OK T3 Saturated Condensing Thermistor Faulty Thermistor Circuit A EE ERE Thermistor OK T4 Saturated Condensing Thermistor Faulty Thermistor Circuit B eu T5 Evaporator Refrigerant L LA Or Thermistor Circuit A Thermistor Faulty or Not Used EXV Units En E Thermistor OK T6 Evaporator Refrigerant Thermistor Circuit B Thermistor Faulty or Not Used EXV Units ce Bh Thermistor OK T7 Compressor Thermistor Thermistor Faulty or Not Used Circuit A EXV Units EE EE Thermistor OK T8 Compressor Thermistor Thermistor Faulty or Not Used Circuit B EXV Units EG Mi Thermistor OK T10 Accessory Remote Thermistor Faulty or Not Used Ua EB L Potentiometer OK P1 Leaving Fluid Set Point Potentiometer Faulty elias No Significance EE Hu Potentiometer OK P3 Accessory Reset Limit Potentiometer Potentiometer Faulty or Option Not Used Mu n Bl P
77. uspension point so that angle from horizontal is not less than 45 degrees Raise and set down unit carefully Export units and domestic units with skids are rigged and placed as described below DOMESTIC UNITS Standard units are shipped without skids If overhead rigging is not possible place chiller on skid or pad for rolling or dragging When rolling use mini mum of 3 rollers When dragging pull the pad Do not apply force to the unit When in final position raise from above to lift unit off the pad EXPORT UNITS AND DOMESTIC UNITS WITH SKIDS All units are mounted on skids with vertical coil protec tion At the job site leave unit on the skid until unit is in final position While on the skid the unit can be rolled or skidded on the floor with force applied to the skid not the unit When the skid is removed the unit must be handled by overhead rigging as described previously If it is necessary to remove the skid before the unit is in final position and unit can be dragged place unit on a large pad and drag by the pad Do not apply force to the unit When in final po sition raise from above to lift unit off the pad PLACING UNIT Refer to Fig 1 and 2 for airflow clear ances Provide ample room for servicing and removing cooler depending on unit location Refer to cooler dimensions in Fig 1 and 2 For multiple units allow 8 ft 2440 mm sepa ration between units for airflow and service Placement area must be l
78. ve EXV will be closed as part of initialization sequence This does not occur on FIOP factory installed option units where a con ventional thermostatic expansion valve TXV is used After a 2 minute period display turns off and unit is al lowed to start If button is pressed after the has been removed from display operational status codes or di agnostic information will be shown as long as button is held in Code numbers on display will have following significance CODE OPERATIONAL NUMBER STATUS 0 12 Capacity stage 20 26 Operational information 51 87 Overload information Under normal operation only stage number will be dis played If an operational status code or an overload code is displayed the display will rotate every 2 seconds and will display up to 3 numbers Overload information will take pri ority over all other codes The codes will be stored by the microprocessor as long as board is energized IMPORTANT The memory is cleared when control power is removed Actual Start Up Actual start up should be done only under supervision of a qualified refrigeration mechanic 1 Be sure all service valves are open The unit is shipped from the factory with the suction discharge and liquid line service valves closed 2 Set leaving fluid temperature using LWT setpoint knob on front of control No cooling range adjustment is necessary 3 If accessory reset boards are used set potentiometers prop erly Refe
79. vered with closed cell insulation applied over heater cables Heaters plus insulation protect cooler against low ambient temperature freeze up to 0 F 18 C IMPORTANT If unit is installed in an area where am bient temperatures fall below 32 F 0 C it is rec ommended that inhibited ethylene glycol or other suit able corrosion inhibitive antifreeze solution be used in chilled fluid circuit AIR T1 FLUID VENT LOCATION IN FLUID T2 DRAIN OUT LOCATION Fig 23 Cooler Heater Cables Copyright 1996 Carrier Corporation Low Fluid Temperature Microprocessor is programmed at the factory to shut chiller down if leaving fluid tempera ture drops below 35 F 1 7 C When fluid temperature rises 6 F 3 3 C above leaving fluid set point safety resets and chiller restarts Loss of Fluid Flow Protection Microprocessor contains internal logic that protects cooler against loss of cooler flow Entering and leaving fluid temperature sensors in cooler de tect a no flow condition Leaving sensor is located in leav ing fluid nozzle and entering sensor is located in first cooler baffle space in close proximity to cooler tubes as shown in Fig 13 When there is no cooler flow and the compressors start leaving fluid temperature does not change However entering fluid temperature drops rapidly as refrigerant en ters cooler Entering sensor detects this temperature drop and when entering temperature is 5 F 2 8

Carrier 30GT060

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