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Acer 752 Laptop User Manual

1. ee M r 0810 LV I CPC I PL10 8 5 1 GRA BLU iraa IT LOGIC C Yrer 187 I cpcs B1 1 PL10 7 CPC5 A2 I 0 M R LOGICE C cecs BRN cPCS B2 PLE 3 ACCESSORY WEM I yEL uu BLU 3 BRN 1 e PL1 5 PLI 6 DAK Pn gt BRN RED 5 1 OR 4 ow 1 LOGICKE BRN aie NES BRN E CPCS A2 PLIO 5 f CPCS B2 I ME L os cl BRN ke uwa was u apa an M 080 110 ONLY PL7 3 ACCESSORY PL 4 sa GRA BRN 2 Ta L u2 B1 RUPEE ee m U1 B1 9 080 110 50 60 Hz and 130 60 Hz LEGEND Contactor PL Plug Snubber pes Compressor Protection Control System SNB Control Relay TB Terminal Block DSIO Relay Module TRAN Transformer LV Low Voltage U Unloader Fig 23 Accessory Unloader Control Wiring 69 130 50 Hz 150 210 225 250 AND 280 UNITS and n C To change the configuration type and the Install control wiring The minimum wire size for in keypad LCD will display FLD CFG Press COM HGBPR NO SNB stallation is 16 AWG American Wire Gage Refer to Fig 24 and 25 for proper wiring Open the control box door Locate unloader relays A and B URA URB in place of the hot gas bypass
2. DISPLAY COMMENT No schedule override OVRD 0 in effect OVRD 3 3 hours override in effect OVRO 0 Override cancelled CLOCK 0 Schedule function is inactive Schedule function is enabled through local unit clock Schedule function is enabled CLOCK 65 throuah CCN clock 65 Define schedule period 1 Start of occupied time For this example first period should stat t here at midnight so no entry is needed Start of unoccupied time end of period For this example period 1 should end at 3 00 a m Period 1 ends at 3 00 a m PERIOD 1 OCC 00 00 UNO 00 00 UNO 3 00 Monday is now flagged no for period 1 To out period 1 into effect on Monday Monday must be flagged yes Monday is now flagged for period 1to be in effect For this example period 1 is to be in effect on Monday only All other days must be checked to be sure that they are flagged no If any day is flagged yes change to no Tuesday is now flagged no for period 1 PERIOD 2 Define schedule period 2 occ 00 00 Start of occupied time Occupied time will start at 7 00 am Start of unoccupied time end of period For this example period 2 should end at 18 00 6 00 p m Period 2 ends at 18 00 6 00 pm onday is now flagged no for period 2 To put period 2 into effect on Monday onday must be flagged yes onday is now flagged for period 2 to be in effect Tuesay is now flagged no for period 2 To put period 2 into ef
3. SUE B2 B3 Al A2 A3 B1 t B2 B3 A1 A2 A3 B1 Sa B3 Al A2 A3 B1 B2 B3 Atth Ri At Bitt Al Bt A1 PW ry Bi Al 2 A1 BP an B2 ATE 2 1 vig tt B2 A1 A2 B1 A1 Bitt B2 A1 2 B1 A1 B1 B2 170 270A 3008 AIL ARE Bitt p A1 B1 B2 330A B 360B 50 Hz A11 B1 gt gt D Be w _ CU Unloaded compressor TCompressor unloader standard E Compressor unloader accessory t TtTwo unloaders both unloaded Nese NOTE These capacity control steps may vary due to lag compressor sequencing Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont LOADING SEQUENCE A 8 LOADIN SEQUENCE B UNIT CONTROL 96 e SIZE STEPS Displacement Compressors Displacement Compressors Approx Approx 190 360A B 5 390B 60 Hz 4 A1 B1 5 6 1 2 3 4 190 360A B 3908 60 Hz 5 A1 B1 8 9 10 11 12 1 2 3 5 3905 A B 6 B NEP Al AB BI Bp Al 2 1 8 A Ab Bi B2 B3 10 Al A2 B1 B2 B3 Al A2 A3 B1 B2 B3 ia Al A2 A3 B1 B2 B3 190 360A B Al A B1 390B 60 Hz A ABI B2 A1 B1 AI A2 B1 B2 Al A2 81 Al A238 B2 Al A2 A3 B1 B2 AL A2 A3 B1 B2 A2 A3 BI B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 190 360A 390B 50 Hz A1 B1 190 360A 390B 50 AI B Unloaded compressor TCompressor unloader standard Compressor unloader accessory TT Two unloaders both unloaded N
4. 1 2 3 4 5 6 11 12 13 FC 2 FC 3 4 14 15 16 19 20 21 22 FC 5 FC 6 FC 7 27 11 12 13 14 15 16 FC 5 FC 6 Compressor Al Compressor B1 FC 2 First Stage Microprocessor 1 2 3 4 FC 3 Second Stage Microprocessor 1 2 3 4 5 6 FC 2 FC 3 Third Stage Microprocessor Compressor Al Compressor B1 5 6 FC 2 First Stage Microprocessor 1 2 3 4 13 Second Stage 14 15 16 20 Microprocessor Third Stage Microprocessor FC 3 FC 6 FC 7 13 FC 2 FC 3 FC 5 FC 6 FC 7 1 Compressor Al FC 4 5 6 FC 2 9 20 1 2 3 4 13 14 15 16 21 22 FC 3 FC 6 FC 7 14 15 16 19 20 7 8 10 18 mn O Compressor B1 First Stage Microprocessor Second Stage Microprocessor Third Stage Microprocessor saturated suction temperature is below 15 F 26 C At this point the EXV starts to open and continues to open gradually to provide a controlled start up to prevent liquid flood back to the compressor At shutdown the pumpout cycle continues until the sat urated suction temperature for that circuit is 10 F 5 5 C below the saturated suction temperature when pumpout is initiated or saturated suction temperature reaches 15 F 26 C At that point the compressor shuts down and the EXV continues to move until fully closed Keypad and Display Module Also Called HSIO or LID The only function of this module is to allow the operator to communi
5. Displacement Approx Compressors Ian 2 Bt Tr Al A A2 B1 B2 Al A2 B1 B2 A1TtT A2 B1 11 2 1 AT 2 Br B2 Al Tl A2 B1 B2 Al A2 2 AI 2 B1 BD tt B1 tt Al t A2 B1 1 th A2 Bi A1 A2 81 A4 A2 B1 Al tt A2 B1 1 A2BI A19 78 Al AQ BI B2 NOTE These capacity control steps may vary due to lag compressor sequencing LOADING SIEQUENCE B 96 Displacement Approx 8 Compressors Al A1 EP B2 A1 Bitt B2 Ai Bt B2 A1 B1 B2 VE A21 57 A2 B1 B2 A1 A2 B1 B2 Bitt BI B1 A1 Bitt Ai B1 Ai B1 A1 Bitt B2 Al B1tt B2 Al Bt B2 Bi ES Al AZBIt i D AT n HB B2 Al it E tte Be BitrB2 AM BILBO A1 B1 B2 A1 B1 B2 Al if A2 B1tt B2 NOME P e BI p B2 Al Bo Al Yo B Table 4B Capacity Control Steps 080 110 and Associated Modular Units cont LOADING SEQUENCE B lacement Compressors EXE SEQUENCE UNIT CONTROL roa At 110 60 Hz 110 60 Hz AT BlT N O OO O OH 110 60 Hz 11 1 Ajo 110 50 Hz A1t B1T OQ cO OO L O Q gt G gt pO Unloaded compressor Toma ss unloader standard Compressor unloader accessory THUWO unloaders both unloaded Approx BT B1 i 1 1 Al Br A bo A1 B1 B2 A1 B1 B2 A1 A2 B1 B2 Al A2 B1 B2 Al
6. 040 420 250 28 eer Acn BY JOG Chillers wr Gad Contrc ing e HEATING amp COOLING with Sas CONTENTS Page Page SAFETY CONSIDERATIONS 1 Restart Procedure 48 e POWER FAILURE EXTERNAL TO THE UNIT GENERAL Ua 2 Alarm Codes une 49 MAJOR SYSTEM COMPONENTS susu wa ede 2 4 Compressor Alarm Circuit iti dea ore 50 Processor Module 2 Electronic Expansion Valve 56 Low Voltage Relay Module AI UH OSEE 2 e EXV OPERATION Electronic Expansion Valve Module 2 e CHECKOUT PROCEDURE Options Module TEM OU UM 2 4 235 u 1x00 C9 EAR a a CA atl 60 Keypad and Display Module LOCATION Also Called HSIO or LID 2 e THERMISTOR REPLACEMENT T1 T2 T7 T8 Control Swilch cor y rr hey 2 Compressor and Cooler Electronic Expansion Valve EXV 4 Pressure Transducers OO SONSOMS oe i q XN S ha OX CE E X e 4 e TROUBLESHOOTING Compressor Protection Control e TRANSDUCER REPLACEMENT Module CPCS verre RR uqa ay 4 Control Modules 64 OPERATION DATA ODE e PROCESSOR MODULE PSIO 4IN AQUT Capacity Control ere MODULE SIO LOW VOLTAGE RELAY Head Pressure Control j
7. Configuration omitted Network command day Possible causes of failure 1 High Pressure Switch Open High pressure switch for each compressor is wired in series with 24 v power that energizes compressor control relay If high pressure switch opens during operation compressor stops This is detected by microprocessor through the feedback terminals 2 DSIO LV or DSIO EXV Module Failure If a DSIO LV t relay module relay fails open or closed microprocessor detects this locks compressor off and indicates an error 3 Wiring Errors If a wiring error exists causing CPCS CR or feedback switch not to function properly micro processor indicates an error 4 Processor PSIO Failure If hardware that monitors feedback switch fails or processor fails to energize re lay module relay to on an error may be indicated NOTE The control does not detect circuit breaker fail ures If a circuit breaker trips on lead compressor in a circuit a low oil pressure failure is indicated On the other compressors no failure is indicated 5 Ground Fault Module on 130 2 10 225 250 280 and associated modular units CGFA or CGFB Open Mod ule contacts are in lead compressor circuits but ground fault could be in any compressor in affected circuit Ground fault of any 040 1 10 and associated modular unit compressor field supplied accessory 040 060 and 070 60 Hz units standard on 070 50 Hz and 80 1 10 and as
8. A2 B1 B2 Al 1 1 2 A1 Bt Al B1 Al Tt A2 B1 A EE Al ik 2 dh B z Al D BY 2 P A2 Bi B2 B1 tt Bi B1 Al Bitt A1 B1 A1 Bit _ A1 B1tt B2 _ A1 B1 B2 A1 B1 B2 Al A2 B1TT B2 Al A2 B1 7 82 E A A2 B1 B2 as B1 B2 a BIF is 1 B1 A1 B1 ar cA Ad os A1 B1 Al m KD 3 tt Al BTTT B2 Al ft A2 1 A1 Bitt B2 A1 t A2 B1 A1 B1 B2 A2 N thee B B2 ATE a 3 A d 2 B1 82 B2 A Bi B2 5 Bt B2 B1 B1 1 81 Al Al B1 N B B2 Al BI B2 a BP B2 AI yi Al A2 B1 B2 I A2 B1 B2 A1 A2 B1 B2 NOTE These capacity control steps may vary due to lag compressor sequencing TEE m 12 Table 4B Capacity Control Steps 080 110 and Associated Modular Units cont SEQUENCE B UNIT CONTROL 30GN STEPS Displacement Compressors Displacement Compressors Approx Approx 2 3 4 5 110 50 Hz 6 Bt A1 B1T 7 1 1 8 Ai A2 B1 9 A1 A2 B4 a 10 Al tt A2 B1 B2 11 AI 2 B1 B2 12 Al A2 B1 B2 Bitt 2 B1 i B1 4 A1 B1tt 5 1 110 50 Hz 6 A1 B1 A1f B1T 7 A T tt B2 8 1 BS 9 0 Al n BE 1 AU A2 B1 2 Al A2 BI EA 1 Bitt 2 B1 3 B1 4 A1 Bitt 5 A1 B1 Mt Bit 5 BIFEB 7 p 2 ue 8 i B1 B2 0 A2 2 AC Be B2 0 Alt Al 1 Al A2 B1 B2 Al yo Bo 2 Al A2 B1 B2 Al A2 B1 B2 Unloaded compressor Compressor unloader standard Compressor unloader accesso
9. Replace heaters check wiring and crankcase heater relay contacts Check cooler and compressor thermistors Test EXV Repair leak and recharge Open valve or remove restriction Replace coil Replace valve Rewire correctly Replace spring Rewire correctly Replace valve Clean or replace strainer Clean or replace the necessary parts ACCESSORY UNLOADER INSTALLATION Some of the 30G Flotronic II units come standard with unloader s and many permit additional unloader s to be added if desired See Table 18 IMPORTANT Accessory hot gas bypass cannot be installed with accessory unloaders on units with more than 4 compressors If accessory unloaders are desired an accessory unloader package is used Package includes a suction cutoff unloader head package The 24 v coil in the package can be used for 040 1 10 130 60 Hz and associated modular units A 115 v or 230 v coil must be used for 130 50 Hz 150 210 225 250 280 and associated modular units Coil voltage depends on control circuit voltage Consult current Carrier price pages for appropriate part numbers NOTE The accessory package will include all necessary components and wiring with the following exceptions The field must provide screws and on the 130 2 10 225 250 280 and associated modular units the field must also sup ply a 20 vdc part number HK356AB001 unloader relay and wire 90 C or equivalent Table 18 Standard and Accessory
10. Table 3 Thermistor and Transducer Locations THERMISTORS Sensor Location Leaving Water Temp Cooler T2 Cooler Entering Water Temp T7 Compressor Suction Gas Temp Circuit A T8 Compressor Suction Gas Temp Circuit B T10 Remote Temperature Sensor Accessory PRESSURE TRANSDUCERS Sensor Location DPT A Compressor Al Discharge Pressure SPT A Compressor Al Suction Pressure OPT A Compressor Al Oil Pressure DPT B Compressor BI Discharge Pressure SPT B Compressor B1 Suction Pressure OPT B Compressor B1 Oil Pressure Compressor Protection Control Module CPCS Each compressor on models 30GN070 50 Hz 080 100 and 240B 270B has its own CPCS as standard equip ment All 30GN040 060 and 070 60 Hz units feature the CPCS as an accessory and CR control relay as standard equipment See Fig 2 The 30GN130 2 10 and associated modular units and the 30GT225 250 and 280 Flotronic II units have a CR as standard equipment The CPCS or CR is used to control and protect the compressors and crankcase heaters The CPCS provides the following functions compressor contactor control crankcase heater control compressor ground current protection status communication to processor board high pressure protection The CR provides all of the same functions as the CPCS with the exception of compressor ground current protec tion Ground current protection is accomplished by using a CGF compressor grou
11. Fig 8 4 20 mA Demand Limiting Reading and Changing Time Displav Time is entered and displayed in 24 hour time The day of the week is n tered as a number Mon 2 Tue 7 Sun etc C Key is used as the colon when entering time See Ex ample 8 Example 8 Setting Time of Day and Day of Week KEYPAD ENTRY COMMENTS Time display sub DISPLAY RESPONSE ser TIME function of set point function 4 MON 1600 Current setting is Monday 4 00 p m TES New setting of ENTR Tuesday 1 05 p m is entered and displayed TUE 13 05 JAN 01 90 date is New setting 4 1 5 P 9 0 15 90 dp To Top ENTR and displayed SERVICE FUNCTION This function allows the techni cian to view and input configuration data Factory config uration data field configuration data and service configu ration data may be viewed or entered through the keypad and display module See Table 9 for a complete listing of configurable items Whenever a processor module is re placed in the field the complete list of configuration codes must be entered Logging On Logging Off The service function is pass word protected Therefore to gain entry to this function this password must be entered Pressing E pm allows the technician to view change or enter configura tion codes To log off perform the following keystrokes The service function is once aga
12. If a good connec tion is assured and condition persists replace PSIO module If only DSIO or SIO module indicates communication failure check COMM plug on that mode for proper seat ing If a good connection is assured and condition persists replace DSIO or SIO module All system operating intelligence rests in PSIO module the module that controls unit This module monitors con ditions through input and output ports and through DSIO modules low voltage relay module and EXV driver module The machine operator communicates with microproces sor through keypad and display module Communication between PSIO and other modules is accomplished by 3 wire sensor bus These 3 wires run in parallel from module to module On sensor bus terminal strips terminal 1 of PSIO mod ule is connected to terminal 1 of each of the other modules Terminals 2 and 3 are connected in the same manner See Fig 19 If a terminal 2 wire is connected to terminal 1 sys tem does not work In Flotronic II Chillers processor module low voltage relay module and keypad and display module are all pow ered from a common 21 vac power source which connects to terminals 1 and 2 of power input strip on each module A separate source of 21 vac power is used to power options module through terminals 1 and 2 on power input strip A separate source of 12 5 vac power is used to power EXV driver module through terminals 1 and 2 on power input strip
13. MODULE i t J7 2 STAGE M es STAGE NOTE Contacts must be rated for dry circuit application capable of reliably switching a 5 vdc mA to 20 mA load Fig 26A Demand Limit Two External Switch Inputs 30GN040 210 and Associated Modular Units 71 136 8 Peewee eee TB7 STAGE id iier a a er REESE a em Hero fi STAGE2 IURE T TB7 TB Terminal Block NOTES 1 Requires accessory options module package 2 Contacts must be rated for dry circuit application capable of re liably switching a 5 vdc 1 mA to 20 load Fig 26B Demand Limit Two External Switch Inputs 30GT225 250 280 Units _ 2 72 FIELD SUPPLIED LOQR amp GLATOR EXTERNAL POWER GENERATOR f oss SSS EXTERNAL O mA POWER SIGNAL GENERATOR 30GN040 210 AND ASSOCIATED MODULAR UNITS Rm J7 14 30GN040 210 AND ASSOCIATED MODULAR UNITS PHONES 3 7 H FIELD SUPPLIED 77 TE 18 4 LOOP ISOLATOR uM FLOTRONIC Il UNITS 2 a Jaen Terminal Bloc 30GT225 250 280 FLOTRONIC Il UNITS NOTE The 30GT225 250 280 Flotronic II units require the acces 4 options module package for this feature TB Terminal Block NOTE The 30GT225 250 280 Flotronic Il units require the acces Fig 27 Demand Limit 4 20 mA Signal sory options module package for this feature
14. Thermistor Locations Circuits A and B Lead Compressor Only 30 4143 COUPLING JACKETED JACKETED SENSOR THERMISTOR ACCESSORY i CABLE CABLE TUBE WELL 3 2 S 65 ae dit d NOTE BEND suert si 2 FOR INSERTION FERRULES 3 16 4 8 DIA 1 4 6 4 INTO WELL INSIDE OD COUPLING WATER SIDE TEMPERATURE SENSOR T2 ALL UNITS REFRIGERANT TEMPERATURE SENSOR T7 T8 040 210 AND T7 T8 225 250 280 ASSOCIATED MODULAR UNITS Fig 15 Thermistors 59 Thermistors All thermistors are identical in their tem perature vs resistance performance Resistance at various temperatures are listed in Tables 15 and 16 LOCATION General location of thermistor sensors are shown in Fig 13 Cooler Leaving Water Thermistor TI is located in leaving water nozzle The probe is immersed directly in the water All thermistor connections are made through a 1 4 in coupling See Fig 15 Actual location is shown in Fig 13 and 14 Cooler Entering Water Thermistor T2 T2 is located in cooler shell in first baffle space near tube bundle Ther mistor connection is made through a 4 1 coupling See Fig 15 Actual location is shown in Fig 13 and 14 Compressor Suction Gas Temperature Thermistors T7 and T8 7 and T8 are located in lead compressor in each Circuit in suction passage between motor and cylinders above oil pump They are well type thermistors on 040 210 and asso
15. codes listed for this unit model on the component ar rangement label diagram on the control box door If they are different or are all zeros reenter the 6 codes If any changes are required the PSIO display becomes blank and reconfigures itself after pressing the ke key 74 while displaying CODE 6 The display returns in ap proximately 15 seconds NOTE Codes with leading zeros in the configuration will be displayed starting with the first number greater than zero 14 Press a to verify each item is configured as needed for this particular installation Table 9 shows the fac tory configuration code default settings Table 9 also shows the service replacement code default settings which are used if no model number was specified when or dering the replacement PSIO module It is strongly sug gested that the Start Up Checklist for Flotronic II Chiller Systems completed at time of original start up be used at this time to verify and or reprogram the various op tions and configurations required for this job 15 After completing the configuration steps outlined above restore main power and perform a unit test as de scribed in EN and 2 sections on page 38 16 Complete this procedure and restore chiller to normal operation by returning the LOCAL ENABLE STOP CCN switch to desired position NS Copyright 1994 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time
16. cont 7 PRESSURE 8 ANALOG 9 INPUTS Table 9 Keypad Directory cont KEYPADENTRY STATUS cont DISPLAY PRESSURE DPA X SPA X XXXX OPA X DPB X SPB X XXXX OPB X ANALOG REF X LMT X RST X 31 COMMENT Circuit B Saturated Condenser Temperature Circuit B Saturated Suction Temperature Compressor B1 Suction Temperature Circuit B Suction Superheat Reset Temperature Refrigerant System Pressure psig Circuit A Discharge Pressure Circuit A Suction Pressure Circuit A Discharge Suction Circuit A Oil Pressure Differential Circuit B Discharge Pressure Circuit B Suction Pressure Circuit B Discharge Suction Circuit B Oil Pressure Differential Status of Analog Inputs Transducer Supply Voltage Demand 4 20 mA Signal Reset 4 20 mA Signal Status of Switch Inputs Dual Set Point Switch Demand Limit Switch 1 Demand Limit Switch 2 SUBFUNCTION 10 OUTPUTS Table 9 Keypad Directory cont STATUS cont OUTPUTS ALMR X FRA1 X FRA2 X FRB1 X FRB2 X CHWP X ULA1 X ULA2 X ULP1 X ULB2 X EXVA X EXVB X HGBA x HGBB X MMA X i pep et pe Ee Ee e us MMB X TEST COMMENT Status of Outputs Alarm Relay Fan Relay K1 Fan Relay K2 Fan Relay K4 Fan Relay K5 Cooler Water Pump Relay K6 Unloader Al t Unloader 2 Unloader Bit Unloader B2T EXVA Percent Open EXVB Percent Open Hot Gas Bypass Relay Circuit A Hot Gas Bypass Relay Circuit B Motormaster A Outp
17. ods occupied time will take precedence over unoccupied time Occupied times can overlap in the schedule with no consequence To extend an occupied mode beyond its normal termina tion for a one time schedule override program as shown below Override is set for 0 Enter the number of hours of override desired Unit will now remain in occupied mode for an additional 3 hours az Bz Holidav Schedule Press schedule up to 30 holiday periods All holidays are entered with numerical values First the month 01 to12 then the day 01 to 3 1 then the duration of the holiday period in days Examples July 24 is 07 04 01 Dec 25 26 is 1225 02 If any of the 30 holiday periods are not used the display shows NEW See Example 10 47 Example 10 Holiday Schedule Function ENTER DISPLAY HOLIDAY JANO1 02 Includes Jan 1st and 2nd APR17 01 Includes April 17th MAY21 01 Includes May 21 st JULO3 01 Includes July 3rd 3E ES TES TEST E S Ed JULO4 01 Includes July 4th SEP07 01 Includes Sep 7th NOV26 02 Includes Nov 26th and 27th DEC24 02 Includes Dec 24th and 25th DEC30 02 includes Dec 30th and 31st NEW ELIE ILI MAY25 01 Includes May 25th NEW NEW NEW NEW NEW 30TH HOLIDAY NEW indicates a holiday that has not been assigned yet A G H PERIOD FRI SAT SUM PERIOD 5 FERION FERIO D 3
18. protection COOLER FREEZE XN PROTECTION COMMENTS Keypad has not been used for at least 10 minutes Alternating summary display appears on screen 2 alarms detected First alarm code Explanation of alarm code When a diagnostic alarm code is stored in the display and the machine automatically resets the code is deleted Codes for safeties which do not automatically reset are not deleted until the problem is corrected and the machine is switched to STOP then back to LOCAL ENABLE or CCN Modes The operating mode codes are dis played to indicate the operating status of the unit at a given time See Table 10 37 Table 10 Operationat and Mode Display Codes The operating modes are displayed by name or code num ber to indicate the operating status of the unit at a given time The modes are CODE DESCRIPTION Unit is off LOCAL ENABLE STOP CON switch is in OFF position or LOCAL ENABLE STOP CCN switch may be in LOCAL position with external ON OFF switch in OFF position Unit is off due to CCN network command LOCAL ENABLE STOP CCN switch is in CCN position Unit is off due to internal clock schedule LOCAL ENABLE STOP CON switch is in LOCAL position Unit is on LOCAL ENABLE STOP CON switch is in LOCAL position If external ON OFF switch is used it will be in ON hosition Unit is on due to CCN command LOCAL ENABLE STOP CON switch is in CCN position Unit is on due to internal clock schedule
19. ule receives signals from the processor and operates the elec tronic expansion valves Options Module This module allows the use of Flo tronic II features such as dual set point remote reset de mand limit hot gas bypass and accessory unloaders The options module also allows for reset and demand limit to be activated from a remote 4 20 mA signal The options mod ule is installed at the factory on 040 210 and modular 240 420 units It is a field installed accessory for 225 250 and 280 units Keypad and Display Module also called HSIO or LID This device consists of a keypad with 6 func tion keys 5 operative keys 12 numeric keys and an al phanumeric g character LCD Key usage is explained in Accessing Functions and Subfunctions section on page 28 Control Switch Control of the chiller is defined by the position of the LOCAL ENABLE STOP CCN switch This is a 3 position manual switch that allows the chiller to be put under the control of its own Flotronic controls manually stopped or put under the control of a Carrier Corn fort Network CCN Switch allows unit operation as shown in Table 2 E ELECTRONIC EXPANSION VALVES 30 dd a q 4 IN 4 OUT DRIVER MODULE MODULE DSIO EXV LOW VOLTAGE RELAY MODULE 6 PACK DSIO LV TB 7 RELAY BOARD TRANSDUCER POWER SOURCE PSI PSIO PROCESSOR MODULE COOLER HEATER RELAY A COOLER 4EAT ER RELAY B TB 3 FIELD CONTROL POWER CONNECTION
20. 330A B 360B 50 Hz 1 1 Al A2 A3 B1 B2 Al A2 A3 B1 B2 Al A2 A3 B1 B2 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Unloaded compressor Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 18 A1 Bitt MGBATR 1 B1 Ai Bitt B2 1 A1 B1tt B2 A1 B1 B2 A1 B1 B2 ie Al AA2 B1 B2 Al A2 B1 B2 Al 2 1 2 3 Al B3 Al AI Bitt B2 A1 Bitt B2 A1 B1 B2 Me Bit Al Al A2 B1 B2 Al A2 B1 B2 Raho 3 gt ho Nom DW at rm AT AL 0200 o3 gt fo RS 0325 Bo ME NR 85 a Ur TO UJ ceo Al A2 A3 B1 1 2 3 uu AI AD B1 2263 Al A2 B1 B2 B3 Al A2 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 AI A2 A3 B1 B2 B3 Table 4C Capacity Control Steps 130210 and Associated Modular Units cont LOADIINCi SEQUENCE A T LOADING SEQUENCE B UNIT CONTROL SIZE STEPS Displacement Compressors Displacement Compressors Approx Approx 1 Auc 2 T 3 s 4 5 6 7 8 Al t A2 B1 9 Aitt A2 Bt A1 A2 B1 170 270A 300B Al A2 B1 330 360 100 Hz Al tt B1 B2 2 W WEE 170 270A 3008 330A B 360B 50 Hz A1t BtT AI af Bat B2 B3 Al A2 B1 t 2 83 2 l A2 B1 AI
21. 4 070 50 Hz 5 1 1 6 c 7 8 cm 9 A1 A2 B1 4 10 A1 A2 B1 d 1 BiH 3 070 50 Hz 4 AISB1 ATTE 5 Al Bi 6 Al A2 B1 7 Al A2 B1 1 B1Tf 2 3 A B1 4 A11F B1 1 1 070 50 Hz 5 Aft B1 Al B1 Al 1 B1 6 AI B1 Al A2 B1 7 A1 B1 Al A2 B1 8 A1TT A2 B1 9 A1 A2 B1 10 A1 A2 B1 Unloaded compressor Compressor unloader standard Compressor unloader accessory unloaders both unloaded Table 4B Capacity Control Steps 080 110 and Associated Modular Units LOADING SEQUENCE A T LOADING SEQUENCE B UNIT CONTROL 30GN STEPS Displacement Compressors Displacement Compressors Approx Approx 1 Bt 2 B1 080 50 Hz ni A1T B1t 5 Al 6 Al A2 B1 7 A1 A2 B1 1 2 3 080 60 Hz Ait Bit d Z 7 mit 8 e Q 1 BITT 2 B1 3 B1 080 60 Hz 4 ALBI AS 7 Al 2 B1 8 Al A2 B1 Bit 2 B1 3 B1 080 60 Hz P Ait Bit 7 A1 A2 B1 8 Al A2 B1 9 1 2 B1 3 A1 B1 gs e Hz 4 Eum 1f B1 5 zn 6 Al A2 B1 7 Al A2 B1 8 Al A2 B1 1 eei 2 5 E 4 080 50 H2 A1t B1T 7 Al Bt 8 AI TT 2 B1 9 Attt A2 B1 10 Ad 2 81 Al A2 B1 1 Bitt 2 B1 3 ren 080 50 Hz 4 A1B1 ALS A 7 A1 A2 B1TT 8 1 A2 B1 Q A1 A2 B1 A Bitt 1 3 B1 A1 B1 080 50 Hz 5 AABI AI A2 ATT BTE 6 Al B1 A1 A2 B1 tt 7 Al 1 2 1 A1 A2 B1 8 A1
22. 4 IN A OUT MODULE SIO LOW VOLTAGE RELAY MODULE DSIO AND EXV DRIVER MODULE DSIO The PSIO DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware Proper operation of these modules is indicated by EDs light emitting diodes on the front surface of the DSIOs and on the top horizontal sur face of the PSIO and SIO RED LED Blinking continuously at a 3 to 5 second rate indicates proper operation Lighted continuously indicates a problem requiring replacement of module Off continu ously indicates power should be checked If there is no in put power check fuses If fuse is bad check for shorted secondary of transformer or for bad module On the PSIO module if the light is blinking at a rate of twice per sec ond the module should be replaced GREEN LED On a PSIO and an SIO this is the green LED closest to COMM connectors The other green LED on module indicates external communications when used Green LED should always be blinking when power is on It indicates modules are communicating properly If green LED is not blinking check red LED If red LED is normal check module address switches See Fig 18 Proper addresses are PSIO Processor Module 01 different when CCN connected DSIO Relay Module 19 DSIO EXV Driver Module 31 SIO 4 In 4 Out Module 59 H all modules indicate communication failure check COMM plug on PSIO module for proper seating
23. 7 C or more below leaving water tem perature for more than one minute unit shuts down without pumpout Chilled water pump also shuts down Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence This is a suitable method for sensing low water flow be cause entering water thermistor is in the cooler shell and responds more quickly to compressor operation than the leav ing water thermistor in the leaving water nozzle Possible causes of fault are faulty chilled water pump control or thermistor Code 44 Low cooler suction temperature Circuit A Code 45 Low cooler suction temperature Circuit B If saturated suction temperature is less than 32 F 0 C and is 20 F 11 C for water or 30 F 16 C for brine or more below leaving fluid temperature mode 14 is dis played Unit continues to run but additional compressors are not allowed to start If condition persists for more than 10 minutes fault code is displayed and unit shuts down without pumpout Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence Possible causes of fault are low refrigerant plugged filter drier or a faulty EXV or thermistor Code 46 High suction superheat Circuit A Code 47 High suction superheat Circuit B If EXV is fully open suction superheat is greater than 75 F 42 C and saturated evaporator temperature is less than MOP maximum operating pressure for more than 5 minutes uni
24. B1 B2 Al A2 AS E B2 Al a ra Bi 8 150 50 Hz AT Bit O Q 0m Al Ritt B2 A po Al A2 Bitt B2 Al iets I A2 Al A3 B1TT B2 SEI Al A2 A3 B1 B2 150 50 Hz Ait B1t C 179 270A 3008 No 330A B 60 Hz Ait Bit 2 B1 Al A2 1 B2 Al A2 B1 B2 B3 Al A2 A3B1 B2 A1 A2 B1 B2 B3 Al A2 A3B1 B2 2 FEW Cree Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 i i Al B1 AI TT A2 B1 Aitt A2 B1 1 170 270A 3008 330A B 60 Hz A yos xL B2 Ait Bit E 2 An 2 B1 B2 B3 1 A2 A3 B1 B2 B3 2 A2 A3 B1 B2 B3 1141 Unloaded compressor Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 17 Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont LOADING SEQUENCE A LOADING SEQUENCE UNIT CONTROL 95 SIZE STEPS Displacement Compressors Displacement Compressors Approx Approx 1 2 3 4 5 6 7 8 9 170 270A 300B 330A B 60 Hz Ait Bit Al B1 A1tt A2 B1 1 2 1 1 2 1 170 270 300 Al 2 1 330A B 80 Hz A1tt A2 B1 B2 Al TT A2 B1 B2 AI A2 B1 B2 Al A2 B1 B2 aaNet E A2 A3 B1 B2 AT BTE Al t 170 270A 3008
25. B2t Test Compressor B3T Test Compressor B4t Energize Unloader AI T Energize Unloader A2t Energize Unloader B1T Energize Unloader B2T The Schedule function key used to configure the occupancy schedule The clock select subfunction be used for unoccupied shutdown or unoccupied setback depending on the cooling set point control configuration The Schedule function described is for clock 1 which is the internal clock Password required for all subfunctions except override SUBFUNCTION 1 1 OVERRIDE KEYPAD ENTRY DISPLAY OVRD X For example to extend current occupied mode for 3 hrs press 2 CLOCK SELECT LEGEND Carrier Comfort Network EXV Electronic Expansion Valve MOP Maximum Operating Pressure 3 OVRD 3 CLOCK XX Must be configured tlf applicable 33 COMMENT Number of Override Hrs 0 4 Hrs Extended Occupied Time Type of Clock Control 0 No Clock 1 Clock 1 Internal Table 9 Keypad Directory SCHEDULE cont SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT PERIOD 1 Period Time Schedule OCC HH MM Occupied Time 3 PERIOD 1 Yes Schedule Operational for that day UNO HH MM Unoccupied Time MON X Monday Flag TUE X Tuesday Flag WED x Wednesday Flag THU X Thursday Flag FRI X Friday Flag SAT X Saturday Flag SUN X Sunday Flag Holiday Flag EE To toggle between inputs Yes No Press 4 PERIOD 2 i o WPEBIOM2i m
26. Carrier Comfort Network EXV Electronic Expansion Valve And associated modular units 45 SERVICE EPLACEMENT CODE 001 000 9600 The schedule function can be programmed for inactive single set point or dual set point operation When schedule is configured for inactive chilled water pump relay remains energized continuously but is not used since chiller is usually controlled by remote chilled water pump interlock contacts When unit is configured for single set point operation chilled water pump relay is energized whenever chiller is in occupied mode regardless of whether chiller is running When chiller is in unoccupied mode chilled water pump relay is not energized When unit is configured for dual set point chilled water pump relay is energized continuously in both occupied and unoccupied modes Occupied mode places occupied chilled water set point into effect unoccupied mode places unoc cupied chilled water set point into effect The schedule consists of from one to 8 occupied time pe rods set by the operator These time periods can be flagged to be in effect or not in effect on each day of the week The day begins at 00 00 and ends at 24 00 The machine is in unoccupied mode unless a scheduled time period is in ef fect If an occupied period is to extend past midnight it must be programmed in the following manner occupied pe riod must end at 24 00 hours midnight a new occupied period must be programm
27. Ff COOL DOW w Day of Week HH Hour s MM Minute s The default display is displayed every 2 seconds if there has been no manual input from the keypad for 10 minutes To return to automatic display enter ny time Table 6 Keypad and Display Module Usage FUNCTION KEYS USE STATUS For displaying diagnostic codes and current operating information about the machine HISTORY For displaying run time cycles and previous alarms SERVICE For entering specific unit configura tion information TEST For checking inputs and outputs for proper operation SCHEDULE For entering occupied unoccupied schedules for unit operation SET POINT For entering operating set points and day time information CJ ail E OPERATIVE KEYS USE EXPAND For displaying a non abbreviated ex pansion of the display CLEAR For clearing the screen of all displays i UP ARROW For returning to previous display c l position i DOWN ARROW For advancing to next display c i position ENTER For entering data KEYPAD OPERATING INSTRUCTIONS Refer to Table 9 1 White keys on left side of keypad are shown and oper ated in these instructions according to the following ex ample keypad entry press the then the white key marked 2 The standard display uses abbreviations T in formation scrolls through the display whenever is pressed key 3 AII functions are made up of a group of subf
28. LOCAL ENABLE STOP CCN Switch and start up follows normal sequence Possible causes for this ducer or a faulty EXV Code 40 Low oil pressure Circuit A Code 41 Low oil pressure Circuit B If oil pressure differential is less than set point for more than 2 minutes at start up or more than one minute during normal operation affected circuit shuts down without go ing through pumpout process Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence Factory configured differential oil pressure is 6 psig Possible causes of fault are faulty compressor EXV crank case heater or transducer refrigerant overcharge insuffi cient oil charge or tripped circuit breaker alarm are a bad thermistor or trans Code 42 Cooler freeze protection If cooler entering or leaving water temperature is below 34 F 1 1 C for water or more than 8 F 4 4 C below set point for brine unit shuts down without pumpout Chilled water pump continues to run if controlled by chiller con trols Reset is automatic when leaving water temperature reaches 6 F 3 C above set point providing there has been no prior occurrence of this fault the same day If fault has occurred previously the same day reset is manual with LOCAL ENABLE STOP CCN switch Possible causes of fault are low water flow or faulty thermistor Code 43 Low water flow If any compressors are operating and entering water tem perature is 3 F 1
29. TB 6 COMMUNICATIONS BUS i LOCAL ENABLE STOP CCN COMM 1 ovv qun KEYPAD DISPLAY GROUND FA GFI Ter MODULE HSIO LID 208 230 460 575 3 60 V ONLY LEGEND CCN Carrier Comfort Network TB 1 erminal Block Fig 1 30GN Control Panel 040 110 240B 270B Unit Shown In the LOCAL ENABLE position the chiller is under lo cal control and responds to the scheduling configuration and set point data input at its own local interface device key pad and display module In the CCN position the chiller is under remote control and responds only to CCN network commands The occupied unoccupied conditions are defined by the network All key pad and display functions can be read at the chiller regard less of position of the switch CCN run or stop condition is established by a command from the CCN network It is not possible to force outputs from the CCN network except that an emergency stop com mand shuts down the chiller immediately and causes AL 52 to be displayed Table 2 LOCAL ENABLE STOP CCN Switch Positions and Operation UNIT OPERATION CONFIGURATION AND SET POINT CONTROL Keypad Control CCN Control Unit Cannot Rup Read Write Read Onlv Unit Can Run Read Limited Write Read Only Unit Cannot Run Read Only Read Write Unit Can Run Read Onlv Read Limited SWITCH POSITION STOP LOCAL ENABLE CCN Stop Run Write Electronic Expansion Valve EXV The micro processor control
30. Unloaders NO OF ACCESSORY UNLOADERS PERMITTED 30GN040 070 30GNO080 170 m ud 3067225250280 1 And associated modular units NO OF STANDARD UNIT UNLOADER s Installation 1 Be sure all electrical disconnects are open and tagged before any work begins Inspect the package contents for any damage during shipping File a claim with the shipper if damage has occurred 2 For ease of installation factory supplied wiring for the additional unloader is provided in the compressor harness 3 Install the additional unloader cylinder head on the lead compressor Al or Bl according to instructions pro vided by the compressor manufacturer in the accessory package 4 Continue installation per either 040 1 10 130 60 Hz units or 130 50 Hz 150 210 225 250 and 280 units section as appropriate 040 1 10 130 60 Hz UNITS and associated modular units 1 Wire the solenoid before any field wiring begins Wir ing between components and control box must be en closed in conduit All local electrical codes and National Electrical Code NEC must be followed Factory wires are provided in the compressor harness to connect the solenoid These wires are in the compressor control box 2 Wire the control side Open the left side control box door and remove inner panel Using the holes provided and field supplied screws install field supplied trans former above the DSIO LV on the control pa
31. are displayed in 24 hr time Decimal point serves as colon MM DD YR Month Day Year When entering date enter a decimal point between entries Each entry must be two numbers 36 ZY wn BIEN E STATUS FUNCTION This function shows the rotating display current status of alarm diagnostic codes capacity stages operating modes chilled water set point all meas ured system temperatures and pressures superheat values pressure switch positions analog inputs and switch inputs These subfunctions are defined on pages 37 and 38 tin g Alarms are messages that one or more faults have been detected Each fault is assigned a code num ber which is reported with the alarm See Table 10 for code definitions The codes indicate failures that cause the unit to shut down terminate an option such as reset or result in the use of a default value as set point Display Up to 5 alarm codes can be stored at once To view them in sequence press gt to enter the alarm displays and then press plays Press after a code has been displayed The mean ing of the code scrolls across the screen See Example 1 to move to the individual alarm dis Example 1 Reading Alarm Codes KEYPAD DISPLAY ENTRY RESPONSE TUE 12 45 MODE 13 0 STAGES 2 ALARMS 2 4 2 ALARMS ALARM o COOLER LEAVING b FLUID THERMISTOR Explanation of alarm code FAILURE Second alarm code Cooler ALARM 42 freeze
32. ath Shut off all power to this equipment during installation and service There may be more than one disconnect switch Tag all disconnect locations to alert others not to restore power until work is completed When working on this equipment observe precautions in the literature and on tags stickers and labels attached to WARNING the equipment and any other safety precautions that apply This unit uses a microprocessor based electronic con Follow all safety codes Wear safety glasses and work gloves trol system Do not use jumpers or other tools to short Use care in handling rigging and setting this equipment out components or to bypass or otherwise depart from and in handling ali electrical components recommended procedures Any short to ground of the control board or accompanying wiring may destroy the electronic modules or electrical components Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 PC 903 Catalog No 563 015 Printed in U S A Form 30GN 2T Pg 1 1 94 Replaces pus Sr 1T Gt GENERAL IMPORTANT This publication contains controls op eration and troubleshooting data for 30GNO040 420 30GT225 250 and 280 Flotronic II chillers Circuits are identified as circuits A and B and com pressors are identified as Al A2 etc in circuit A and B B2 etc in circuit B Use this guide
33. be sure EXV cables are not crossed EXV DRIVER BOARD J4 A230 1560 EXV A EXV B 2 ayt EXV Electronic Expansion Valve Fig 12 EXV Cable Connections to EXV Driver Module DSIO EXV 3 Check resistance of EXV motor windings Remove plug at J4 terminal strip and check resistance between com mon lead red wire terminal D and remaining leads A C and E see Fig 12 Resistance should be 25 ohms 2 ohms Control of valve is by microprocessor A thermistor and a pressure transducer located in lead compressor are used to determine superheat The thermistor measures tem perature of the superheated gas entering the compressor cylinders The pressure transducer measures refrigerant pressure in the suction manifold The microprocessor con verts pressure reading to a saturation temperature The difference between temperature of superheated gas and saturation temperature is the superheat Because the EXVsare controlled by the processor mod ule it is possible to track valve position During initial start up EXV is fully closed After start up valve po sition is tracked by processor by constantly observing amount of valve movement The processor keeps track of EXV position by counting the number of open and closed steps it has sent to each valve It has no direct physical feedback of valve posi tion Whenever unit is switched from STOP to RUN po sition both valves are initialized allowing
34. e Schedule rAp IPFERODS 5 PERIOD 3 9 PERIOD 7 eie iode ES penopS o d 7 Time Schedule elle i o dPEBIOD8i m e Schedule HOLIDAYS 10 PERIOD 8 11 HOLIDAYS Define Calendar Holidays DAT MM DD Holiday Date 1 New Unassigned Holiday Date DAT MM DD NN Holiday Date 30 For example To enter July 4th holiday press 07 04 01 Display shows Jul 04 For further information on the Schedule function and its operation refer to Schedule Function section on page 45 SERVICE To view and modify configurations the password must be entered under the log on subfunction SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 LOG ON AND LOG OFF 1 LOG ON Enter Password Disable Password Protection Logged Onl 1 LOGGEDON At this time configurations may be modified When finished viewing and or modifying configu log out as follows LOG OFF Disable Password Protection EXIT LOG Logged Off Enable Password Protection 2 VERSION VERSION Software Information XXXXXXXX Version No of Software CESRXX X Language Options See legend on page 30 34 Table 9 Keypad Directory cont SERVICE cont The next 3 subfunctions provide the ability to modify configurations Refer to separate Installation Start Up and Service Instructions supplied with unit for further information on changing configurations To change a configuration enter the new configuration and press ewsm while on
35. failure circuit A Circui Auto 25 Suction pressure transducer failure circuit B Circui Auto 26 Oil pressure transducer failure circuit A Circui Auto 27 Oil pressure transducer failure circuit Circui Auto 28 Transducer supply voltage Unit shut down Auto 29 Interlock switch oaen Unit shut down Manual 30 4 20 mA reset input failure ormal set point used 31 4 20 mA demand limit failure emand limit ignored 32 Loss of communication with DSIO LV nit shut down 33 Loss of communication with DSIO EXV nit shut down 34 Loss of communication with 4 In 4 Out module nit shut down 35 Not used 36 Low refrigerant pressure circuit A Circuit A shut down 37 Low refrigerant pressure circuit B Circuit B shut down 38 Failure to pump out circuit A Circuit A shut down 39 Failure to pump out circuit B Circuit B shut down 40 Low oil pressure circuit A Circuit A shut down Manual 41 Low oil pressure circuit B Circuit B shut down Manual 42 Cooler freeze protection Unit shut down N 43 Low cooler water flow Unit shut down No Manual 44 Low suction temperature circuit A Circuit A shut down No Manual after 10 minutes 45 Low suction temperature circuit B Circuit B shut down Manual afler 10 minutes 46 High suction superheat circuit A Circuit A shut down Manual 47 High suction superheat circuit Circuit B shut down Manual 48 Low suction superheat circuit A Circuit A shut down Manual 49 Low suction superheat circuit B Circuit B shut down Manual 50 Il
36. fully open Lead screw movement should be smooth and uniform from fully closed to fully open position Press check open to closed operation If valve is properly connected to processor and re ceiving correct signals yet does not operate as de scribed above valve should be replaced Operation of EXV valve can also be checked without removing top cover This method depends on oper ator s skill in determining whether or not valve is moving To use this method initiate EXV test and open valve Immediately grasp EXV valve body As valve drives open a soft smooth pulse is felt for ap proximately 26 seconds as valve travels from fully closed to fully open When valve reaches end of its opening stroke a hard pulse is felt momentanly Drive valve closed and a soft smooth pulse is felt for the 26 seconds necessary for valve to travel from fully open to fully closed When valve reaches end of its stroke a hard pulse is again felt as valve overdrives by 50 steps Valve should be driven through at least 2 complete cycles to be sure it is operating properly If a hard pulse is felt for the 26 second duration valve is not moving and should be replaced The EXV test can be repeated as required by enter ing any percentage from 0 to 100 to initiate movement If operating problems persist after reassembly they may be due to out of calibration thermistor s or inter mittent connections between processor board termina
37. motor and lead screws 7760 discrete steps of motion are obtained The large num ber of steps and long stroke result in very accurate control of refrigerant flow The subfunction shows EXV valve position as a percent of full open Position should change constantly while unit operates If a valve stops moving for any reason mechanical or electrical other than a processor or ther mistor failure the processor continues to attempt to open or close the valve to correct the superheat Once the calcu lated valve position reaches 60 fully closed for 040 210 and associated modular units 145 fully closed for 225 250 and 280 units or 760 fully open it remains there If EXV position reading remains at 60 145 or 760 and the thermistors and pressure transducers are reading correctly the EXV is not moving Follow EXV checkout procedure below to determine cause The EXV is also used to limit cooler suction temperature to 50 F 10 C This makes it possible for chiller to start at higher cooler water temperatures without overloading com pressor This is commonly referred to as MOP maximum operating pressure and serves as a load limiting device to prevent compressor motor overloading This MOP or load limiting feature enables the 30G Flotronic II chillers to operate with up to 95 F 35 C entering water temperatures during start up and subsequent pull down 30 392 STEPPER MOTOR 12 VDC ORIFICE ASSEMBLY INSIDE PISTO
38. or occu pied override function LOCAL ENABLE STOP CCN switch is in LOCAL position Dual set point is in effect In this mode unit contin ues to run in unoccupied condition but leaving wa ter set point is automatically increased to a higher level 5 2 set point is in SET function Temperature reset is in effect In this mode unit is using temperature reset to adjust leaving water set point upward and unit is currently controlling to the modified set point The set point can be modified based on return water outdoor air temperature or Space temperature Demand limit is in effect This indicates that ca pacity of unit is being limited by demand limit con trol option Because of this limitation unit may not be able to produce the desired leaving water temperature Load limit is in effect This indicates that capacity of a system of units is being limited by a CCN load shed command Due to this limitation unit may not be able to produce the desired leaving water temperature Not applicable Ramp load pulldown limiting is in effect In this mode the rate at which leaving water temperature is dropped is limited to a predetermined value to prevent com pressor overloading See CRAMP set point in the SET function in Table 9 The pulldown limit can be modified if desired to any rate from 2 F to 2 F 1 to 1 C minute Timed override is in effect This is a 1 to 4 hour temporary override of the programmed schedule forc
39. r r air 2 CRTYP 2 l mporature reer an activated Reset type is changed to CRTYP 3 s CRTYP 0 4 20 mA signal reset and activated Reset is deactivated 10 9 8 7 RESET CRST2 10 lt MAX RESET REFERENCE CREF2 10 S s JE MIN RESET CRST1 2 o 5 5 MIN RESET REFERENCE CREF 90 lt 3 m m 5 Da A BO m 4 se 3 60 2 40 20 2 100 RESET REFERENCE TEMPERATURE OUTDOOR AIR oR SPACE TEMP Fig 5 Cooling External Temperature Reset 41 COMM3 dae Snc a II m CHANNEL 1 REMOTE DEMAND LIMIT ALARM CODE 312 MODE 9 um pe s s UO AR CHANNEL 2 m emer g f 5 MODE 7 SW 5 mcm mmi sum w s mm x u Mecum RR R amm ms umi MN MEB m AM Xo m ALARM CODE 21 30 z MODE B fay REMOTE RESET THERMISTOR ALARM CODE 21 m cxz JB tn C xr 5 ao Q9 0 2 lt 5 U s 5 e eo z ce LEGEND lt e COMM Communications Bus e PWR Power SW Switch NOTE For specific connection points see Fig 24 29 Fig 6 4 IN 4 OUT Options Module Wiring for Reset Demand Limit and Dual Set Point Table 11 Service Functions To view and modify configurations the password must be e
40. relays as shown on the com ponent arrangement diagram on the unit Mount the re lays with the field supplied screws Be careful not to damage the components and wiring in the area when mount ing the relays Wire the control side Wire the URA coil in series be tween J6 18 and J6 19 of the 4 IN A OUT module with the wires provided Wire the URB coil in series be tween 16 21 and J6 22 of the same module with the wires provided Locate the black wire in the control harness originating from TRANS labeled HGBPR A COM Connect this wire to the URA terminal COM Connect the wire labeled HGBPR A NO to URA NO Connect the wire from URA NO to TB3 5 For an extra unloader on circuit connect the wire labeled HGBPR B COM to UR B COM and the wire labeled HGBPR B NO to URB NO Connect the wire from URB NO to TB3 6 3 Wire in the solenoid valves NOTE Wires external to the control box must be run in conduit Terminal blocks are provided for easy field wiring Use one of the isolated in 22 mm holes in the side of the compressor electrical box with a strain relief to run the wires to the solenoid coil Connect URA between TB3 5 and TB3 8 Connect URB between TB3 6 and TB3 8 Check all of the electrical connections for proper location and tightness and replace and secure the elec trical box of the compressor Configure the microprocessor Once the relays are mounted in the control box the microprocessor must be config
41. sociated modular units will cause a trip 6 Checkout Procedure Shut off main power to uni Tum on control power then step through subfunc tion 2 to proper compressor number 1 failure code 5 is compressor Bl Next energize the step If step works correctly then failure code is caused by e HPS high pressure switch open e Misplaced feedback wire from J4 and J5 terminals Ground wire and 24 v feeds reversed on one or more points on J3 Compressor Alarm Circuit For compressor Al alarm circuit processor closes contacts between J4 termi nals 2 and 3 to start compressor See Fig 10A 10D Safe ties shown to left of J4 must be closed in order for power to reach compressor control relay and the feedback input ter minals on J3 Failure of power to terminal 1 on J3 when contacts be tween 2 and 3 on J4 should be closed causes a code 1 alarm Terminal 2 on J3 is the other leg of the compressor Al feedback channel It is connected to the 24 v common NOTE Similar connections for each compressor can be fol lowed on the unit wiring diagrams located on the unit Code 9 Leaving water thermistor failure Code 10 Entering water thermistor failure If temperature measured by these thermistors is outside range of 40 to 240 F 40 to 116 C unit shuts down after going through a normal pumpout Reset is automatic if tem perature returns to the acceptable range and unit start up follows normal sequence Cau
42. specifications or designs without notice and without incurring obligations Book 2 PC 903 Catalog No 563 015 Printed in U S A Form 30GN 2T Pg 76 1 94 Replaces 30GB GT 1 T Tato 5c 30GN 1T
43. the correct configuration SUBFUNCTION COMMENT 3 FACTORY CONFIGURATION FACT CFG Factory Configuration Codes XXXXXXXX Configuration Code 1 XXXXXXXX Configuration Code 2 XXXXXXXX Configuration Code 3 XXXXXXXX Configuration Code 4 XXXXXXXX Configuration Code 5 XXXXXXXX Configuration Code 6 4 FIELD FLD CFG Adjustable Field Configuration CONFIGURATION ENO X CCN Element Address BUS X CCN Bus Number BAUD X CCN Baud Rate FLUID X Cooler Fluid Select UNITS X Display Unit Select LANG X Display Language Select NULA X No Circuit A Unloaders NULB X No Circuit B Unloaders HGB X Hot Gas Bypass Select SEQT X Loading Sequence Select SEQF X Lead Lag Sequence Select OPS x Oil Pressure Switch Select HEADM X Head Pressure Control Method MM X Motormaster Select CSPTYP X Cooling Set Point Control Select CRTYP X Cooling Reset Control Select ERTYP X External Reset Sensor Select LSTYP X Demand Limit Control Select RAMP X Ramp Load Select LOCK X Cooler Pump Interlock Select CPC x Cooler Pump Control Select 9 SERVICE SRV CFG Service Configurations CONFIGURATION XXXXXXXX Configuration Code 7 XXXXXXXX Configuration Code 8 REFRIG X Refrigerant TDTYP X Pressure Transducer Select OPS x Cil Transducer Set Point LPS x Low Pressure Set Point it F FANTYP X Fan Staging Select Nai SH X EXV Superheat Set Point MOP X EXV MOP Set Point 35 Table 9 Keypad Directory cont HISTORY SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 RUN TIME R
44. the proces sor to send enough closing pulses to the valve to move it from fully open to fully closed then reset the position counter to zero The EXV test can be used to drive EXV to any desired position When EXV opens the metering slots begin to provide enough refrigerant for operation at these steps step 60 for sizes 040 210 and associated modular units or 145 for sizes 225 250 and 280 This is fully closed position when circuit is operating The fully open posi tion is 760 steps Check thermistors and pressure transducers that control EXV Check thermistors and pressure transducers that control processor output voltage pulses to EXVs See Fig 13 for locations Circuit A Thermistor T7 Suction Pressure Trans ducer SPTA Circuit B ducer SPTB a Use temperature subfunction of the status function Cel Ee to determine if thermistors are reading correctly Thermistor T8 Suction Pressure Trans b Check thermistor calibration at known temperature by measuring actual resistance and comparing value measured with values listed in Tables 15 and 16 c Make sure thermistor leads are connected to proper pin terminals at J7 terminal strip on processor mod ule and that thermistor probes are located in proper position in refrigerant circuit See Fig 14 and 15 d Use the pressure subfunction of the Status function 7 eb to determine if pressure transducers are reading correctly Connect a calibrated g
45. ured for the unloader option To do so a Be sure the LOCAL ENABLE STOP CCN switch is in the STOP position b Log into the processor and enter the service func tion using the keypad and display module Type The keypad LCD will display PASSWORD Enter the keypad LCD will display LOGGEDON until either 0 or NULA 1 is displayed depending on the number of unloaders provided as standard Then press 1 bw for 1 unloader on Al Or for 2 unloaders on compressor Al The display will now read either NULA 1 or NULA 2 as appropriate Press to get to the NULB display and change this setting in the same manner as with circuit A d Once the configuration is complete press and the keypad LCD will display LOGGEDON Press until the keypad LCD display reads LOG OFF Press and the keypad LCD will display EXIT LOG 5 Once the unloader heads are installed the unit is checked for leaks and the system is prepared for operation per the instructions for the compressor unloader head instal lation check the output of the relays using the test func tion as follows a Press 2 Jf and the display will read COMP b Press the OFF c Press and the compressor should start d and the compressor should stop e Press o until the display reads ULA OFF f Press and the solenoid
46. 1 DAT PL1 4 TB RED K GRA 9 0 p0 01 0 9 58 J GRA UD CPRC5 81 ALARM CODE me PL2 3 WPS A2 DsT A2 PL2 4 PL10 7 den muca aan g nA nE AA Pi 412 RTI LOGICIK C BRN CPCS 81 n zi ERN TD CPCS 82 PLE 3 Joe PLB 4 i ALARH CODE 52 HPS B1 D6T 1 PL3 3 PL3 4 PLIO amp PCS H TE RED KE OR e opoe 0 0 OR VEL ORY 4 ow RTI LOGIC E C BRN Y BRN ALARM CODE 8 t CPCS 82 i PL4 3 HP 82 067 02 PL4 4 PLIOS 187 RED BU BLU Ly RES R1 J LOGI CIE C BRN 090 110 ONLY STL I pL2 3 ACCESSORY PL7 4 RED LEGEND Contactor COMM Communications Bus CPCS Compressor Protection Control Module m Discharge Gas Thermostat Optional amp l DSIO Relay Module Low Voltage P HPS l tigh Pressure Switch LV Low Voltage PWR Power TB m Terminal Block TRAN Transformer U Unloader Fig 10B 24 V Safety Circuit Wiring 080 110 and Associated Modular Units 53 TU TB CGF COMM CR DSIO HPS PL SNB TB TRAN ALARH CODE 1 PLI 3 HPS AI PLI 4 rep w aa e coe 2 PL2 3 rex E vio e e e a IOGMD 150 210 ONLY PL3 3 ipsas SEN PL3 4 rep au 2i004Y 77 ALARH CODE 4 PLA 3 ry PL4 4 axe COE 5 PLS 3 PLS 4 RED Kee ORN coor 71 PL 3 HPS
47. 170 2 Two Unloaders No Circuit B Unloaders 30GN040 070 0 No Unloaders 190 210 1 One Unloader 30GT225 250 280 2 Two Unloaders 30GN080 170 Hot Gas Bypass Select 0 0 No Valve L oading Sequence Select I Equal Circuit Loading Staged Circuit Loading Lola Sequence Select 1 Automatic Oil Pressure Switch Select Not Use Air Cooled ead Pressure Control Type Not Used Air Cooled ead Pressure Gontro Method EXV Controlled Set Point Control for Both Circuits Set Point Control for Circuit A EXV Control for Circuit B Set Point Control for Circuit B EXV Control for Circuit A Cooling Set Point Control Select 0 Single Set Point Control 1 External Switch Controlled Set Point 2 z Clock Controlled mcr F Mus nung un gt Set Point Cooling Reset Control Select 0 No Reset 1 Return Fluid Reset 2 3 4 rsp A Controlled Reset External Reset Sensor Select 0 Thermistor Connected to Options Module 1 Obtained Through CCN Demand Limit Control Select No Demand Limiting 1 Two External Switch Input 2 z External 4 20 mA Input 3 CCN Load Limiting Multi Unit CCN Loadshed Interface Ramg Load Select Pulldown Control 0 Disabled 1 Enabled Cooler Pump Interlock Select 0 No Interlock 1 With Interlock Cooler Pump Control Select 0 Not Controlled 1 ON OFF Controlled LEGEND m
48. 2 A3 A4 B1 B2 B3 Al A A3 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 83 B4 A1 2 A3 A B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 B4 Al A2 A3 A4 B1 B2 B3 B4 Unloaded compressor tCompressor unloader standard Compressor unloader accessory TfTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 24 Table 4D Capacity Control Steps 225 250 280 cont LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 1 2 3 250 50 Hz 4 280 60 Hz 5 6 T 8 1 2 3 4 5 6 250 50 Hz i 280 9 Al A1 A2 A3 B1 B2 B3 A2 A3 B1 B2 B3 Al AOA3 M Bi 2 d d A3 A4 B1 B2 BS 2 A3 A4 B1 B2 AS A3 A4 B1 B2 85 Xn Al A2 je B2 2 250 50 Hz Al A2 1 52 Al A2 B1 B2 280 A2 1 2 AI A2 B1 2 B3 us A1 B1 A 2 Bt B B3 iN AT a Ad SET 299 B3 A1 A2 A3 B1 B2 B3 A2 A3 B1 B2 53 Al 2 B1 B2 B3 B4 Al A2 A3 B1 B2 B3 B4 Al A2 A3 B1 B2 83 B4 A1 2 4 1 2 83 4 1 2 4 2 3 4 A1 A2 A3 A4 B1 B2 B3 B4 Al A2 A3 A4 B1 B2 B3 B4 Unloaded compressor PA Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may Vary due to lag compressor sequencing F C 25 Head Pressure Control The microprocessor con trols the condenser fans in order to maintain the low
49. 20 22M DSIO ADDRESS SELECTOR m n d PSIO SIO iai ADDRESS SELECTOR Fig 18 Module Address Selector Switch Locations 830 1565 Fig 19 Sensor Bus Wiring Communications PROCESSOR MODULE PSIO Fig 20 Inputs Each input channel has 3 terminals only 2 of the terminals are used Application of machine determines which terminals are used Always refer to individual unit wiring for terminal numbers Outputs Output is 24 vdc There are 3 terminals only 2 of which are used depending on application Refer to unit wiring diagram NOTE Address switches see Fig 20 must be set at 01 different when CCN connected 30 2 30 ui CHASSIS GROUND REAR NETWORK CONNECTOR le J5 26 as 5e HIR HE l FORWARD 115 0 SENSOR BUS 20 S5 ADDRESS CONNECTOR ise SWITCHES J8 ue 15 29 PSIO Sindino 9 PWR Power Fig 20 Processor Module PSIO 65 LOW VOLTAGE RELAY MODULE DSIO Fig 21 Inputs Inputs on strip J3 are discrete inputs ON OFF When 24 vac power is applied across the 2 terminals in a channel it reads as on signal Zero v reads as an off signal Outputs Terminal strips J4 and J5 are internal relays whose coils are powered up and powered off by a signal from micro processor The relays switch the circuit to which they are connected No power is supplied to these connections by DSIO
50. 30GN210 30GN210 6 Hz units 50 Hz units The Flotronic II control system cycles compressor un loaders and or compressors to maintain the selected leaving water temperature set point It automatically positions the EXV to maintain the specified refrigerant superheat enter ing the compressor cylinders It also cycles condenser fans on and off to maintain suitable head pressure for each cir cuit Safeties are continuously monitored to prevent the unit from operating under unsafe conditions A scheduling func tion programmed by the user controls the unit occupied unoccupied schedule The control also operates a test pro gram that allows the operator to check output signals and ensure components are operable The contrelsystem consists of a processor module PSIO a low voltage relay module DSIO LV 2 EXVs an EXV driver module DSIO EXV a 6 pack relay board a key pad and display module also called HSIO or LID ther mistors and transducers to provide inputs to the microprocessor An options module SIO is used to pro vide additional functions This module is standard on 30GN modules and is a field installed accessory on the 30GT Flo tronic II units See Fig 1 MAJOR SYSTEM COMPONENTS Processor Module This module contains the oper ating software and controls the operation of the machine It continuously monitors information received from the vari ous transducers and thermistors and communicates with the relay mod
51. 5 57162 87 2622 3906 183 0 649 533 8 0 4696 55311 88 2593 3814 184 0640 524 7 0 4 688 53526 89 2563 3726 185 0632 516 6 0 4676 51804 90 2533 3640 186 0 623 508 5 0 4666 50143 91 2505 3556 187 0 615 501 4 0 4657 48541 92 2 476 3474 188 0607 494 3 0 4648 46996 93 2447 3395 189 0600 487 2 0 4 636 45505 94 2417 3318 190 0592 480 1 0 4 624 44066 95 2388 3243 191 0 585 473 0 0 4 613 42679 96 2360 3170 192 0579 467 1 0 4602 41339 97 2332 3099 193 0572 461 2 0 4592 40047 98 2 305 3031 194 0566 456 3 0 4579 38800 99 2277 2964 195 0560 450 4 0 4 567 37596 100 2 251 2898 196 0554 445 5 0 4554 36435 101 2217 2835 197 0548 439 6 0 4540 35313 102 2189 2113 198 0542 434 7 0 4527 34231 103 2 162 2713 199 0 537 429 8 0 4 514 33185 104 2136 2655 200 0 531 424 9 0 4 501 32176 105 2107 2597 201 0526 419 10 0 4487 31202 106 2080 2542 202 0 520 415 11 0 4472 30260 107 2053 2488 203 0515 410 12 0 4457 29351 108 2028 2436 204 0 510 405 13 0 4442 28473 109 2 001 2385 205 0 505 401 14 0 4427 27624 110 1 973 2335 206 0 499 398 15 0 4413 26804 111 1 946 2286 207 0 494 391 16 0 4397 26011 112 1 919 2239 208 0488 386 17 0 4 381 25245 113 1897 2192 208 0 483 382 18 0 4366 24505 114 1870 2147 210 0 477 377 19 0 4348 23789 115 1 846 2103 211 0471 372 20 0 4 330 23096 116 1 822 2060 212 0465 367 21 0 4313 22427 117 1792 2018 213 0 459 361 22 0 4 295 21779 118 1771 1977 214 0 453 356 23 0 4278 21153 119 1 748 1937 215 0 446 350 24 0 4258 20547 120 1724 1898 116 043
52. 8 164 0883 765 69 0 3152 6081 165 0868 750 70 0 3123 5929 166 0853 734 61 TEMPERATURE boh oL 22 ol N G gt O I oo Table 16 Thermistor Temperature C vs Resistance Voltage Drop Flotronic Il VOLTAGE DROP V RESISTANCE Ohms 168230 157440 147410 138090 129 410 121 330 113810 106 880 100 260 94165 88 480 83 170 78125 13 580 BO RJ BO BO RO CW C CO CO CO CO p gt Pe RR CO On On c 1 1 co o w co wo 62 Tere VOLTAGE DROP V RESISTANCE Ohms 2 272 2184 2 101 2 021 1 944 1 871 1 801 1 734 1670 1609 550 493 439 387 337 290 244 200 158 118 079 041 006 971 938 906 876 836 805 115 747 719 693 669 645 623 602 583 564 547 531 516 502 489 477 466 456 446 436 427 419 410 402 393 385 376 367 357 346 335 324 312 299 285 oa Ls oa as a a ai E THERMISTOR __ REFRIGERANT DISCHARGE 30 ENTERING TEMPERATURE PRESSURE CYLINDERS TRANSDUCER ALIZER OIL PRESSURE SUCTION PRESSURE SIGHT GLASS Lead compressor only INE TRANSDUCER TRANSDUCER EACH COMPRESSOR m Fig 17 Lead Compressor Transducer and Thermistor Locations 63 Control Modules CAUTION Turn controller power off before servicing controls This ensures safety and prevents damage to controller PROCESSOR MODULE PSIOY
53. 9 344 25 0 4241 19960 121 1 702 1860 217 0432 338 26 0 4223 19393 122 1676 1822 218 0 425 332 11 0 4202 18843 123 1653 1786 219 0417 325 28 0 4184 18311 124 1 630 1750 220 0 409 318 29 0 4 165 17796 125 1 607 1715 221 0401 311 30 0 4145 17297 126 1 585 1680 222 0393 304 31 4125 16814 127 1562 1647 223 0384 297 32 0 4103 16346 128 1538 1614 224 0375 289 33 0 4082 15892 129 1 517 1582 225 0366 282 34 0 4 059 15453 130 1496 1550 35 0 4037 15027 131 1474 1519 36 0 4017 14614 132 1453 1489 37 0 3994 14214 133 1 431 1 459 38 0 3 968 13826 134 1408 1430 39 0 3 948 13449 135 1389 1401 40 0 3927 13084 136 1369 1373 4 0 3902 12730 137 1348 1345 42 0 3 878 12387 138 1 327 1318 43 0 3854 12053 139 1308 1291 44 0 3828 11730 140 1291 1265 45 0 3805 11416 141 1 289 1240 46 0 3781 11112 142 1 269 1214 47 0 3757 10816 143 i 250 1190 48 0 3729 10529 144 1230 1165 49 0 3705 10250 145 1211 1141 50 0 3 679 9979 146 1192 1118 51 0 3653 9717 147 1173 1095 52 0 3627 9461 146 1 155 1072 53 0 3600 9213 149 1 136 1050 54 0 3 575 8973 150 1 118 1029 55 0 3547 8739 151 1100 1007 56 0 3520 8511 152 1 082 986 51 0 3493 8291 153 1 064 965 58 0 3464 8076 154 1 047 945 N 59 0 3437 1868 155 1 029 925 60 0 3409 1665 156 1 012 906 61 0 3382 7468 157 0 995 887 62 0 3 353 7277 158 0978 868 63 0 3 323 7091 159 0 962 850 aa 64 0 3295 6911 160 0945 832 A 65 0 3 267 6735 161 0 929 815 66 0 3238 6564 162 0914 798 67 0 3210 6399 163 0 898 782 68 0 3 181 623
54. A 4D The unit controls leaving chilled water tem perature Entering water temperature is used by the micro processor in determining the optimum time to add or sub tract steps of capacity but is not a control set point The chilled water temperature set point can be automat ically reset by the return temperature reset or space and out door air temperature reset features It can also be reset from an external 4 20 mA signal with a loop isolator or from a network signal The operating sequences shown are some of many pos sible loading sequences for the control of the leaving water temperature If a circuit has more unloaders than another that circuit will always be the lead circuit Table 4A Capacity Control Steps 040 070 UNIT CONTROL 30GN STEPS Displacement Compressors Displacement Compressors App prox Approx 1 040 60 Hz 2 Alt 3 50 4 r 1 040 60 Hz 2 B1 A1 B1 3 A1 B1 4 A1 B1 040 60 Hz 045 60 Hz 3 4 1 040 50 Hz 2 045 60 Hz 3 Al 9 Ait B1 4 Al B1 5 Al B1 B1TT 040 50 Hz 045 60 Hz 4 AT B1TT A1T B1 5 A1 B1 6 A1 B1 1 045 50 Hz 050 60 Hz Alt 4 1 B1 045 50 Hz 2 B1 ee DUE t Al Bi 1 045 50 Hz 2 050 60 Ha 3 1 4 5 2 045 50 Hz 3 050 60 Hz 4 1 1 _ 7 Bitt 2 Bi 045 50 Hz 3 B1 050 60 Hz 4 A1 B1tt A1f B1 5 A1 Bitt 6 A1 B1 7 Al B1 Unloaded compressor Co
55. A2 A3 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 Al A2 A3 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 Al A2 A3 B1 B2 B3 B4 Al A2 A3 A4 B1 B2 B3 AL A2 A3 B1 B2 3 64 A1 A2 A3 A4 B1 B2 83 B4 A1 A2 A3 A4 B1 B2 B3 B4 1 2 4 R4 1 2 A3 A4 B1 B2 83 B4 A1 A2 A3 A4 B1 B2 B3 B4 At A2 A3 A4 B1 A2 B3 B4 B1 A1 B1 Al B1 B2 AI A2 B1 B2 225 50 Hz Al A2 B1 B2 B3 Al A2 8152 3 Al A2 A3 B1 82 B3 B4 A1 A2 A3 A4 B1 B2 83 B4 225 50 Hz A1 E101 1151931341111071471q Unloaded compressor tCompressor unloader standard Compressor unloader accessory P ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 23 Table 4D Capacity Control Steps 225 250 280 cont LOAOING SEQUENCE LOAC ING SEQUENCE B UNIT CONTROL 96 926 30GT STEPS Displacement Compressors Displacement Compressors Approx Approx BI B1 A1 B1 o G n GO 225 50 Hz 1 1 A1 AD AR Ad 1 Al A2 A3 A4 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 B4 250 60 Hz Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 AI A A3 B1 B2 B3 B4 A2 A3 A4 B1 B2 B3 B Al A2 A3 A4 B1 B2 B3 B4 250 60 Hz 1 Al 2 Al A2 A3 A4 B1 B2 B3 1 3 A4 B1 B2 B3 B4 A1 A2 A2 A4 B1 82 B3 B4 07 Qa 250 60 Hz 1 1 2 2 B1 A1 A2 A3 B1 B2 B3 B4 A1 A2 A3 A4 B1 B2 B3 At A2 A3 B1 B2 B3 B4 Al A
56. B PL7 4 170 210 ONLY LEGEND Ground Fault Module Communications Bus Compressor Contactor Rela Relay Module Low Voltage Switch High Pressure Low Voltage Plu Snubber Terminal Block Transformer Unloader FROH 15 OR 230 CONTROL SCHEHAT C CBS TRAN 9 2 OVE 2 2v SECONDARY CR A2 V CR M CR A3 CR A2 CR 81 TB p SE D CR A3 Gp CR B2 P CR B do CR B3 p CR 82 SEAN Ted PL17 1 v o gt gt n r Fig 10C 24 V Safety Circuit Wiring 130 210 and Associated Modular Units 34 CGFA n an aa ED 8 RB RED ene NS See aw Gyara E gt 8l 5 Bi I PLI 3 HP5 A1 OGT Al PLI 4 PL12 S PLII S vomm v 10 9 0 T OOOO 10 Y e as ox OX 7 PL2 3 MPS A2 DGT A2 PL2 4 PLIZ 6 PL11 6 cae 20 880 PL3 5 HPS A3 0OT A3 PL3 4 Ti someoene o e o ao EC i2 PL4 3 PPS A4 DOT A4 PLA 4 PLIZ PLII B I SRM v10 oeo ru Ce s B PL5 3 we5 Bl OGT Bi PLS 4 PLI4 S PL1I3 5 0 010 0 00 0 0165 0 10 9 c 0 CRI 9 ECCO 2 HPS B2 DGT 52 PLB 4 PL14 6 PL13 5 f nio afa 9 s ait on Y PL7 3 Me5 B3 DGT 83 PL7 4 PLIA 7 PLI3 7 CM VOCE 10790 Toe oor OPV OE Pe 10 M10 PLB 3 H
57. Externally Powered Fig 30 Remote Reset from 4 20 mA Signal Externally Powered 15 70 MODULE 373 4 20 mA SIGNAL 2 SIGNAL GENERATOR m 77 GENERATOR Ses Se J7 44 30GN040 210 AND ASSOCIATED MODULAR UNITS 30GN040 210 AND ASSOCIATED MODULAR UNITS a rez m TBZ a 4 4 30GT225 250 280 FLOTRONIC Il UNITS 30GT225 250 280 FLOTRONIC Il UNITS E TB Terminal Block TB Terminal Block NOTE The 30GT225 250 280 Flotronic Il units require the acces NOTE The 30GT225 250 280 Flotronic II units require the acces sory options module package for this feature sory options module package for this feature Fig 28 Demand Limit 4 20 mA Signal Fig 31 Remote Reset from 4 20 mA Signal Internally Powered Internally Powered w o hf 4379 4 IN4 OUT CONTACTS OE JUMPER MODULE eee csl 3 TBS TA TITULI ais REMOTE THERMISTOR p Es J Lu s de d 7 16 30GN040 210 AND ASSOCIATED MODULAR UNITS 30GT225 250 280 FLOTRONIC UNITS TB Terminal Block 30GT225 250 280 FLOTRONIC II UNITS TB Terminal Block NOTES NOTE The 30GT225 250 280 Flotronic II units require the acces 1 30GT225 250 280 Flotronic II units require the accessory op sory options module package for this feature tions module for this feature MA A 2 Contacts must be rated for dry circuit application ca
58. N EAD i SLEEVE PISTON SLEEVE Fig 11 Electronic Expansion Valve EXV 56 CHECKOUT PROCEDURE Follow steps below to di agnose and correct EXV problems Check EXV driver outputs Check EXV output signals at appropriate terminals on EXV driver module see Fig 12 as follows Connect positive test lead to terminal 1 on EXV driver Set meter for approximately 20 vdc Enter outputs subfunction of test function by pressing then advance to EXVA test by pressing 8 times Press The driver should drive circut fully open During next several seconds connect nega tive test lead to pins 2 3 4 and 5 in succession Voltage should rise and fall at each pin If it remains constant at a voltage or at zero v remove connector to valve and recheck Press for to close circuit A EXV If a problem still exists replace EXV driver module If voltage reading is correct expansion valve should be checked Next test EXVB Connect positive test lead to pin 7 and the neg ative test lead to pin 8 9 10 11 in succession during EXVB test 2 Check EXV wiring Check wiring to electronic expan sion valves from terminal strip on EXV driver See Fig 12 a Check color coding and wire connections Make sure they are connected to correct terminals at driver and EXV plug connections b Check for continuity and tight connection at all pin terminals c Check plug connections at driver and at EXVs to
59. OTE These capacity control steps may vary due to lag compressor sequencing 20 ur Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont LOADING SEQUENCE A SEQUENCE B UNIT CONTROL 96 9b SIZE STEPS Displacement Compressors Displacement Compressors TS Approx Approx E 1 SE 2 B1 3 A1 B1 4 ipm 5 AL 190 360A 1 390B 50 Hz A1B1 B2 A1 B1 7 AI A2 B1 B2 8 l A2 B1 B2 9 Al A2 B1 B2 B3 0 B2 B3 1 2 1 82 83 2 Al A2 A3 B1 B2 B3 1 2 3 4 5 6 7 190 360A 8 3908 50 Hz 9 A1 B1 Al A2 A3 B t 3 A2 A3 B1 B2 B3 f 52 3 210 390 420A B 60 Hz A1B1 210 390A 420A B 60 Hz A1 B1 Al A2 A3 B1 B2 B3 9 A2A3A4Bi B2 B3 n A2 A3 A4 B1 B2 B3 210 390A 420A B 60 Hz A1 B1 Al AZ ABE Al A2 a M Unloaded compressor j Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 21 Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont LOADII Gi SEQUENCE A LOADING SEQUENCE B UNIT CONTROL SIZE STEPS Displacement Compressors Displacement Compressors Approx Approx A 1 At 9 BI 2 A1 B1 3 1 A BT 4 B1 Al 1 5 1 1 A1 B1 6 Al A2 B1 A1 B1 B2 7 Al A2 B1 Al B1 B2 9 AT AS 5 2 Al S AD BT foo 9
60. P5 B4 067 84 PLB 4 PLI4 B PLI3 B Dea 109 009 00 9 10 7 M s EXY A 8 LEGEND C Contactor CGF Ground Fault Module COM Common CR Control Relay DGT Discharge Gas Thermostat Optional 0510 Relay Module Low Voltage EXV Electronic Expansion Valve HPS High Pressure Switch LV Low Voltage NC Normally Closed PL Plug RB Reset Button TB Terminal Board Fig 10D 24 V Safety Circuit Wiring 225 250 and 280 Units 55 Electronic Expansion Valve EXV OPERATION These valves control the flow of liq uid refrigerant into the cooler They are operated by pro cessor to maintain a specified superheat at lead compressor entering gas thermistor located between compressor motor and cylinders There is one EXV per circuit See Fig 11 High pressure liquid refrigerant enters valve through bot tom A series of calibrated slots are located in side of ori fice 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 thereby changing orifice size Sleeve is moved by a linear stepper motor Stepper motor moves in increments and is controlled directly by processor module As stepper motor rotates motion is transferred into linear movement by lead screw Through stepper
61. TYP 1 SET POINT CPS1 44 0 CPS145 6 RESET CRST2 0 0 CRST2 10 0 CREF2 0 0 CREF2 1 0 CRST10 0 CRST1 2 0 CREFI 0 0 CREF1 8 0 COMMENTS Field configuration subfunction of service function Scroll past single dual Display shows no reset type has been selected Return water temperature is selected and activated System set points Present occupied chilled water set point Enter new chilled water set point Reset set points Cooling maximum reset is F Cooling maximum reset is 10 F Cooling maximum reset reference is 0 F Cooling maximum reset reference is 1 F Cooling minimum reset is F Cooling minimum reset is 2 F Cooling minimum reset reference is 0 F Cooling minimum reset reference is 8 F 9 DENEN jose Em omes mae lt J o m as Se u was Lp _ RESET REFERENCE TEMPERATURE COOLER EWT LWT Fig 4 Cooling Return Water Reset 40 BUILDING LOAD Temperature Reset Based on External Temperature If de sired temperature reset can be based on an external tem perature such as space or outdoor air temperature This re quires a thermistor T10 Part No 30GB660002 located in the space or outdoor air and wired to terminals as follows also see Field Wiring section on page 71 4 in 4 out Module J7 15 and J7 16 At the field configuration step selec
62. UN TIME Run Time Information HR X Total Hrs Unit Has a Comp Operating HRA X Circuit A Run Time HRB X Circuit B Run Time 2 STARTS STARTS Starts Information CY x Cycles from Stage 0 to Stage 1 CYA X Circuit A Starts CYB X Circuit B Starts 3 ALARM HISTORY ALRMHIST ALARM X Last 5 Alarms ALARM X ALARM X Alarm Description ALARM X ALARM X SET POINT To read a set point go to proper subfunction and read desired set point To Change a set point enter new set point value then press LOCAL ENABLE STOP CON switch must be in LOCAL or STOP position SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 SET POINTS SET POINT Unit Set Point CSP1 x Chiller Fluid Set Point 1 CSP2 x Chiller Fluid Set Point 2 HSPA X Head Pressure Set Point Circuit A HSPB X Head Pressure Set Point Circuit B CRAMP X Pulldown Limit 2 RESET SET POINTS RESET Reset Set Points 1 m 4 CRST2 X Cooling Max Reset CREF2 X Max Reset Occurs at X m or Degree CRST1 X Cooling Minimum Reset CREF1 X Min Reset Occurs at X mA or Degree 3 DEMAND SET POINTS DEMAND Demand Set Points s E DLS1 X Demand Switch 1 Set Point DLS2 X Demand Switch 2 Set Point DMAX X 4 20 mA Maximum Demand Limit RMAX X Max Demand Limit Occurs at X mA DMIN X 4 20 mA Minimum Demand Limit RMIN X Minimum Demand Limit Occurs at X m SHED X CCN Loadshed Amount 4 DATE AND TIME DATE TIME Date Time and Day of Week DAY HR MIN Day 1 Mon 2 Tues 7 Sun Hours
63. a eis aes Se Read ios 26 IG DSIO AND EXV DRIVER MODULE PUMPOUT RE bce 27 Keypad and Displa Module RED LED Also Called HSIO or LID 28 Ca MODULE SO ACCESSING FUNCTION TION x SUMMERS cee e AND e LOW VOLTAGE RELAY MODULE DSIO KEYPAD OPERATING INSTRUCTIONS 4IN AOUT MODULE SIO STATUS FUNCTION ACCESSORY UNLOADER INSTALLATION 68 71 TEST FUNCTION Installation peg eA Y x TERRAS 68 HISTORY FUNCTION e 040 110 130 60 Hz UNITS SET POINT FUNCTION and associated modular units SERVICE FUNCTION e 130 50 Hz 150 210 225 250 and 280 UNITS SCHEDULE FUNCTION and associated modular units TROUBLESHOOTING 48 67 FIELD WIRING 71 73 Checking Display Codes 48 REPLACING DEFECTIVE PROCESSOR Unit Shutoff 48 MODULE PSIO TERRE 73 74 Complete Unit Stoppage 48 Installation 7 Single Circuit Stoppage 2 48 Lag Compressor Stoppage 48 SAFETY CONSIDERATIONS Installing starting up and servicing this equipment can be hazardous due to system pressures electrical compo nents and equipment location roof elevated structures Only trained qualified installers and service mechanics should install start up and service this equipment WARNING Electrical shock can cause personal injury and d
64. accessory TT Two unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont UNIT 30GN CONTROL STEPS Approx 130 240A 300A 50 Hz 1 1 130 240 300A 50 Hz 130 240 300 50 Hz 1 150 60 Hz AT B1 Unloaded compressor TCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded LOADING SEQUENCE A Displacement Compressors Al B1 Al A2 B1 A1tt A2 B1 A1 A2 B1 A1 A2 B1 Al tt 2 B1 B2 Aitt A2 B1 1 2 Al t Uo 1 Al A2 MUERE Al AI 2 3 B1 82 Al A2 A3 B1 B2 I FL 2 B1 iE U Atti A2 Btt B2 Al MARE 2 B1 A A bi B Al H P 2 B1 Bs A1 A2 A3 B1 B2 Al A2 AS B1 B2 A2 51 B2 At AD 1 B A2 A3 BiB A2 A3 B1 Bs NOTE These capacity control steps may vary due to lag compressor sequencing 15 LOADING SEQUENCE Compressors Bitt w ma A1 B1 BITE B2 Al BI Al BI ff B2 AL B1 B2 Al A EIE B2 Al A2 B1 B2 Al A2 B1 B2 Al S By i B2 Al B2 B3 Al Y ra 2 B3 e H B2 Al BI Al B1tt B2 A1 B1 B2 Al B2 Al 2 B2 A2 B1 B2 I A2 B1 B2 Al A3 B1tt B2 Al A2 Bie B2 Al A2 A3 B1 B2 Table 4C Capacity Control Step
65. age to lead compressor suction or discharge pressure connection to check transducer reading e Make sure transducer leads are properly connected in junction box and at processor board Check trans former 5 output Check voltage transducer 5 vdc 2 v When above checks have been completed check ac tual operation of EXV by using procedures outlined in Step 5 Check operation of EXV a Close liaujd line service valve of circuit to be checked and run through the test step 2 for lead com pressor in that circuit to pump down low side of sys tem Repeat test step 3 times to ensure all refrigerant has been pumped from low side NOTE Be sure to allow compressors to run for the full pumpout period b Turn off compressor circuit breaker s Close com pressor discharge service valves and remove any re maining refrigerant from low side of system 57 c Remove screws holding top cover of EXV Carefully remove top cover If EXV plug was disconnected dur ing this process reconnect it after cover is removed A CAUTION When removing top cover be careful to avoid dam aging motor leads d Enter appropriate EXV test step for EXVA or EXVB in the outputs subfunction of the test function Press o initiate test With cover lifted off EXV valve body observe operation of valve motor and lead screw The motor should turn counterclockwise and the lead screw should move up out of motor hub until valve is
66. alarm SET POINT FUNCTION Set points are entered through the keypad Set points can be changed within the upper and lower limits which are fixed The ranges are listed below Chilled Water Set Point Water 38 to 70 F 3 3 to 21 C Brine 15 to 70 F 9 4 to 21 C Pulldown Set Point 0 2 to 2 0 F 0 11 to 1 1 C min Reset Set Points Maximum Reset Range P to 20 F 0 to 11 C Maximum Reset Reference Range Return Fluid Reset 0 to 20 F 0 to 11 C External Temperature Reset 20 to 125 F 6 6 to 51 6 C External Signal Reset 4 to 20 mA Minimum Reset Reference Range Return Fluid Reset 0 to 20 0 to 11 C External Temperature Reset 20 to 125 F 6 6 to 51 6 C External Signal Reset 4 to 20 mA Demand Limit Set Points Switch Input Step 1 0 to 100 Capacity Reduction Step 2 0 to 100 Capacity Reduction External Signal Maximum Demand Limit 4 to 20 mA Minimum Demand Limit 4 to 20 mA Set points are grouped in subfunctions as follows bisfays chiller water and cooling ramp set points a The first value shown is the occupied chilled water set point 39 b The next value displayed depends on how the sched ule function has been programmed See pages 45 47 If dual set point has been selected the next set point after has been pressed is the unoccupied chilled water set point If single set point or inactive schedule has been selected in the schedule function then when is p
67. an be displayed TEST FUNCTION The test function operates the diag nostic program To initiate test function the LOCAL ENABLE STOP CCN switch must be in STOP position To reach a particular test enter its subfunction number then scroll to desired test by pressing the key Press to start a test Press or or to terminate or exit a test Pressing the key after a test has started ad vances system to next test whether current test is operating or has timed out Once in the next step you may start test by pressing or advance past it by pressing While the unit is in test you may leave test function and access another display or function by pressing appropriate keys However a component that is operating when an other function is accessed remains operating You must re enter test function and press the key to shut down the component Components with a timed operating limit time out normally even if another function is accessed Keypad entry allows the operator to make the following checks by using 1 LID display check Proper display is 8 8 8 8 8 8 8 8 Operation of remote alarm Operation of condenser fans Operation of chilled water pump Operation of EXVs To drive EXV fully open enter 1 o 100 open To drive EXV fully closed en ter 0 open P Keypad etay eE accesses the compressor and compressor unloader operational tests WARNING During compressor operational t
68. ans to automatically switch chiller from an occupied mode to an unoccupied mode When using schedule function chilled water pump relay must be used to switch chilled water pump on and off Connections for chilled water pump relay are TB3 3 and TB3 4 040 210 and associated modular units or TB3 3 and TB5 4 225 250 and 280 units The chilled water pump relay starts chilled water pump but compres sors do not run until remote chilled water pump interlock contacts are between TB6 1 and TB6 2 on 30GN040 210 and associated modular units or between TB5 and TB5 2 on 30GT225 250 and 280 Flotronic units are closed and leaving chilled water temperature is above set point If a remote chilled water pump interlock is not used the first compressor starts upon a call for cooling approximately one minute after chilled water pump is turned on Table 13 Adjustable Field Configurations FIELD CONFIGURATION ITEM AND CODES FACTORY CONFIGURATION CODE CCN element address Entered by CCN Technician Bus Number m 000 Entered by CCN Technician CCN Baud Rate 9600 Entered by CCN Technician Cooler Fluid Solset 1 Water 38 to Standard Models 3 3 to 21 o Point 2 Medium 15 to 70 Brine Models f 9 to 21 C Set Point Display Unit Select 0 English 1 Metric SI Display Language Select 1 z English No Circuit A Unloaders 3061228 280 de 1 One Unloader 30GN040
69. cate with the processor It is used to enter configurations and set points and to read data per form tests and set schedules This device consists of key pad with 6 function keys 5 operative keys 12 numeric keys 0 to 9 and and an alphanumeric g character LCD liquid crystal display See Fig 3 See Table 6 for key usage IMPORTANT When entering multiple character in puts beginning with a zero a decimal point must be entered in place of the first zero When entering an input of zero only the decimal point need be entered ACCESSING FUNCTIONS AND SUBFUNCTIONS See Tables 6 8 Table 7 shows the 6 functions identified by name and the subfunctions identified by number P a LU BEM EEEN Ge POWER SENSOR BUS Fig 3 Keypad and Display Module SUMMARY DISPLAY When keypad has not been used for 10 minutes display automatically switches to the rotat ing summary display This display has 4 parts listed be low which appear in continuous rotating sequence DISPLAY EXPANSION TUE 15 45 TODAY IS TUE TIME IS 15 45 3 45 PM CLOCK ON UNIT IS ON VIA CLOCK SCHEDULE COOL 1 NUMBER OF STAGES IS 1 2 ALARMS 2 ALARMS DETECTED AUTOMATIC DISPLAY OPERATION DEFAULT DIS PLAY In this mode the keypad displays the current time 24 hour format current operating modes cooling capac ity st and total ber of al ity stages and total number o RUE CET AA ow cir e none x
70. cement Compressors Approx i 090 50 Hz 1 1 KO Bi AY Bie PE AL BU i ATAS Al EET Al H Ir ri B2 M A281 8 B2 Al ABT 5 100 2408 270B 60 Hz At B1T AI A2 B1 B2 AI Ad B1 B2 Al A2 B1 B2 100 240B 270B 60 Hz Ait B1t Al A2 B1 B2 100 240B 270B 60 Hz Unloaded compressor tCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 10 T LOADING SEQUENCE B Displacement Approx Compressors e a gt A1 A1 Bitt B2 Al Bitt B2 Ai B1 B2 A1 B1 22 A2 Bitt B1 ay A2 B1 A1 A2 B1 B2 A1 3 B B2 Al A2 B1 B2 Prt tiered aid id addy Bitt Bi Bi A1 Bitt Ai R4 A1 B1 A1 Bitt B2 A1 B1tt B2 A1 B1 B2 A1 B1 B2 A A2 Bitt B2 V 2 Ahan B2 AT n BI s pee EEE Table 40 Capacity Control Steps 080 1 10 and Associated Modular Units cont UNIT 30GN 100 2406 270B 60 Hz Ait BT EA 100 240B 2708 50 Hz A1t B1T 100 240B 2708 50 Hz Att Bit 100 2408 270B 50 Hz A1t B1t 100 2408 270B 50 Hz Ait B1t Unloaded compressor CONTROL STEPS O 0 O Gi AGN 0 A A O N 00 10 CO N O D oo TCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded LOADING SEQUENCE A
71. ciated modular units or ferrule type on 225 250 280 units See Fig 13 and 14 THERMISTOR REPLACEMENT TI T2 T7 8 Com pressor and Cooler CAUTION Thermistors are installed directly in fluid or refrigerant circuit Relieve all refrigerant pressure using standard refrigerant practices or drain fluid before removing Proceed as follows see Fig 15 To replace sensors T1 T2 T7 225 250 280 and T8 225 250 280 1 Remove and discard original thermistor and coupling IMPORTANT Do not disassemble new coupling Install as received 2 Apply pipe sealant to 1 4 m NPT threads on replace ment coupling and install in place of original Do not use packing nut to tighten coupling This damages fer rules see Fig 15 3 Insert new thermistor in coupling body to its full depth If thermistor bottoms out before full depth is reached pull thermistor back out in before tightening packing nut Hand tighten packing nut to position ferrules then finish tightening 1 4 turns with a suitable tool Ferrules are now attached to thermistor which can be withdrawn from coupling for unit servicing To replace thermistors T7 and 78 040 210 and associated modular units Add a small amount of thermal conductive grease to ther mistor well Thermistors are friction fit thermistors which must be slipped into receiver located in the compressor pump end 60 Pressure Transducers Two types of pressure trans ducer
72. e different because machine is operating to the modified chilled water set point If current temperature is equal to set point but set point is not the one desired remember that if dual set point has been selected in the schedule function there are 2 set points to which the machine can be operating Check the programming of schedule func tion to see if occupied or unoccupied set point should be in effect Unit Shutoff To shut unit off move LOCAL ENABLE STOP CCN Switch to STOP position Any re frigeration circuit operating at this time continues to com plete the pumpout cycle Lag compressors stop immediately and lead compressors run to complete pumpout Complete Unit Stoppage Complete unit stop page can be caused by any of the following conditions 1 Cooling load satisfied Remote ON OFF contacts open Programmed schedule Emergency stop command from CCN General power failure Blown fuse in control power feed disconnect Open control circuit fuse LOCAL ENABLE STOP CCN switch moved to STOP position 9 Freeze protection trip 10 Low flow protection trip 10 tA P WN 11 Open contacts in chilled water flow switch optional 12 Open contacts in any auxiliary interlock Terminals that are jumpered from factory are in series with control switch Opening the circuit between these terminals places unit in stop mode similar to moving the control switch to STOP position Unit cannot start if t
73. ed to begin at 00 00 hours NOTE This is true only if the occupied period starts at 00 00 midnight If the occupied period starts at a time other than midnight then the occupied period must end at 00 00 hours midnight and new occupied period must be programmed to start at 00 00 in order for the chiller to stay in the occupied mode past midnight The time schedule can be overridden to keep unit in oc cupied mode for one 2 3 or 4 hours on a one time basis See Example 9 All subfunctions of schedule function are password pro tected except the override subfunction Pass word entry into subfunctions 2 E through is done through service function See page 44 logging logging off Figure 9 shows a schedule for an office building with the chiller operating on a single set point schedule The sched ule is based on building occupancy with a 3 hour off peak cool down period from midnight to 3 a m following the weekend shutdown To eam how this sample schedule would be programmed see Example 9 NOTE This schedule was designed to illustrate the pro gramming of the schedule function and is not intended as a recommended schedule for chiller operation 46 Example 9 Using the Schedule Function KEYPAD ENTRY gt Ao a EIEE PROGRAMMING PERIOD 1 Ls be nU PROGRAMMING PERIOD 2 az s LILA fe Ee ee 55098 n 7 Carrier Comfort Network
74. ess function name key for desired function display shows the first subfunction or Access a specif ic sub function by using the sub function number and the function name kev Table 7 Functions and Subfunctions Table 8 Accessing Functions and Subfunctions KEYPAD ENTRY 21 29 DISPLAY RESPONSE RESET CRST2xx CREF2xx CRST1 xx CREF 1xx RESET CRST2xx DEMAND TIME X ALARMS STAGE FUNCTIONS SUBFUNCTION Status Test Schedule Service History Set Point NO el SMS 28 2 1 Automatic outputs Override Log On and Run Time Set Points Display Log Off Chiller Fluid 2 Alarm Compressors Clock Set Version Starts Reset Display and Unloaders Software Set Points 3 Mode Operating Period 1 Factory Alarm Demand Limit Display Configuration History Set Points 4 Capacity Period 2 Field Date and Stages Configuration Time Set Points Period 3 Service ET Current Operating Configuration i Temperatures Proa 4 7 Pressures ooo sf lt TE 8 Analog Period 6 ms Pero 7 j 10 outputs Pero e po f zl wwsI J DESCRIPTION Reset Set Points Cooling Maximum Reset xx Cooling Maximum Reference xx Cooling Minimum Reference xx Cooling Minimum Reference xx Reset Set Cooling Maximum Reset xx Demand Set Points Current Time and Day of Week Unit Set Points Rotating Di
75. est con densing temperature possible thus the highest unit efficiency Instead of using the conventional head pressure control meth ods the fans are controlled by the position of the EXV and suction superheat As the condensing temperature drops the EXV opens to maintain the proper suction superheat Once the EXV is fully open if the condensing temperature continues to drop the suction superheat begins to rise Once the suction super heat is greater than 40 F 22 2 C a fan stage is removed after 2 minutes As the condensing temperature rises the EXV closes to maintain the proper suction superheat Once the EXV has closed to 39 5 open 300 steps open a fan stage is added after 2 minutes During start up all the condenser fans are started when the condensing temperature reaches 95 F 35 C to prevent excessive discharge pressure during pulldown See Table 5 for condenser fan sequence of operation Table 5 Condenser Fan Sequence FAN ARRANGEMENT 30GN040 050 judo Q 30GN060 070 29 OO 30GN080 090 CONTROL 30GN130 170 and associated modular units dm ere oe 30GN190 210 and associated modular units E EL v 588 C 9 C2 Control box FAN NUMBER S FAN rey CONTROLLED BY 4 FC B2 1 FC AI E uw h FC B2 FC B3 68 Fr 5 7 FC AI 6 8 FC B1 FOR 26 C
76. ests compressor starts and runs for 10 seconds Compressor service valves must be open Energize crankcase heaters 24 hours prior to performing compressor tests Since test function checks only certain outputs it is good practice to also check all inputs and outputs accessible through the status function These are located at e 164 e f and 10 fer see Table 9 If keypad is not used for 10 minutes unit automatically leaves test function and resumes rotating display See Example 3 o Example 3 Using Test Function KEYPAD DISPLAY ENTRY RESPONSE COMP COMMENTS Factory field test of compressors subfunction of test function CPA 1 OFF Circuit A Compressor 1A test CPA 1 ON Pressing ENTR starts the test when the compressor should be running the display shows CPA1 on If the test is allowed to time out 10 sec onds the display will show CPA1 off Pressing the down arrow key advances the system to Circuit A compressor 2 test CPA 1 OFF CPA 2 OFF NOTE Once a compressor has been run using the E function it is not allowed to run again for 30 seconds HISTORY FUNCTION Keystrokes and sub sequent keystrokes display total unit run time and total run time for each circuit Keystrokes and subsequent keystrokes dis play total unit starts and the total starts for each circuit Keystrokes and subsequent keystrokes dis play the last 5 alarms along with a description of each
77. et points must be entered through keypad and display module see Set Point Function section on page 39 See Table 17 for overall troubleshooting information AR WN 509195 ADDRESS SWITCHES L e e e e e e e e e e e e e LEGEND COMM Communications Bus PWR Power Fig 22 4 In 4 Out Module SIO 66 SYMPTOMS COMPRESSOR DOES NOT RUN COMPRESSOR CYCLES OFF ON LOW PRESSURE COMPRESSOR SHUTS DOWN ON HIGH PRESSURE CONTROL UNIT OPERATES LONG OR CONTINUOUSLY SYSTEM NOISES COMPRESSOR LOSES OIL FROSTED SUCTION LINE HOT LIQUID LINE FROSTED LIQUID LINE COMPRESSOR DOES NOT UNLOAD COMPRESSOR DOES NOT LOAD Table 17 Troubleshooting CAUSE REMEDY Power line open Control fuse open High Pressure Switch HPS tripped Tripped power breaker Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective Seized compressor Loss of charge Bad transducer Low refrigerant charge High pressure control erratic in action Compressor discharge valve partially closed Condenser fan s not operating Condenser coil or dirtv Low refrigerant charge Control contacts fused Partially plugged or plugged expansion valve or filter driver Defective insulation Service load Inefficient compressor Piping vibration Expansion valve hissing Compressor noisy Leak in system Mechanical damage blown piston or br
78. fect on Tuesday Tuesday must be flagged yes Tuesday is now flagged for period 2 to be in effect For this example period 2 is to be in effect only on onday and Tuesday All other days must be checked to be sure that hey are flagged no If a day is flagged yes change to no Wednesday is now no for period 2 occ 7 00 UNO 00 00 UNO 18 00 MON NO MON YES TUE YES WED YES flagged Example 9 continued next page Example 9 Using the Schedule Function cont KEYPAD ENTRY PROGRAMMING PERIOD 3 Define schedule az period 3 occ 00 00 aa of occupied o Occupied time will start at 7 00am Start of unoccupied time UNO 00 00 e E TES S Ee Ten DISPLAY COMMENT PERIOD 3 occ 7 00 end of period 3 For this example period 3 should end at 21 30 8 30 p m Period 3 ends at 21 30 8 30 p m Check to be sure that Monday and Tuesday are flagged for period 3 UNO 21 30 MON NO TUE NO Wednesday is flagged WED NO no change to yes Wednesday is now flagged yes for period 3 Check to be sure that all other days are flagged no WED YES THUR NO FRI NO SAT NO SUN NO Period 4 and 5 can be programmed in the same manner flagging Thursday and Friday yes for period 4 and Saturday yes for period 5 For this example periods 6 7 and 8 are not used they should be programmed OCC 00 00 UNO 00 00 NOTE When a day is flagged yes for 2 overlapping peri
79. g the DSIO EXV module or the 24 vac trans former supplying PS 1 for the transformers These transformers should not be grounded or serious damage to controls can result Check to be sure the transformers are not grounded Code 36 Low refrigerant pressure Circuit A Code 37 Low refrigerant pressure Circuit B If suction pressure transducer senses a pressure below set point for more than 5 minutes at start up or more than 2 minutes during normal operation affected circuit shuts down without going through the pumpout process Reset is automatic when pressure reaches 10 psig above set point if there have been no previous occurrences of this fault on the same day If this is a repeat occurrence on same day then reset is manual with LOCAL ENABLE STOP CCN switch Factory configured set point is 27 psig for standard chillers and 12 psig for brine chillers Possible causes of fault are low refrigerant charge faulty EXV plugged filter drier or faulty transducer Code 38 Failure to pump out Circuit A Code 39 Failure to pump out Circuit B The pumpout process is terminated when saturated suc tion temperature is 10 F 5 5 C below temperature at be 51 ginning of pumpout or 10 F 5 5 C below leaving water temperature or reaches a saturated suction temperature of 15 F 26 C If appropriate saturated suction temperature is not met within 3 minutes on 2 consecutive tries circuit shuts down without pumpout Reset is manual with
80. he following information to display the stage number Percent of total unit capacity being utilized Percent of each circuit capacity being utilized Demand limit set point in effect can be any value be tween 0 and 100 Load limit set point in effect This is a CCN function for controlling operation of multiple units between 0 and 100 of total capacity of all units combined Status of each compressor relay When a compressor is on the number of that compressor is displayed If a com pressor is off a 0 is displayed For example In a given circuit if compressors 1 and 3 are running and 2 and 4 are not running 0301 is displayed for that circuit Load Unload factor for compressors This factor is an in dication of when a step of capacity is added or sub tracted Its value can range from slightly less than 1 O to slightly more than 1 O When load unload factor reaches 1 0 a compressor is added When the load unload factor reaches 1 O a compressor is subtracted If compressor unloaders are used at 6 a compressor is unloaded and at 6 a compressor is loaded up s lt Set Point This subfunction displays leaving water temperature and leaving chilled water set point If unit is programmed for dual set point the chilled water set point currently in effect either occupied or unoccupied is displayed If reset is in effect the unit operates to the mod ified chilled water set po
81. hese contacts are open If they open while unit is running unit pumps down and stops 13 Cooler entering or leaving fluid thermistor failure 14 Low transducer supply voltage 15 Loss of communications between processor module and other control modules 16 Low refrigerant pressure Single Circuit Stoppage Single circuit stoppage can be caused by the following Low oil pressure in lead compressor Open contacts in lead compressor high pressure switch Low refrigerant pressure Thermistor failure Transducer failure ON gt O Ground fault in lead compressor indicator indicator is field supplied on 040 060 070 60 Hz 080 110 and associated modular units High suction superheat Low suction superheat Lead compressor circuit breaker trip Stoppage of one circuit by a safety device action does not affect other circuit When a safety device trips on a lead compres sor circuit is shut down immediately and EXV closes 10 Ground fault for any circuit compressor 130 210 225 250 280 and associated modular units Lag Compressor Stoppage Lag compressor stop page can be caused by the following Open contacts in high pressure switch 2 Compressor ground fault indicator is field supplied on 040 060 070 60 Hz 080 110 and associated modular units 3 Compressor circuit breaker trip 4 Not required to run to meet cooling load requirement CAUTION If stoppage occur
82. in conjunction with separate Instal lation Instructions booklet packaged with the unit The 306 Series standard Flotronic II chillers feature microprocessor based electronic controls and an electronic expansion valve EXV in each refrigeration circuit NOTE The 30GN040 and 045 chillers with a factory installed brine option have thermal expansion valves TXV instead of the EXV Unit sizes 240 270 and 300 420 are modular units which are shipped as separate sections modules A and B Instal lation instructions specific to these units are shipped inside the individual modules See Table 1 for a listing of unit sizes and modular combination For module 240B and 270B follow all general instructions as noted for unit sizes 80 110 For all remaining modules follow instructions for unit sizes 130 210 Table 1 Unit Sizes and Modular Combinations eem Tu o yoGnos s 30GNoS0 s wono 0 _ enoro m 30600 so 30GNO090 90 30GN100 100 10 gt 25 _ aans 146 0 10 306190 39 aana 29 1 306725 225 30GN240 225 30GN130 30GN100 30GT250 250 30GN170 30GN100 See e 30GN300 30GN130 30GNf 70 30GN330 325 30GN170 30GN170 30GN360 350 _ 30GN190 306G N f 90 20GN170 300 390 380 30GN210 30GN190 30GN420 2400
83. in pass word protected Software Information 2 fe lt l displays the version number of the software that resides in the processor mod ule Press a second time to display the language op tions that are available in the field configuration group The e ang sht Bd cf i ns are summarized in 1 Table 11 Factory Configuration Codes s E4 allows entry into the factory configuration subfunction Under this subfunc tion there are 6 groups of configuration codes that are down loaded at the factory Each group is made up of 8 digits If processor module is replaced in the field these 6 groups of configuration codes must be entered through the keypad and display module Factory configuration codes groups 1 through 6 that apply to the particular Flotronic II chiller being serviced are found on a label diagram located inside the control box cover See Table 12 for a summary of factory configuration subfunction keystrokes Table 12 Factory Configuration Keystrokes To t a configuration enter the new configuration and press while on the correct configuration SUB KEYPAD FUNCTION ENTRY DISPLAY COMMENTS TORY 3 FACTORY FACT CFG CONFIGURATION 4 XXXXXXXX Confort Configuration XXXXXXXX Code 2 1 NxXXXXXX Configuration Code 3 XXXXXXXX Configuration XXXXXXXX Contig rates Configuration XXXXXXXX 5 SERVICE SRV CFG CONFIGURATION CFG 5 CODES XXXXXXXX configuration Configu
84. ing unit to occupied mode Override can be im plemented with unit under LOCAL or CCN control Override expires after each use Low cooler suction protection is in effect In this mode circuit capacity is not allowed to increase if cooler saturated suction temperature is 20 11 C for water or 30 F 16 C for brine or more below leav ing fluid temperature and saturated suction tem perature is less than 32 F 0 C If these conditions persist beyond 10 minutes circuit is shut down and fault code 44 or 45 is displayed CCN CarrierComfort Network LOCAL OFF CCN OFF CLOCK OFF LOCAL ON CCN ON CLOCK ON MODE 7 MODE 8 MODE 9 MODE 10 MODE Il MODE 12 MODE 13 MODE 14 To enter the MODES subfunction depress BZ and use the key to determine if more than one mode ap plies See Example 2 to read current mode with expansion Example 2 Reading Current Operating Modes KEYPAD ENTRY DISPLAY RESPONSE TUE 15 45 LOCAL ON COOL 1 0 ALARMS 2 MODES COMMENTS Keypad has not been used for at least 10 minutes Rotating summary display appears on screen There are 2 modes currently in effect LOCAL ON Unit is on by chiller on off switch MODE 8 Temperature reset is in effect l Stage This subfunction displays the capac ity stage number See Tables 4A 4D for compressor load ing sequence To enter the STAGE subfunction press 4 and use the Additional 4 provides t
85. int This means the leaving water temperature may not equal the chilled water set point The modified chilled water set point can also be displayed in the Status function To enter the set point subfunction de press s Jbl and use the to display modified leaving chilled water set point followed by leaving water set point and actual cooler leaving fluid temperature 4fmpprature The temperature subfunction dis plays the readings at temperature sensing thermistors To read a temperature enter e E then scroll to de sired temperature using the key See Table 9 for the order of readouts Pressure This subfunction displays suction discharge and net oil pressure at lead compressor of each circuit of unit 38 Analog Inputs This subfunction displays analog inputs if any Enter then use the The transducer supply voltage 4 20 mA reset signal can be dis played This is useful for problem diagnosis prior to using the test function uts This subfunction displays status ON OFF of input switch where applicable Status of dual set point switch and demand limit switches 1 and 2 can be displayed This is useful for problem diagnosis prior to us ing the test function Outputs This function displays ON OFF sta tus of alarm relay all fan relays and chilled water pump relay It also displays ON OFF status of compressor unload ers if used The position of each EXV in percent open c
86. l unloader was added to compressor Keypad LCD displays the word B l press until NULB 1 appears in keypad dis play Press for the number of unloaders on circuit B Keypad display now reads NULB 2 f When configuration is complete press pad display reads LOGGEDON Press until key pad display reads LOG OFF Press Keypad dis play reads EXIT LOG Using test function check unloaders Press p Key pad display reads OUTPUTS Press until display reads ULA 2 OFF Press Relay energizes Press and relay deenergizes Press until display reads ULB2 OFF Press Relay energizes Press and relay deenergizes return LOCAL ENABLE STOP CCN to proper position Close and se cure control box door A 30 3 3 FROM 115V OR 230V CONTROL scuemaniG d T TRAN 24V SECONDARY EN Pre ag fan Serbs NM 2 a pelo n LV CCPCS AT SEE view RIJILOGICIK PL10 8 PLS 4 gu Ls us anu 1 PLE 3 ACCESSORY PLE 4 BLU 35 BnN U2 A1 PLI 5 01 1 PLI G oye 1 rj SEE VIEW 747 4 R14 L06ICIK PL10 6 I ORN rnd CDR xe BRN Z T BRN PL10 5 RED B PL7 3 ACCESSORY 7 4 1 GRA 9 BRN U2 Bt a 5 ACCESSORY PLE PNK PNK JD BRN Ut Bt 040 070 FROM 115 230 CONTROL SCHEMATIC TRAN e OOS
87. legal 51 Initial configuration configuration required 52 Emergency stop by CCN command LEGEND Compressor Protection Control Module CPCS PS Power Supply Unit cannot start Manual Unit cannot start Unit shut down Yes Manual CCN Reset automatic first time manual if repeated same 49 J3 terminal strip receives voltage when compressor is not PROBABLE CAUSE High pressure switch trip discharge gas thermostat trip or wiring error CPCS Ground Fault Protection Thermistor or transducer failure or wiring error Transducer failure or wiring error Unit voltage low or PSI faulty Chilled water pump inoperative Wiring error or faulty module or improper address code Low refrigerant charge plugged filter EXV drier faulty Low retriderant charge plugged filter drier faulty EXV Faulty EXV Faultv EXV Low oil level circuit breaker trip faulty EXV crankcase heater or Pressure Transducer or thermistor or thermistor transducer transducer Low oil_l vel circuit breaker trip fautty EXV crankcase heater or pressure transducer Low water flow or faulty thermistor Chiled water pump failure or faulty thermistor Faulty EXV or thermistor Faulty EXV or thermistor Low charge faulty EXV or thermistor or plugged filter drier Low charge faulty EXV or thermistor or plugged filter drier Faulty EXV or thermistor Faulty EXV or thermistor Configuration error
88. lled water set point is to be increased when reset is initiated 4 Minimum Reset Reference CREFI allowable range 0 to 20 F 0 to 11 C This is the cooler temperature drop at which reset is at its minimum value Reset be gins here NOTE Reset set points are not accessible unless the reset function is enabled first This is done as a field configura tion Select one of the 3 choices for type of reset Return Fluid Reset External Temperature Reset or 4 20 mA Ex ternal Signal with a loop isolator Reset If dual set point control is enabled see Field Wiring sec tion on page 7 1 the amount of reset is applied to which ever set point is in effect at the time Example 5 demonstrates how to activate reset Example 6 demonstrates how to change the type of reset Assume that reset is to be based on return water temperature the desired reset range is to be 2 to 10 F 1 to 5 5 C and full load is a 10 F 5 5 C drop across the cooler See Fig 4 Activating reset based on external temperature or 4 20 m signal is done the same way except the reference set point range is 20 to 125 F 6 6 to 5 1 6 C or 4 to 20 mA depending on which method was selected at the field configuration step Example 5 Using Return Water Temperature Reset KEYPAD ENTRY 4 ERS ni EN LIL Jb TEe TE 2 n LJe Je s Bz s E DISPLAY RESPONSE FLD CFG CSPTYP X CRTYP 0 CR
89. loose connection Code 22 Compressor A 1 discharge pressure transducer failure Code 23 Compressor B 1 discharge pressure transducer failure Code 24 Compressor A 1 suction pressure transducer failure Code 25 Compressor B 1 suction pressure transducer failure Code 26 Compressor Al oil pressure transducer failure Code 27 Compressor Bl oil pressure transducer failure If output voltage of any of these transducers is greater than 5 v affected circuit shuts down without going through pumpout process Other circuit continues to run Reset is automatic if output voltage returns to the acceptable range and circuit start up follows normal sequence Cause of fault is usually a bad transducer or a wiring error Code 28 If transducer supply voltage is less than 4 5 v or greater than 5 5 v unit shuts down without going through pumpout process Reset is automatic if supply voltage returns to the acceptable range and circuit start up follows normal se quence Cause of fault is usually a faulty transformer or primary voltage is out of range The voltage supplied to the processor is polarized When checking for proper voltage supply be sure to consider this polarity If voltage appears to be within acceptable toler ance check to be sure the transformer supplying 51 is not grounded Grounding the supply transformer can result in serious damage to the control system Code 29 Chilled water pump interlock switch open applies only if unit i
90. ls and EXV plug Recheck all wiring connections and volt age signals Other possible causes of improper refrigerant flow con trol could be restrictions in liquid line Check for plugged filter drier s or restricted metering slots in the EXV Formation of ice or frost on lower body of electronic ex pansion valve is one symptom of restricted metering slots However frost or ice formation is normally expected when leaving fluid temperature from the cooler is below 40 F Clean or replace valve if necessary NOTE Frosting of valve is normal during compressor Test steps and at initial start up Frost should dissipate after 5 to 10 minutes operation in a system that is oper ating properly If valve is to be replaced wrap valve with a wet cloth to prevent excessive heat from damag ing internal components MUFFLERS COMPRESSORS FILTER DRIER CIRCUIT B CIRCUIT A LEGEND DPT w Discharge Pressure Transducer OPT Oil Pressure Transducer SPT Suction Pressure Transducer T Thermistor Number Fig 13 Thermistor and Pressure Transducer Locations 58 30 270 B 578 LEAVING WATER BRINE THERMISTOR T1 SD ENTERING WATER BRINE SUCTION BAFFLE CONNECTION CONNECTION INLET DRAIN LEAVING COOLER CONNECTION WATER BRINE TUBE CONNECTION TYPICAL 40 276 ENTERING WATER BRINE THERMISTOR T2 Ao 72 COMPRESSOR THERMISTORS T7 AND T8 Fig 14
91. module 250 9 3 SENSOR BUS CONNECTOR INPUTS 24 VAC CHANNEL Il J3 PINS 2 2 384 3 586 4 T88 2 4 6 AND 8 ARE GROUND RED STATUS LIGHT PET COMMUNICATION P COMMON NO NEL 12 0 91e COMMON J5 8 NO lI OUTPUT 7 NC RELAYS 6 COMMON 5 NO 10 4 NC 3le COMMON 2 NO 9 I N 2 e COMMON le NO 8 NC s e COMMON ale NO 7 binds cOMMON RELAYS ale NO 6 3 e COMMON 2 e NO 5 NC ADDRESS ADJUSTMENT NOT SHOWN ON UNDERSIDE LEGEND COMM Communications Bus NC Normally Closed NO Normally Open PWR Power Fig 21 Low Voltage Relay Module DSIO 4 N 4 OUT MODULE SIO Fig 22 4 In 4 Out mod ule allows the following features to be utilized 1 Temperature Reset by outdoor air or space temperature A remote thermistor Part No 30GB660002 is also re quired NOTE This accessory is not required for return water temperature reset Temperature Reset by remote 4 20 mA signal Demand Limit by remote 2 stage switch Demand Limit by remote 4 20 mA signal Dual Set Point by remote switch The options module is standard on 30GN040 210 and associated modular chillers and is available as a field installed accessory on 30GT225 250 and 280 Flotronic II chillers Remember to reconfigure the chiller for each feature se lected see Table 13 For temperature reset demand limit and dual set point desired s
92. mpressor unloader standard Compressor unloader accessory TtTwo unloaders both unloaded Table 4A Capacity Control Steps 040 070 cont LOADING SEQUENCE B UNIT CONTROL A 30GN STEPS Displacement Displacement Compressors Approx Approx 18 B1 31 a 045 50 Hz 44 B1 050 60 Hz 56 A1 B1T1 A1 T B1 060 60 Hz 050 50 Hz A1 B1 050 50 Hz 060 60 Hz Alt es ri RN O 050 50 Hz 060 60 Hz 060 60 Hz Alp B1 050 Go Hz 050 50 Hz 060 60 Hz ATI BT 060 50 Hz 070 60 Hz Alt 060 50 Hz 070 60 Hz A1f B1 060 50 Hz 070 60 Hz A1 T 060 50 Hz 070 60 Hz A1t B1 060 50 2 070 60 Ha Ait B1 NN i Unloaded compressor Compressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded 1 Table 4A Capacity Control Steps 040 070 cont LOADING SEQUENCE A LOADING SEQUENCE UNIT CONTROL x 30GN STEPS Displacement Compressors Displacement Compressors Approx Approx 1 en 1 k 060 50 Hz 070 ron 1 1 5 Ad Rae 6 Ai B1 1 2 zs 070 50 Hz 3 a Alt 4 5 6 1 Bis 2 B1 3 A1 070 50 Hz A1f B1 i WP 6 A1 A2 B1 7 Al A2 1 8 1 2 81 1 2 3 070 50 Hz 4 5 1 1 6 Altt A2 Bt 7 A1 A2 B1 8 A1 A2 B1 1 2 3
93. nd fault board in conjunction with the CR The CGF provides the same ground fault function as the CPCS for units where the CPCS is not utilized One large relay is located on the CPCS board This relay or CR controls the crankcase heater and compressor contactor The CPCS also provides a set of signal contacts that the microprocessor monitors to determine the operating status of the compressor If the processor board determines that the compressor is not operating properly through the signal contacts it will lock the compressor off by deener gizing the proper 24 v control relay on the relay board The CPCS board contains logic that can detect if the current to ground of any compressor winding exceeds 2 5 amps If this condition occurs the CPCS module shuts down the compressor A high pressure switch with a trip pressure of 426 7 psig 2936 48 kPa is wired in series with the CPCS If this switch opens during operation the compressor stops and the failure is detected by the processor when the signal contacts open The compressor is locked off If the lead compressor in either circuit is shut down by the high pres sure switch or ground current protector all compressors in the circuit are locked off COMPRESSOR PROTECTION BOARD TOROID Fig 2 Compressor Protection Control Module rJ OPERATION DATA Capacity Control The control system cycles compressor to give capacity control steps as shown in Tables 4
94. nel 68 When unloader check has been performed Wire the primary side of the transformer in parallel with TRAN3 See Fig 23 This supplies transformer with proper line voltage Be sure to connect proper tap of the trans former to ensure supply of proper secondary voltage Wire the secondary side of transformer to DSIO LV J5 9 and a jumper from DSIO LV J5 9 to DSIO LV 14 9 Wire the secondary common to TB7 2 Connect the transformer ground to ground hole supplied near the transformer These connections provide DSIO with nec essary power to energize the solenoid coils When all connections are made check for proper wiring and tight connections Replace and secure inner panel Restore power to unit Configure the processor With the addition of extra un loaders the unit configuration has changed To change the configuration of the processor enter the service func tion using the keypad and display module Before any changes can be made the LOCAL ENABLE STOP CCN switch must be in the STOP position and the ser vicer must log on to the processor Press PASSWORD b Enter l lj spes p Keypad y S LOGGEDON c To change configuration press a lt Keypad LCD displays FLD CFG d If an additional unloader was added to compressor Al press until NULA 1 appears in keypad dis play Press number of unloaders on circuit A Keypad display now reads NULA 2 e If an additiona
95. ntered under the log on subfunction KEY FAD ENTRY LJe FEED TE NOTE Configurations may be modified at this time When finished viewing and or modifying configurations log out as follows DISPLAY COMMENT SUB FUNCTION Enter Disable Password 1Log On Password PASSWORD LOGGED ON Logged On LOGGED ON Disable Password LOG OFF Protection Logged Off EXIT LOG Enable Password Protection 2 Version Software VERSION nformation Version No XXXXXXXX of Software X Language Options 42 To use Demand Limit first enable loadshed then enter demand limit set points See Example 7A Closing the first stage demand limit contact puts unit on the first demand limit level that is the unit does not exceed the percentage of capacity entered as demand limit stage 1 Closing con tacts on second stage demand limit relay prevents unit from exceeding capacity entered as demand limit stage 2 The demand limit stage that is set to the lowest demand takes priority if both demand limit inputs are closed The demand limit function must be enabled in order to function and may be turned off when its operation is not desired The demand limit relays can in off condition re main connected without affecting machine operation Demand Limit 4 20 mA Signal The controls can also accept a 4 20 mA signal for load shedding Input for the signal are terminals shown below Externally powered loop isolator required Positi
96. oken discharge valve Crankcase heaters not energized durina shutdown Expansion valve admitting excess refrigerant nomad d d Que IO eak Burned out coil Defective capacity control valve Miswired solenoid Weak broken or wrong valve body spring Miswired solenoid Defective capacity control valve Plugged strainer high side Stuck or damaged unloader piston or piston ring s 67 Reset circuit breaker Check control circuit for ground or short Replace fuse Move LOCAL ENABLE STOP CCN switch to STOP position then back to RUN or CCN position Check the controls Find cause of trip and reset breaker Check connections Check wiring and rewire Check line voltage Determine location of voltage drop and remedy deficiency Check motor winding for open or shot t Replace compressor if necessary Replace compressor Repair leak and recharge Replace transducer Add refrigerant Replace control Open valve or replace if defective Check wiring Repair or replace motor s if defective Clean coil Add refrigerant Replace control Clean or replace Replace or repair Keep doors and windows closed Check valves Replace if necessary Support piping as required Add refrigerant Check for plugged liquid line filter drier Check valve plates for valve noise Replace compressor worn bearings Check for loose compressor holddown bolts Repair leak Repair damage or replace compressor
97. ompressor Compressor B1 First Stage Microprocessor Second Stage Microprocessor Compressor Al Compressor B1 First Stage Microprocessor Second Stage Microprocessor Compressor Al Compressor B1 First Stage Microprocessor Second Stage Microprocessor Compressor Al Compressor B1 First Stage Microprocessor Second Stage Compressor Third Stage Microprocessor Compressor Al Compressor B1 First Stage Microprocessor Second Stage Microprocessor Compressor Al Compressor B1 Frist Stage Microprocessor Second Stage Microprocessor D Table 5 Condenser Fan Sequence cont FAN ARRANGEMENT 30GT225 PT 307 OO GOEOOOS O OOMOOOO 30GT250 60 Hz 0 exe oT 1X OO 30GT250 50 Hz AND 30GT280 ool Control box TPower box NL x OM 909 9 OO Pumpout When the lead compressor in each circuit is started or stopped that circuit goes through a pumpout cycle to purge the cooler and refrigerant suction lines of refrigerant The pumpout cycle starts immediately upon starting the lead compressor and continues until the saturated suction temperature is 10 F 5 5 C below the saturated suction temperature at start up is 10 5 5 C below the cooler leaving fluid temperature or reaches saturated suction tem perature of 15 F 26 C No pumpout is necessary if the 5 6 1 2 3 4 5 6 11 12 co
98. oviding leaving water temperature reset based on return water temperature Be cause the temperature difference between leaving water tem perature and return water temperature is a measure of the building load return water temperature reset is essentially an average building load reset method Under normal operation the chiller maintains a constant leaving water temperature approximately equal to chilled water set point As building load drops from 10046 down to 0 entering cooler water temperature drops in proportion to load Thus temperature drop across the cooler drops from a typical 10 F 5 5 C at full load to a theoretical 0 F 0 C at no load See Fig 4 At partial load leaving chilled water temperature may be lower than required If this is allowed to increase reset the efficiency of the chiller increases Amount of reset can be defined as a function of cooler temperature drop as shown in Fig 4 This is a simple linear function that requires 4 pieces of input data for the set function 1 Maximum Reset Amount CRST2 allowable range 0 to 20 F 0 to 11 C This is maximum amount leav ing chilled water set point is to be increased 2 Maximum Reset Reference CREF2 allowable range 0 to 20 F 0 to 11 C This is the cooler temperature drop at which reset reaches its maximum value 3 Minimum Reset Amount CRST1 allowable range 0 to 20 0 to LI C This is minimum amount leav ing chi
99. pable of re e Fig 29 Remote Reset from Space or liably switching a 5 vdc 1 mA to 20 mA load i Outdoor Air Temperature Fig 32 Remote On Off 72 A20 18 75 4IN 4 OUT SWITCH MODULE p 7 0 0 i sne Z MTM 30GN040 210 AND ASSOCIATED MODULAR UNITS g ya ai 1 1 11 TB 11 30GT225 250 280 FLOTRONIC Il UNITS TB wa Terminal Block NOTE The 30 T225 250 280 Flotronic 1 units require the acces sory options module for this feature Fig 33 Remote Dual Set Point Control ee 7h C 30GT225 250 280 FLOTRONIC II UNITS CWP Chilled Water Pump TB Terminal Block NOTE The maximum load allowed for the chilled water pump circuit is 125 va sealed 1250 va inrush at 115 or 230 v Fig 34 Chilled Water Pump 57 ALARM SHUTOFF SWITCH 30GN040 210 AND ASSOCIATED MODULAR UNITS 4di TB 5 2 de TB 5 30GT225 250 280 FLOTRONIC Il UNITS Block NOTE The maximum load allowed for the alarm circuit is 125 va sealed 1250 va inrush at 115 or 230 v TB Terminal Fig 35 Remote Alarm 73 CWP1 CWFS eps oce TU ew ee nm on one 2 res 30GN040 210 AND ASSOCIATED MODULAR UNITS ZEN UL AES ds 30GT225 250 280 FLOTRONIC UN ITS CWP1 Chilled Water Pump Interlock CWFS Chilled Water Flow Switch not required low flow protection is provided by Flotronic II controls TB Terminal Block NOTE Contacts must be ra
100. pod Bl occ 2 uNoccuPIEp Fig 9 Sample Time Schedule TROUBLESHOOTING The Flotronic II control has many features to aid the technicians in troubleshooting a Flotronic II Chiller By us ing keypad and display module and status function actual operating conditions of the chiller are displayed while unit is running Test function allows proper operation of com pressors compressor unloaders fans EXVs and other com ponents to be checked while chiller is stopped Service function displays how configurable items are configured If an op erating fault is detected an alarm is generated and an alarm code s is displayed under the subfunction along with an explanation of the fault Up to 5 current alarm codes are stored For checking specific items see Table 9 Checking Display Codes To determine how ma chine has been programmed to operate check diagnostic information 214 and operating mode displays 3 Es If no display appears follow procedures in Control Mod ules section on page 64 If display is working continue as follows Note all alarm codes displayed 214 2 Note all operating mode codes displayed 3 Note leaving chilled water temperature set point in ef fect and current leaving water temperature If machine is running compare the in effect leaving water temperature set point with current water tempera ture Remember if reset is in effect the values may b
101. r EXV relay module control relay feed back switch or signal is sensed as open during operation of If lead compresor in a pressor energizes alarm light and displays a code of 1 2 3 4 5 6 7 or 8 depending on the compressor Compres sor locks off to reset use manual reset method circuit shuts down the other com pressors in the circuit stop and lock off Only the alarm mode for lead compressor is displayed The microprocessor is also programmed to indicate com pressor failure if feedback terminal on DSIO LV or EXV supposed to be on a compressor microprocessor detects this and stops com DISPLAY DESCRIPTION 0 No Alarms Exist Table 14 Alarm Codes ACTION TAKEN CKT RESET BY eet PUMPDOWN METHOD Compressor failure A shut down Manual 2 3 4 Compressor A2 A3 A4 failure Compressor shut down Manual 5 Compressor B1 failure Circuit B shut down Manual 6 7 8 Compressor B2 B3 B4 failure Compressor shut down Manual 9 Leaving water thermistor failure Unit shut down Auto 10 Entering water thermistor failure Unit shut down Auto 19 Compressor Al sensor failure Circuit A shut down Auto 20 Compressor B1 sensor failure Circuit B shut down Auto 21 Reset thermistor failure Normal set point used Auto 22 Discharge pressure transducer failure circuit A Circui Auto 23 Discharge pressure transducer failure circuit B Circui Auto 24 Suction pressure transducer
102. r factory and field con figurations are correctly entered The usual cause of this fault is replacement of the pro cessor module Refer to instructions accompanying the re placement module Code 52 Emergency stop by CCN command Unit goes through normal shutdown when this command is received and goes through normal start up when com mand is cancelled FD D 81 OR CPCS 81 GON Ud lt CPCS 1 g LEGEND STANDARD 040 060 50Hz STANDARD 07050 Hz 04007000 HE i ACCESSORY 040090 60 Hz CB e CR S CPCS 5 COMM Communications Bus GHD CPCS Compressor Protection Control Module i T GREND CR Compressor Contactor Relay DGT Discharge Gas Thermostat Optional DSIO Relay Module Low Voltage HPS High Pressure Switch LV Low Voltage PL Plug PWR Power SNB Snubber TB Terminal Block TRAN Transformer U Unloader 1 Fig 10A 24 V Safety Circuit Wiring 040 070 52 FROM 115v OR 230v CONTROL SCHEHATIC RED m 25 TRAN iu SECONDARY CPCS Bl 5 1 ALARM CODE 1 CPCS HI 2 CPCS A2 ALARM CODE 2 Fh GH H2 CPC5 A1 1 PL3 7 CPCS 81 ALARM CODE 32 PLS 5 ALARM CODE 5 PLS 6 CPCS B2 REI CPCS B2 BLUE Hen CPCS B1 ALARM CODE 6 POINT NUMBER OF FIRST CHANNEL ALARM CODE 1
103. ransducer from 4 In male flare fitting When installing new pressure transducer do not use thread sealer Thread sealer can plug transducer and render it inoperative 4 Insert weathertight wiring plug into end of transducer until locking tab snaps in place 5 Check for refrigerant leaks pao 757 1 4 SAE FEMALE FLARE WHITE DOT LOW PRESSURE TRANSDUCER RED DOT HIGH PRESSURE TRANSDUCER SAE Society of Automotive Engineers Fig 16 Pressure Transducer Table 15 Thermistor Temperature F vs Resistance Voltage Drop Flotronic II TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE F DROP V OHMS F DROP V OHMS F DROP V OHMS 25 0 4821 98010 71 3 093 5781 167 0 838 719 24 0 4818 94707 72 3 064 5637 168 0824 105 23 0 4814 91522 73 3034 5497 169 0 810 690 22 0 4806 88449 74 3005 5361 170 0 797 677 21 0 4 800 85486 75 2977 5229 171 0 783 663 20 0 4193 82627 76 2 947 5101 172 0770 650 19 0 4786 79871 77 2 917 4976 173 0758 638 18 0 4779 77212 78 2884 4855 174 0745 626 17 0 4772 74648 79 2857 4737 175 0734 614 16 0 4764 72175 80 2 827 4622 176 0722 602 15 0 4 151 69790 81 2797 4511 177 0 710 591 14 0 4749 67490 82 2766 4403 178 0 700 581 13 0 4740 65272 83 2738 4298 179 0 689 570 12 0 4734 63133 84 2708 4196 180 0678 561 11 0 4724 61070 85 2679 4096 181 0668 551 10 0 4715 59081 86 2 650 4000 182 0659 542 9 0 470
104. ration XXXXXXXX Code 8 Adiustable Field Configurations After logging on press 4 fr to enter subfunction The subfunction allows oper ation of the chiller to be customized to meet the particular needs of the application The chiller comes from the fac tory preconfigured to meet the needs of most applications Each item should be checked to determine which configu ration alternative best meets the needs of a particular appli cation See Table 13 for factory loaded configuration codes and alternative configurations If processor module is replaced the replacement module is preloaded with factory default configuration codes Each configuration code must be checked and if necessary re configured to meet needs of the application See Table 13 for pre loaded service replacement configuration codes Service Configuration Codes Press to enter the service configuration subfunction The first 2 items under this subfunction are 2 groups 8 digits each of configura tion codes that are downloaded at the factory If processor module is replaced in the field the 2 groups of configura tion codes must be entered through the keypad and display module The 2 groups of configuration codes groups 7 and 8 that apply to the unit being serviced can be found on a label diagram inside the control box cover See Table 12 for keystroke information to enter configuration codes 7 and 8 SCHEDULE FUNCTION This function provides a me
105. ressed the display shows the modified chilled water set point c The final value displayed when the is pressed is the cooling ramp loading rate This is the maxi mum rate at which the leaving chilled water is al lowed to drop and can be field set from 0 2 to 2 0 F 11 to 1 1 C minute This value is not displayed unless the function is enabled see Adjustable Field Configurations on page 45 Reading and Changing Set Points Example 4 shows how to read and change the chilled water set point Other set points can be changed by following the same procedure Refer to Table 9 for the sequence of display of set points in each subfunction Example 4 Reading and Changing Chilled Water Set Point RESPONSE ENTRY COMMENTS SET POINT CSP1 44 0 CSP1 420 System set points Present occupied chilled water Set point is 44 0 F Press the ENTR Display shows new occupied chilled water set point is 42 0 F Present unoccupied chilled water set point is 44 0 F Press the bs T os fe a y shows new unoccupied chilled water set point is 50 0 F Displays the maximum reset and minimum reset set points The minimum and maximum reference reset set points can also be displayed These set points are not accessible when reset type has been configured for NONE in the service function CSP2 44 0 Gig CSP2 50 0 Temperature Reset Based on Return Water Temperature The control system is capable of pr
106. rm condition is reset Probable cause of condition is a faulty or improperly connected plug wir ing error or faulty module Loss of communication can be attributed to a grounded transformer with a secondary voltage of 21 vac supplying the PSIO DSIO LV or 4 IN 4 OUT modules the 12 5 vac transformer supplying the DSIO EXV module or the 24 vac transformer supplying PS 1 for the transformers These transformers should not be grounded or serious damage to controls can result Check to be sure the transformers are not grounded NOTE If a blank PSIO module is downloaded without be ing connected to the modules DSIO this alarm is energized Code 34 Loss of communication with 4 In 4 Out module This applies only if one or more of the following options are used external temperature reset e 420 mA temperature reset external switch controlled dual set point switch controlled demand limit 4 20 mA demand limit hot gas bypass If communication is lost with 4 IN 4 OUT module the unit shuts off automatically after finishing pumpout Reset of alarm is automatic when communication is restored Start up after alarm is remedied follows a normal sequence Proba ble cause of condition is a faulty or improperly connected plug wiring error or faulty module Loss of communication can be attributed to a grounded transformer with a secondary voltage of 21 v c supplying the PSIO DSIO LV or 4 IN 4 OUT the 12 5 vac trans former supplyin
107. ry ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing emet Table 4C Capacity Control Steps 130 210 and Associated Modular Units LOADING SEQUENCE A T LOADING SIEQUENCE B UNIT CONTROL 30GN STEPS Displacement Compressors Displacement Compressors Approx Approx B1 at 2 B1 3 A1 B1 4 Al 130 240A 5 Al 300A 60 Hz E ri o 1 1 1 kas 8 Al B1 B2 9 1 A2 B1 B2 10 Al A2 B1 B2 11 Al A2 B1 B2 te itt B1 At A1 B1 130 240A Al B1 n Mu TB NU CES Al A2 B1 A tt A2 B1 B2 Al TT A2 B1 B2 _ Al B1 2 1 A2 B1 B2 1 B1Tf 2 B1 3 Bt 4 A1 BiTf 5 A1 B1tt 6 A1 B1 300A yt 8 en B z Al 9 A1 B1tf B2 T Bit A1 B1 B2 A1 B1 B2 Al A2 Bitt B2 4 Al A2 B1tt B2 Al A2 B1 B2 Al A2 B1 B2 Bitt B1 B1 A1 Bitt A1 Bitt At B1 A1 B1 130 240A Aitt B1tt B2 Al tt A2 B1 AEN A1 B1 an A2 1 B1 B2 Ai tt ra 20 an B2 Al IAS BT y B2 Al tf A2 B1 B2 Ae ru Al Al A2 B1 TT B2 Al A B1 R2 Al A R1 R2 A1 A2 B1 B2 B1 A1 B1 A1 B1 Al Bi Al B1 B2 130 240A AL 1 300A 50 Hz BI Be A1f B1t A1 A2 B1 B2 Al 2 1 A2 B1 Al A2 B1 B2 Al A2 A3 B1 B2 Al A2 A3 B1 B2 AI A2 A3 B1 B2 Al A2 A3 81 B2 Al A2 A3 B1 B2 A1 A2 A3 B1 B2 Unloaded compressor TCompressor unloader standard Compressor unloader
108. s 130 210 and Associated Modular Units cont UNIT CONTROL 30GN STEPS o gt G N 150 60 Hz ATPBTT 150 60 Hz At B11 150 60 Hz At BTE 150 50 Hz A11 B1 150 50 Hz A1t B1t Unloaded compressor Compressor unloader standard Compressor unloader accessory TfTwo unloaders both unloaded LOADING SEQUENCE A i LOADING SIEQUENCE B 96 Compressors Displacement Compressors Approx ATH AD Br Al TT A2 B1 A Al 2 B1 B2 Al A2 Bi Be Al TE AZ AS Bt B Al 2 3 B1 B2 Al A2 A3 B1 B2 LTE tt bi abraded Al BITF B2 A1 Bit Be A1 B1 Be Al BI Al A2 B1 B2 Al Ne AE B2 Al A2 A3 B1 B2 B1 Al tt 2 ASI B2 APB B2 Al d ASBL B2 A2 B1 B1B A1 A2 B1 B2 Al A2 B1 B2 AT A B1 B2 Al A2 B1 B1 B2 Al A2 B1 B2 we A AS B1 A2 A3 B1 2 A2 R1 Al A2 A3 B1 B2 A2 A3 B1 B2 Al A2 A3 B1 B2 Al B1 Aitt A2 B1 pom Al ti a B2 AL B1 B2 a By T Al 1 B2 A2 A3 1 2 A2 A3 B1 B2 NOTE These capacity control steps may vary due to lag compressor sequencing 16 Table 4C Capacity Control Steps 130 210 and Associated Modular Units cont LOADING SEQUENCE A LOAD SEQUENCE B UNIT CONTROL SIZE STEPS Compressors Displacement Compressors Approx Approx 1 XA A1 B1 A1 B1 t B2 1 1 2 A1 B1 B2 Al A2 B1tt B2 Al A2 B1 B2 AI A2
109. s are used on 30G Flotronic II chillers a low pres sure transducer and a high pressure transducer The low pressure transducer is identified by a white dot on the body of the transducer and the high pressure transducer by a red dot See Fig 16 Three pressure transducers are mounted on each lead com pressor 2 low pressure transducers to monitor compressor suction pressure and oil pressure and a high pressure trans ducer to monitor compressor discharge pressure see Fig 17 for exact locations on compressor Each transducer is supplied with 5 vdc power from a rectifier which changes 24 vac to 5 vdc TROUBLESHOOTING If transducer is suspected of be ing faulty first check supply voltage to transducer Supply voltage should be 5 vdc 2 v If supply voltage is cor rect compare pressure reading displayed on keypad and dis play module against pressure shown on a calibrated pres sure gage If the 2 pressure readings are not reasonably close replace pressure transducer TRANSDUCER REPLACEMENT CAUTION ransducers are installed directly in the refrigerant cir uit Relieve all refrigerant pressure using standard re frigeration practices before removing 1 Relieve refrigerant pressure using standard refrigeration practices 2 Disconnect transducer wiring at transducer by pulling up locking tab while pulling weather tight connection pfug from end of transducer Do not pull on trans ducer wires 3 Unscrew t
110. s configured for use with a chilled water pump interlock Low transducer supply voltage Code can occur under any of these conditions 1 Interlock switch fails to close within one minute after chilled water pump starts 2 Interlock switch opens during unit operation 3 Interlock voltage is detected but unit is not configured for interlock 4 Interlock voltage is outside its valid range If any of these conditions occur all compressors are dis abled and if running shutdown occurs without pumpout Chilled water pump also shuts down Reset is manual with LOCAL ENABLE STOP CCN switch Most probable cause of this fault is shutdown or failure of chilled water pump to start Other possibilities are improper configuration or wir ing errors Code 30 Reset input failure 4 to 20 m Code 31 Demand limit input failure 4 to 20 mA These codes apply only if unit is configured for these functions If 4 20 mA signal is less than 4 or more than 20 mA reset or demand limit function is disabled and unit functions normally If mA signal returns to the acceptable range function is automatically enabled Code 32 Loss of communication with compressor relay module DISO LV Code 33 Loss of communication with EXV relay module DSIO EXV If communication is lost with either of these modules unit shuts down without pumpout This alarm resets auto matically when communication is restored The unit starts up normally after ala
111. s more than once as a result of any of the above safety devices determine and correct the cause before attempting another restart Restart Procedure After cause for stoppage has been corrected restart is either automatic or manual dependin on fault Manual reset requires that LOCAL ENABLE STOP CCN switch be moved to STOP position then back to original operating position Some typical fault conditions are described below For a complete list of fault conditions codes and reset type see Table 14 POWER FAILURE EXTERNAL TO THE UNIT Unit restarts automatically when power is restored Typical Stoppage Faults and Reset Types Chilled Water Low Flow Chilled Water Low Temperature Manual reset Auto reset first time manual if repeat Manual reset Unit restarts automatically when power is restored Manual reset Auto reset first time then manual if within same day Manual reset Manual reset Chilled Water Pump Interlock Control Circuit Fuse Blown High Pressure Switch Open Low Refrigerant Pressure Low Oil Pressure Discharge Gas Thermostat Open fe Alarm Codes Following is a detailed description of each alarm code error and possible cause Manual reset of an alarm is accomplished by moving LOCAL ENABLE STOP CCN Switch to STOP position then back to LO CAL or CCN position See Table 14 for listing of each alarm code Code 0 No alarms exist Codes 1 8 Compressor failure If DSIO LV o
112. s the EXV through the EXV driver mod ule Inside the expansion valve is a linear actuator stepper motor The lead compressor in each circuit has a thermistor and a pressure transducer located in the suction manifold after the compressor motor The thermistor measures the tem perature of the superheated gas entering the compressor cyl inders The pressure transducer measures the refrigerant pressure in the suction manifold The microprocessor con verts the pressure reading to a saturated temperature The difference between the temperature of the superheated gas and the saturation temperature is the superheat The micro processor controls the position of the electronic expansion valve stepper motor to maintain 29 F 16 C superheat At initial unit start up the EXV position is at zero After that the microprocessor keeps accurate track of the valve position in order to use this information as input for the other control functions The control monitors the superheat and the rate of change of superheat to control the position of the valve The valve stroke is very large which results in very accurate control of the superheat Sensors The Flotronic II chiller control system gath ers information from sensors to control the operation of the chiller The units use 6 standard pressure transducers and 4 standard thermistors to monitor system pressures and tem peratures at various points within the chiller Sensors are listed in Table 3
113. se of fault is usually a bad thermistor wiring error or loose connection Code 19 Compressor Al suction sensor failure Code 20 Compressor B suction sensor failure On units with thermistors if temperature measured by these thermistors is outside the range of 40 to 240 F 40 to 116 C affected circuit shuts down after going through a normal pumpout Other circuit continues to run Reset is automatic if temperature returns to the acceptable range 50 and circuit start up follows normal sequence Cause of this fault is usually a bad thermistor wiring error or loose connection On units with transducers if the saturated suction tem perature is greater than the leaving water temperature plus 10 F 5 5 C for more than 5 minutes the affected circuit shuts down after going through normal pumpout The re set is automatic if the saturated suction temperature returns to the acceptable range and start up follows the normal se quence Cause of this fault is usually a bad transducer a wiring error or a loose connection Code 21 Reset thermistor failure applies only to installa tions having external temperature reset If temperature measured by this thermistor is outside range of 40 to 240 F 40 to 116 C reset function is disabled and unit controls to normal set point If temperature returns to the acceptable range reset function is automatically en abled Cause of this fault is usually a bad thermistor wir ing error or
114. should energize g Press to scroll down until the display reads and the solenoid should deenergize h Use the and keys to check the remainder of the unloader coils 6 Once the check has been performed return the LOCAL ENABLE STOP CCN switch to the proper position 7 Close and secure the control box door 8 Start the unit and confirm that the chiller operates properly fl3o 365 UR A TRANS ee 0 HGEPR B UR B HOBPR A 9 KO LEGEND Communications Bus TB Terminal Block Hot Gas Bypass Relay TRAN Transformer Normally Open U Unloader Snubber UR Unloader Relay Fig 24 Flotronic Il 115 230 V Unloader Wiring 130 50 Hz 150 210 225 250 280 70 MER cum ome is sm 4 20 MA OUTPUT HOTORHASTER Paabu T LEGEND C Contactor Sw Switch CB Circuit Breaker TRAN Transformer COMM Communications Bus UR Unloader Relay oo m gt L CIANNEL 1 o m gt L oo m gt gt 30 1466 FROM 115V OR 230V CONTROL SCHEMATIC TRANS CHANNEL 2 BCZ CHANNEL 3 AIRIA AL A MODULE see ei ie o 270C pay Ea SERS CHANNEL 8 CHANNEL 7 CHANNEL 6 CHANNEL S gt 158 I I I BRE Sp Fig 25 Accessory Unloader Control Wiring 130 50 Hz 150 210 225 250 280 FIELD WIRING Refer to Fig 26 36 for field wiring 26 7 4 IN 4 OUT
115. splay Capacity Stages Table 9 Keypad Directory STATUS 1 AUTOMATIC DISPLAY Refer to Automatic Display Operation on page 28 E 2 ALARMS X ALARMS Number of Tripped Alarms ALARM X ALARM X ALARM X Displays Tripped Alarms ALARM X ALARM X 3 MODES S X MODES Number of Modes in Effect MODE X MODE X Displays Mode in Effect MODE X MODE X 4 STAGE 4 lra STAGE Capacity Staging Information STAGE X Number of Requested Stages CAPT X Percent of Total Capacity CAPA X Percent Circuit A Capacity CAPO X Percent Circuit B Capacity s LMT X Demand Limit Set Point LOAD X Load Limit Set Point 4 CIRA X Circuit A Compressor Relay Status CIRBX Circuit B Compressor Relay Status SMZ X Load Unload Factor for Compressors Factor 1 Unloader Factor 0 6 5 SET POINT SET POINT Fluid Set Point Information SP x Set Point MSP X Modified Set Point Set Point Reset F A 5 Cooler Leaving Fluid Temperature 6 TEMPERATURE i H Temperature Information Cooler Entering Fluid Temperature Cooler Leaving Fluid Temperature Circuit A Saturated Condenser Temperature Circuit A Saturated Suction Temperature Compressor AI Suction Temperature u Lu i Circuit A Suction Superheat LEGEND Must be configured CCN Carrier Comfort Network TW applicable EXV Electronic Expansion Valve MOP Maximum Operating Pressure 30 e SUBFUNCTION 6 TEMPERATURE
116. t 100 Loadshed 2 reset to 4096 COMMENTS Field configuration sub function of servicefunction Scroll past other elements in the subfunction Loadshed is enabled for 2 stage switch control Loadshed is now disabled NOTE Select 3 for Carrier comfort Network CCN load limiting Select 4 for CCN demand limiting 4 20 MA INPUT Example 7B Using Demand Limit 4 20 mA First Log On As Shown in Table 11 KEYPAD DISPLAY ENTRY RESPONSE 4 fe FLD cre ERTYP 0 ir LSTYP 0 we LSTYP 2 DEMAND DMAX 100 s pmax 90 RMAX 20 5 rs Rmax 15 DMIN 0 2 o 20 RMIN 4 le I RMING COMMENTS Field configuration subfunction of service function Scroll past other elements in the subfunction Loadshed is not enabled Loadshed is now enabled for 4 20 mA signal control Demand Limit set points Maximum demand limit is 10096 Maximum demand limit is 9096 Maximum demand limit reference is 20 m aximum demand limit reference is 15 mA inimum demand limit is 0 Minimum demand limit is 20 inimum demand limit reference is 4 Minimum demand limit reference is 6 m 100 NR MAX DEMAND DMAX 90 80 60 MAX DEMAND LIMIT REFERENCE RMAX 15 40 MAXIMUM ALLOWABLE MACHINE LOAD 9 5 20 MIN DEMAND LIMIT DMIN 20 MIN DEMAND LIMIT REFERENCE RMIN 6 DEMAND LIMIT SIGNAL 4 20 MA INPUT
117. t external tempera ture reset by entering when CRTYP 0 appears Then enter set points as described previously in Example 5 See Fig 5 Temperature Reset Based on 4 20 mA Signal If desired temperature reset can be based on a 4 20 mA signal For proper connections refer to Field Wiring section on page 71 and Fig 6 At the_field configuration step select 4 20 mA reset by entering when CRTYP 0 appears Then enter set points as described previously in Example 5 See Fig 7 Demand Limit 2 Stage Switch Control This control has been designed to accept demand limit signals from a build ing load shedding control The demand limit function pro vides for 2 capacity steps The keypad is used to set the 2 demand limit set points which range from 100 to 096 of capacity Capacity steps are controlled by 2 field supplied relay contacts connected to the designated chiller terminals See Field Wiring section on page 7 1 and Fig 6 Example 6 Changing Reset Type To change type of reset first log on as shown in Table 11 Also refer to Set Point Function section page 39 for information on entering reset set points using reset feature KEYPAD DISPLAY ENTRY RESPONSE COMMENTS Field configuration 4 FLD CFG subfunction of service function Scroll past single cooling CSPTYP 0 set point Return water temperature 1 CRTYP 0 No reset has been selected reset is selected and activated CRTYP 1 Reset type to
118. t shuts down after normal pumpout process Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence charge Possible causes of fault are low refrigerant charge plugged filter drier or a faulty EXV or thermistor Code 48 Low suction superheat Circuit A Code 49 Low suction superheat Circuit B If EXV is at minimum position suction superheat is less than 10 F 5 5 C or saturated evaporator temperature is greater than MOP maximum operating pressure for more than 5 minutes affected circuit shuts down after going through pumpout process Reset is manual with LOCAL ENABLE STOP CCN switch and start up follows normal sequence Possible causes of fault are faulty EXV or thermistor Code 50 Illegal configuration This fault indicates a configuration error Unit is not al lowed to start Check all configuration data and set points and correct any errors Code 51 Initial configuration required 125 1 1 i 22 RE MR ee eee This fault indicates factory configuration has not been done and unit is not allowed to start Refer to unit wiring label diagrams for factory configuration codes There are 8 groups of S digit numbers that must be entered The first 6 groups must be entered under bar 4 n ction Groups 7 and 8 must be entered under su bd u nction Enter each group then press the key Use the down E after each group to bring up the next empty screen Unit should start afte
119. ted for dry circuit application capable of reliably switching 5 vdc 1mA to 20 load Fig 36 Interlocks REPLACING DEFECTIVE PROCESSOR MODULE The replacement part number is printed on a small label on front of the PSIO module The model and serial num bers are printed on the unit nameplate located on an exte rior corner post The proper software and unit configuration data is factory installed by Carrier in the replacement mod ule Therefore when ordering a replacement processor mod ule PSIO specify complete replacement part number fuil unit model number and serial number If these numbers are not provided the replacement module order is config ured instead as a generic Flotronic 11 replacement mod ule This requires reconfiguration of the module by the installer CAUTION Electrical shock can cause personal injury Disconnect all electrical power before servicing Installation 1 Verify the existing PSIO module is defective by using the procedure described in the Control Modules sec tion on page 64 2 Refer to Start Up Checklist for Flotronic II Chiller Sys tems completed at time of original start up found in job folder This information is needed later in this procedure If checklist does not exist fill out the and 5 configuration code sections on a new check list Tailor the various options and configurations as needed for this particular installation 3 Check that all power
120. to unit is off Carefully discon nect all wires from defective module by unplugging the 6 connectors It is not necessary to remove any of the individual wires from the connectors Remove the green ground wire 4 Remove defective PSIO by removing its mounting screws with a Phillips screwdriver and removing the module from the control box Save the screws for later use 5 Use a small screwdriver to set address switches Sl and S2 on the new PSIO module to exactly match the set tings on the defective module 6 Package the defective module in the carton of the new module for return to Carrier 7 Mount the new module in the unit control box using a Phillips screwdriver and the screws saved in Step 4 above 10 11 12 Reinstall all 6 wire connectors and the green ground Wire Carefully check all wiring connections before restoring power Verify the LOCAL ENABLE STOP CCN switch is in STOP position Restore control power Verify the red and green lights on top of PSIO and front of each DSIO module re spond as described in Control Modules section on page 64 The keypad and display module HSIO or LID should also begin its rotating display Using the keypad and display module press 2 E 4 to verify that the software version number matches the ER engineering requirement number shown on the PSIO label Press felt verify that the 6 factory configuration codes CODE 1 through CODE 6 exactly match the
121. tt A2 B1 A1 A2 B1 9 A1 A2 B1 10 Al A2 B1 Unloaded compressor TCompressor unloader standard Compressor unloader accessory ttTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing Table 4B Capacity Control Steps 080 110 and Associated Modular Units cont LOADING SEQUENCE A Displacement Compressors Displacement Compressors Approx Approx LOADING SEQUENCE B UNIT CONTROL 30GN STEPS 080 60 Hz A1t Bit Al A2 B1 B2 AL A2 B1 B2 Al A2 B1 B2 Al A2 B1 B2 090 60 Hz Ait Bit Al it ARE E A1 A2 B1 P re A2 Bi B2 B1 B2 E S Br B2 COON O t gt CO O O O Q 090 60 Hz A1 B1t BH in 2 1 mol A1Bitt B2 Al EE Al y Bi a B2 Al BI R2 2 1 82 o O G3 OQ 5 090 50 Hz A1t B1f AT 2 B1 B2 A P B1 B2 O D O O T O N L k 090 50 Hz AIt BIT IIlIIIlI 1111111 Mora Unloaded compressor Compressor unloader standard A Compressor unloader accessory pt TiTwo unloaders both unloaded is NOTE These capacity control steps may vary due to lag compressor sequencing Table 4B Capacity Control Steps 080 110 and Associated Modular Units cont LOADING SEQUENCE UNIT CONTROL 30GN STEPS Displa
122. ules and 6 pack relay board to increase or de crease the active stages of capacity The processor module also controls the EXV driver module commanding it to open or close each EXV in order to maintain the proper super heat entering the cylinders of each lead compressor Infor mation is transmitted between the processor module and re lay module the EXV driver module and the keypad and display module through 3 wire communications bus When used the options module is also connected to the commu nications bus For the Flotronic II chillers the processor monitors sys tem pressure by means of 6 transducers 3 in each lead com pressor Compressor suction pressure discharge pressure and oil pressure are sensed If the processor senses high discharge pressure or low suction pressure it immediately shuts down all compressors in the affected circuit During operation if low oil pressure is sensed for longer than one minute all compressors in the affected circuit are shut down At start up the coil pressure signal is ignored for 2 min utes If shutdown occurs due to any of these pressure faults the circuit is locked out and the appropriate fault code is displayed Low Voltage Relay Module This module closes contacts to energize compressor unloaders and or compres sors It also senses the status of the safeties for all compres sors and transmits this information to the processor Electronic Expansion Valve Module This mod
123. unctions To enter a subfunction first press subfunction number desired Then press the function key in which the sub function resides To move within that subfunction press the arrow For example a enters the Temperature Information subfunction 4 At any time another subfunction may be entered by en tering the subfunction number then the function key 5 Prior to starting unit check leaving fluid set point for correct setting Refer to Set Point Function section on page 39 6 Depending on system configuration all displays may not be shown All displays are shown unless marked with the following symbol Must be configured For additional unit start up procedures see separate In stallation Start Up and Service Instructions supplied with unit OO i a a a a U a 4 MEE i P5 H hy OPERATION To access a function press subfunction no and function name key Display shows sub function group To move to other elements scroll up or down using arrow keys NOTE These displays do not show if control is not configured for reset When the last element in a subfunction has been dis played the first element is repeated To move to next subfunction it is not necessary to use subfunction number Press function name key to ad vance display through all subfunctions within a function and then back to the first To move to another function either depr
124. ut Percent Motormaster B Output Percent To use Test function LOCAL ENABLE STOP CCN switch must be in STOP position To operate a test scroll to desired test Then press rm to start test Press to stop test SUBFUNCTION 1 OUTPUTS KEYPAD ENTRY DISPLAY OUTPUTS 8 8 8 8 8 8 8 8 ALMR X FRA1 x FRA2 X FRB1 X FRB2 x CHWP X EXVA X EXVB X HGBRA X HGBRB X MMA X s MMB X 32 COMMENT Test Outputs Display Check Energize Alarm Relay K3 Energize Fan Relay AI K1 Energize Fan Relay A2 K2 Energize Fan Relay B1K4 Energize Fan Relay B2 K5 Energize Cooler Water Pump K6 Enter Desired EXVA Position Enter Desired EXVB Position Energize Hot Gas Bypass Relay A Energize Hot Gas Bypass Relay B Enter Desired Matormaster A Output Signal Enter Desired Motormaster B Output Signal Table 9 Keypad Directory cont TEST cont WARNING During compressor test compressors start and run for 10 seconds Compressor service valves and liquid line valves must be open Energize crankcase heaters 24 prior to performing compressor tests SUBFUNCTION KEYPAD ENTRY DISPLAY 2 COMPRESSORS AND UNLOADERS COMP CPA1 X CPA2 X CPA3 X CPA4 X CPB1 x CPB2 x CPB3 X CPB4 X ULA1 X ULA2 X ULB1 X ULB2 X SCHEDULE hours COMMENT Compressor and Unloader Test Test Compressor Al Test Compressor 2T Test Compressor ASt Test Compressor A4t Test Compressor B1 Test Compressor
125. ve lead to J7 5 4 In 4 Out Module Negative lead to J7 6 4 In A Out Module Internally powered Positive lead to J7 6 4 In 4 Out Module Negative lead to J7 7 4 In 4 Out Module See Field Wiring section on page 71 and Fig 6 At field configuration step select 4 20 mA loadshed by entering when the LSTYP 0 display appears See Example 7B Then enter set points as follows In this ex ample set points are coordinates of the demand limit curve shown in Fig 8 10 8 7 m S gt 5 2 o o i 4L x a 3 2 I Q MAX RESET CRST2 10 MAX RESET REFERENCE CREF2 15 MIM RESET oneT I S MIN RESET REFERENCE CREFI 6 RESET REFERENCE SIGNAL Fig 7 4 20 mA Cooling Temperature Reset Example 7A Using Demand Limit First Log On as Shown in Table 11 E KEYPAD ENTRY KEYPAD ENTRY DISPLAY RESPONSE FLD CFG ERTYP 0 LSTYP Q LSTYP 1 DEMAND DLS1 100 DLS1 60 DLS2 100 DLS2 40 FLD CFG ERTYP 0 LSTYP 1 LSTYP 0 COMMENTS Field configuration sub function of service function Scroll past other elements in the subfunction Loadshed is not enabled Loadshed is now enabled for 2 stage switch control Demand Limit set points subfunction of set point function Loadshed 1 currently set at 100 Loadshed reset to 6096 Loadshed 2 currently set a
126. w 210 yu A A2BI B2 Al A2 B1 B2 tit Al A2 B1 B2 AI A2 Bt B2 Al A2 A3 BT 2 Al A2 B1 B2 B3 Al A2 A3 B1 B2 Al A2 B1 B2 B3 Al A2 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 At A2 A3 A4 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 210 390A 420A B 50 Hz A1 B1 Al A2 A3 B1 B2 B3 Al A2 A3 AA4 B1 B2 B3 210 390A 420A B 50 Hz A1 B1 A2 A3 B1 B2 B3 A1 A2 A3 A4 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 1 1 1 1 Pu 210 390A Al A2B1 420 50 Hz Al on A A1 B1 Al A2 B1 B2 AV A2 B1 B2 B3 Al A2 A3 B1 B2 B3 Al A2 A3 B1 B2 B3 Al AP AB A4 B1 B2 B3 Al A2 A3 A4 B1 B2 B3 210 390A Al A2 B1 420A B 50 Hz Al Ws wD A1 B1 AI A2 B1 B2 B3 Al A2 B1 B2 B3 AI A2 B1 B2 B3 Unloaded compressor TCompressor unloader standard Compressor unloader accessory TTTwo unloaders both unloaded NOTE These capacity control steps may vary due to lag compressor sequencing 22 Table 4D Capacity Control Steps 225 250 280 LOAC ING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL z 30GT STEPS Displacement Compressors Displacement Compressors Approx Approx 2 3 4 225 60 Hz 5 6 7 8 1 2 3 4 5 6 7 225 60 Hz 8 A1 9 225 60 Hz D A1 B1 Al A2 B1 B2 B3 pne Al A2 B1 B2 B3 amp A2A3BB2B3 e Al A2 A3 B1 B2 83 Al A2 A3 B1 B2 B3 AI A2 A3 B1 B2 Al

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