Carrier Air Conditioner 040 420 User Manual

with

CONTENTS

P a g e

Page

Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . ...48

SAFETY CONSIDERATIONS . . . . . . . ,

. , . . , .

POWER FAILURE EXTERNAL TO THE UNIT

GENERAL . . . . . . , . . . . , . , . . . , . , . . . . , . , . . . . . . . . 2

Alarm Codes . . . . . . , . . . . . . . , . . . . . . . . . . , . . . . . 49

Compressor Alarm Circuit . . . . . . . . . . . . . . . . 50

Electronic Expansion Valve . . . . . . . . . . . . . . . . , . 56

MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-4

Processor Module . . . . . . . . . . . . . . . . . . . . . . . . ...2

Low-Voltage Relay Module . , . . . . . . , . , . , , . . . . . 2

Electronic Expansion Valve Module . . . . . . . . . . . 2

EXV OPERATION

CHECKOUT PROCEDURE

Options Module . . . . . . . . . . . . . . . .

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

Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...60

Keypad and Display Module

LOCATION

(Also Called

or LID) . . . . . . . . . . . . . . . . . . 2

THERMISTOR REPLACEMENT

T2, T7, T8)

Control Switch . . . . , . . . . . . . . . . . . . . . . . . . . . . . . 2

Electronic Expansion Valve (EXV) . . . , . . . . . . . . 4

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4

Compressor Protection Control

(Compressor and Cooler)

Pressure Transducers . . . , . . . , . . . . . . . . . . . . . 60

TROUBLESHOOTING

TRANSDUCER REPLACEMENT

Module (CPCS) . . , . . . . . . . . . . . . . . . . . . . . . . . . . 4

Control Modules . . . . . . . . . . . . . . . . . . . . . . . , . . . . 64

PROCESSOR MODULE (PSIO),

MODULE (SIO), LOW-VOLTAGE RELAY

MODULE (DSIO), AND EXV DRIVER MODULE

(DSIO)

OPERATION DATA . . . . . . . . . . . . . , . . . . , . . . . , 5-47

Capacity Control . . . . , , . . . . . . . . . . . . . . . . . . . . . . 5

Head Pressure Control . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Keypad and Display Module

. RED LED

GREEN LED

(Also Called

PROCESSOR MODULE (PSIO)

LOW-VOLTAGE RELAY MODULE (DSIO)

MODULE (SIO)

ACCESSING FUNCTIONS

SUMMARY DISPLAY

KEYPAD OPERATING INSTRUCTIONS

STATUS FUNCTION

ACCESSORY UNLOADER INSTALLATION

68-7 1

. 68

TEST FUNCTION

Installation . . . . . . . , . . . . . . , . . . . . . . . . . . .

HISTORY FUNCTION

SET POINT FUNCTION

SERVICE FUNCTION

040-110, 130 (60 Hz) UNITS

(and associated modular units)

130 (50 Hz), 150-210, 225, 250, and 280 UNITS

(and associated modular units)

SCHEDULE FUNCTION

. . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

48-67

FIELD WIRING . . . . . . . . . . . . , . . . . . . . . . . . . . . . 71-73

REPLACING DEFECTIVE PROCESSOR

. . . . . . . . . . . . . . . . . . . . .

Checking Display Codes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Shutoff

MODULE (PSIO)

. . . . . . . . . . . . . . . . .

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

Complete Unit Stoppage

Single Circuit Stoppage

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...73

. . . . . . . . . . . . . . . . . . . . . 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, etc.).

Only trained, qualified installers and service mechanics should

install, start-up, and service this equipment.

Electrical shock can cause personal injury and death.

Shut off all power to this equipment during installation

and service. There may be more than one disconnect

switch. Tag all disconnect locations to alert others not

When working on this equipment, observe precautions in

the literature, and on tags, stickers, and labels attached to

the equipment, and any other safety precautions that apply.

Follow all safety codes. Wear safety glasses and work gloves.

Use care in handling, rigging, and setting this equipment,

This unit uses a microprocessor-based electronic con-

trol system. Do not use jumpers or other tools to short

out components, or to bypass or otherwise depart from

recommended procedures. Any short-to-ground of the

control board or accompanying wiring may destroy the

electronic modules or electrical components.

and in handling

electrical components.

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

Catalog No.

Printed in S A.

Form

1 - 9 4

Replaces:

T ,

Book 2

T a b

P C 9 0 3

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The

consists of

processor module

GENERAL

a low-voltage relay module (DSIO-LV),

an EXV

IMPORTANT: This publication contains controls, op-

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

tronic II units. See Fig. 1.

eration and troubleshooting data for

and

250, and 280

II chillers,

Circuits are identified as circuits

pressors are identified as Al, A2, etc. in circuit A,

B2, etc. in circuit B.

Use this guide in conjunction with separate Instal-

lation Instructions booklet packaged with the

and B, and com-

and

The

Series standard Flotronic II chillers feature

MAJOR SYSTEM COMPONENTS

microprocessor-based electronic controls and an electronic

expansion valve (EXV) in each refrigeration circuit.

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

NOTE: The

and 045 chillers with a

installed brine option have thermal expansion valves (TXV)

instead of the EXV.

relay modules and

relay board to increase or de-

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 for a listing of unit

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

sizes and modular combinations. For modules

and

follow all general instructions as noted for unit sizes

For all remaining modules, follow instructions for unit

sizes 130-210.

display module through

3-wire communications bus. When

used, the options module is also connected to the commu-

nications bus.

Table 1

Unit Sizes and Modular Combinations

For the Flotronic II chillers, the processor monitors sys-

tem pressure by means of

transducers,

in each lead com-

UNIT MODEL

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.

30G

NO45

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.

160

180

200

225

250

Electronic Expansion Valve Module

This mod-

ule receives signals from the processor and operates the elec-

tronic expansion valves.

Options Module

This module allows the use of

260

2 8 0

tronic II features such as dual set point, remote reset, de-

mand limit, hot gas bypass, and accessory unloaders. The

285

30GNf 70

options module also

activated from a remote 4-20

for reset and demand limit to be

325

350

380

400

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.

3 0 G N f

Hz units/50 Hz units.

Keypad and Display Module (also called

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.

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

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,

from operating under unsafe conditions.

scheduling func-

manually stopped, or put under the control of

Carrier Corn-

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.

fort Network (CCN), Switch allows unit operation as shown

in Table 2.

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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).

Compressor Protection Control Module

Each compressor on models

(50 Hz), 080-

has its own CPCS as standard equip-

and 070 (60 Hz) units feature the

100, and

ment. All

CPCS as an accessory, and CR (control relay) as standard

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.

equipment. See Fig. 2. The

modular units and the

10 and associated

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:

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

52” to be displayed.

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 ground 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.

Table 2

LOCAL/ENABLE-STOP-CCN

Switch Positions and Operation

CONFIGURATION AND

S W I T C H

P O S I T I O N

U N I T

OPERATION

SET POINT CONTROL

Keypad Control CCN Control

STOP

LOCAL/ENABLE

Unit Cannot Run Read/Write

Read Only

Unit Can Run

Read/Limited Write Read

Unit Cannot Run Read Only

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

gizing the proper 24-v control relay on the relay board. The

CPCS board contains logic that can detect if the

Read/Limited

Write

Unit Can Run

R e a d O n l v

Electronic Expansion Valve (EXV)

The micro-

processor controls 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.

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

psig (2936 48

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.

The Flotronic

II chiller control system gath-

Sensors

ers information from sensors to control the operation of the

chiller. The units use 6 standard pressure transducers and

standard thermistors to monitor

pressures and tem-

peratures at various points within the chiller. Sensors are

listed in Table 3.

Table 3

Thermistor and Transducer Locations

THERMISTORS

Location

PROTECTION

BOARD

Sensor

Cooler Leaving Water Temp

Cooler Entering Water Temp

Fig. 2

Compressor Protection Control Module

Compressor Suction Gas Temp Circuit A

Compressor Suction Gas Temp Circuit B

Remote Temperature Sensor (Accessory)

Location

Sensor

D P T - A

S P T - A

O P T - A

Compressor Al Discharge Pressure

Compressor Al Suction-Pressure

Compressor Al Oil Pressure

Compressor Bl Discharge Pressure

S P T - B

O P T - B

Compressor

Suction Pressure

Oil Pressure

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ically reset by the return temperature reset or space and out-

OPERATION DATA

Capacity Control The control system cycles

door air temperature reset features. It can also be reset from

an external 4-20

network signal.

signal with a loop isolator, or from a

compressor to give capacity control steps as shown in

Tables The unit controls leaving chilled water tem-

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.

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-

Table 4A Capacity Control Steps, 040-070

LOADING SEQUENCE

LOADING SEQUENCE A

UNIT

3 0 G N

CONTROL

STEPS

Displacement

Compressors

Displacement

Compressors

A l *

2 5

5 0

Bl*

2 5

1 0 0

Al”

040 (60 Hz)

045 (60 Hz)

2 4

040 (50 Hz)

A l &

Al ,Bl

1 0 0

040 (50

5 3

1 0 0

A l *

045 (50 Hz)

3 8

045 (50 Hz)

050 (60 Hz)

1 0 0

045 (50 Hz)

1 0 0

1 8

5 6

1 0 0

Al ,Bl

045 (50 Hz)

6 4

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded.

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Capacity Control Steps, 040-070

Table 4A

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

3 0 G N

Compressors

Displacement

Compressors

1 8

5 6

7 3

2 8

050 (50 Hz)

B l *

A l %

050 (50 Hz)

1 5

1 8

1 0 0

Al*

060 (50 Hz)

6 6

8 3

1 0 0

060 (50 Hz)

8 3

1 0 0

*Unloaded compressor.

unloader, standard.

unloader, accessory.

unloaders, both unloaded.

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Table 4A

Capacity Control Steps, 040-070

LOADING SEQUENCE

30GN

Displacement

Compressors

. .

1 6

060 (50 Hz)

8 3

1 0 0

6 5

,A2,Bl

1 0 0

B l *

1 5

5 7

070 (50 Hz)

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded.

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Table 4B

Capacity Control Steps, 080-110 and Associated Modular Units

LOADING SEQUENCE A

Compressors

LOADING SEQUENCE B

UNIT

3 0 G N

Displacement

Compressors

A l *

1 0 0

Al”

t t

080 (60 Hz)

A l *

Al ,Bl

t t

A l *

t t

080 (SO Hz)

*Unloaded compressor.

unloader, standard

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

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Table 4B

Capacity Control Steps, 080-110 and Associated Modular Units

UNIT

30GN

CONTROL

STEPS

Displacement

Compressors

Displacement

Compressors

Al *,Bl

5 3

,B2

1 0 0

090 (60 Hz)

BP’

090 (60 Hz)

8 0

8 2

A l *

Al ,Bl

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

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Table 4B

Capacity Control Steps, 080-110 and Associated Modular Units

Displacement

LOADING SEQUENCE B

CONTROL

STEPS

UNIT

3 0 G N

Compressors

Displacement

Compressors

4 3

6 0

090 (50 Hz)

1 0 0

090 (50 Hz)

A l *

100, 2408,

270B (60 Hz)

1 0

*Unloaded compressor

unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing

1 0

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Table 40

Capacity Control Steps, 080-I

and Associated Modular Units

LOADING SEQUENCE A

LOADING EQUENCE B

UNIT

3 0 G N

Compressors

Displacement

Compressors

Displacement

A l *

100, 2406,

270B (60 Hz)

,BZ

100

1 0 0

A l %

2 6

100,

2708 (50 Hz)

.B2

1 0 0

t t

A l *

100,

2708 (50 Hz)

1 4

Bl*

100, 2408,

270B (50 Hz)

1 2

A l *

100, 2408,

270B (50 Hz)

,AZ,Bl

1 6

*Unloaded compressor.

unloader, standard

**Compressor unloader, accessory.

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

1 1

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Table

Capacity Control Steps, 080-110 and Associated Modular Units

LOADING SEQUENCE

UNIT

30GN

Displacement

Compressors

Displacement

Compressors

1 4

, A2, Bl*

A l ”

t t

110 (60 Hz)

A-l

Al*

A l %

110 (50 Hz)

,Bl

,A2,Bl

Al ,Bl

100

*Unloaded compressor.

unloader, standard

**Compressor unloader, accessory.

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing

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Table 4B

Capacity Control Steps, 080-110 and Associated Modular Units

LOADING SEQUENCE A

Displacement Compressors

CONTROL

STEPS

UNIT

3 0 G N

Displacement

Compressors

110 (50 Hz)

Al;; Bl

110 (50 Hz)

1 2

*Unloaded compressor.

unloader, standard.

**Compressor

unloader,

accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

LOADING EQUENCE A

EQUENCE B

UNI T

30GN

Displacement

Compressors

Displacement

Compressors

130,

_{Al l}Al ,Bl

,Bl l

,B2

1 0 0

100

130,

Al *,Bl

Al l ,A2,Bl

A l *

B l *

Al ,Bl

*Unloaded compressor

unloader, standard.

accessory

unloaders, both unloaded

**Compressor

NOTE: These capacity control steps may vary due to lag compressor sequencing+

1 4

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

LOADING SEQUENCE B

LOADING SEQUENCE A

UNIT

3 0 G N

CONTROL

STEPS

Compressors

Displacement

Compressors

Displacement

Al l

,Bl

130,

Al *,Bl

Al ,Bl

All ,Bl

Al ,Bl

130,

,B2

A l ’

Al *,Bl

,A2,Bl

,B2

,A2,Bl

,B2

Al l ,A2,A3,Bl

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

1 5

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

LOADING EQUENCE A

LOADING EQUENCE

UNIT

3 0 G N

Displacement

Compressors

Displacement

Compressors

4 9

5 3

9 5

1 0 0

Al’, Bl

150 (60 Hz)

B l *

A l %

Al ,Bl

t t

A l *

Al*,&

*Unloaded compressor.

unloader, standard

**Compressor unloader, accessory.

unloaders, both unloaded

NOTE: These capacity control steps may vary due to lag compressor sequencing

1 6

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

SEQUENCE B

Compressors

SEQUENCE A

Compressors

Displacement

150 (50 Hz)

A l *

A l %

170,

,B2

170,

3008,

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

1 7

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

LOADING SEQUENCE A

Displacement Compressors

LOADING SEQUENCE B

UNIT

SIZE

Compressors

Al ,Bl

170,

,B2

,B2,B3

t t

Hz)

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing

1 8

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Table 4C

Capacity Control Steps, 130210 and Associated Modular Units

SEQUENCE B

Compressors

i SEQUENCE A

U N I T

CONTROL

STEPS

Compressors

Displacement

1 9

3 7

170,

Hz)

7 2

9 6

1 0 0

Al ,Bl

Al .Bl

170,

3008,

Hz)

Al _l

,Bl

3008,

1 0 0

*Unloaded compressor.

unloader, standard

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

1 9

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Table 4C

Capacity Control Steps,

and Associated Modular Units

SEQUENCE B

Compressors

UNIT

SIZE

Compressors

Displacement

5 6

Hz)

190,

A l *

Al l ,A2,A3,Bl

,B2,B3

,A2,A3,Bl*,B2,B3

Hz)

A l *

,A2,A3,Bi

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded

NOTE: These capacity control steps may vary due to lag compressor sequencing

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Table 4C

Capacity Control Steps, 130-210 and Associated Modular Units

SEQUENCE B

LOADING SEQUENCE A

Displacement Compressors

UNIT

SIZE

CONTROL

S T E P S

Displacement

Compressors

5 0

a 3

9 4

,82,83

Al*

,Bl

1 4

Hz)

A l *

,A2,Bl

210,

Al l ,A2,Bl

Al l ,A2,A3,Bl

Al l ,A2,A3,61

,A2,A3,A4,Bi

210,

,B2

,B2,B3

*Unloaded compressor.

j-Compressor unloader, standard.

**Compressor unloader, accessory.

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

2 1

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Capacity Control Steps, 130-210 and Associated Modular Units

Table 4C

i SEQUENCE A

Compressors

LOADING SEQUENCE B

UNIT

SIZE

Displacement

Compressors

Bl*

Al ,Bl

210,

Al l ,A2,Bl

(60

210,

Hz)

Al”

210,

B l *

Al l ,A2,Bl

*Unloaded compressor

unloader, standard

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

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Table 4D

Capacity Control Steps, 225, 250,280

LOAC

SEQUENCE A

LOADING SEQUENCE B

UNIT

30GT

Compressors

Displacement

1 2

4 6

225 (60 Hz)

Al l ,A2,A3,Bl

A l *

,A2,A3,Bl

,B2,B3

,A2,A3,Bl*,B2,B3

225 (50 Hz)

*Unloaded compressor.

unloader, standard.

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing

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Table 4D

Capacity Control Steps, 225, 250,280

SEQUENCE

LOAC

SEQUENCE B

Compressors

Bl*

LOAC

UNIT

30GT

Compressors

2 2

3 2

250 (60 Hz)

A l *

2 9

3 2

5 4

5 7

A l *

Al ,Bl

Al l ,A2,Bl

9 6

100

*Unloaded compressor.

standard

**Compressor unloader, accessory

unloaders, both unloaded.

NOTE: These capacity control steps may vary due to lag compressor sequencing.

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Table 4D

Capacity Control Steps, 225, 250, 280

SEQUENCE A

LOADING SEQUENCE B

Compressors

UNIT

3 0 G T

CONTROL

S T E P S

Compressors

250 (50 Hz)

280 (60 Hz)

Al”

,A2,Bl

Al**

,A2,A3,A4,Bi

A l *

Al ,Bl

,Bl*,B2

Al l ,A2,Bl

Al l ,A2,A3,Bl

*Unloaded compressor.

-/-Compressor unloader, standard.

““Compressor unloader, accessory

unloaders, both unloaded

NOTE: These capacity control steps may

due to lag compressor sequencing

2 5

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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.

Head Pressure Control

The microprocessor con-

trols the condenser fans in order to maintain the lowest 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,

Table 5

Condenser Fan Sequence

FAN CONTACTOR

CONTROLLED BY

FAN ARRANGEMENT

FAN NUMBER(S)

FC-Al

Compressor Al

Compressor

First Stage

Microprocessor

FC-A2

Second

Stage

Compressor Al

Compressor

FC-Al

First Stage

Microprocessor

Second

Stage

Microprocessor

Compressor Al

Compressor

Compressor Al

Compressor

FC-Al

F C - 8 1

F C - A 2

(and associated modular units)

First Stage

Microprocessor

5, 7,

FC-AS,

Second

Compressor

Stage

3, 4, 5, 6, 7,

FC-A3

FC-B3

Third Stage

Microprocessor

FC-Al

Compressor Al

Compressor

(and associated modular units)

FC-Bl

FC-A2, FC-A3

FC-Al

Compressor Al

(and associated modular units)

6 .

FC-A2

FC-B2

Frist Stage

Microprocessor

3, 9, 11

FC-A2,

Second

Stage

2, 4 , 10, 1 2

Microprocessor

*Control box.

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Table 5

Condenser Fan Sequence

FAN NUMBER(S)

CONTROLLED BY

FAN ARRANGEMENT

FC-1

Compressor Al

Compressor

9, 1 0

FC-4

FC-2

FC-5

First Stage

Microprocessor

11, 1 2

2, 3 ,

FC-3

FC-6

Second

Microprocessor

Stage

13, 14, 15, 16

2, 3, 4,

11, 12,

FC-2, FC-3

FC-5, FC-6

Third Stage

Microprocessor

14, 15, 1 6

7, 8,

FC-1

Compressor

(60 Hz)

9, 17, 1 8

FC-4

FC-2

FC-5

First Stage

Microprocessor

11, 12, 19

2, 3, 4,

14, 15, 16, 20

Second

Microprocessor

Stage

FC-3, FC-6, FC-7

2, 3, 4, 5, 6, 11, 12, 13,

Third Stage

14, 15, 16,

19, 2 0

7, 8, 1 0

Microprocessor

FC-1

(50 Hz) AND

Compressor Al

Compressor

17, 1 8

FC-4

FC-2

FC-5

First Stage

Microprocessor

II, 12,

2, 3, 4, 13,

14, 15, 16, 21, 22

Second

Stage

FC-3, FC-6, FC-7

Microprocessor

1, 2, 3, 4, 5, 6, 11, 12, 13,

14, 15, 16, 19, 20, 21, 2 2

FC-2, FC-3, FC-4,

FC-5, FC-6, FC-7

Third Stage

Microprocessor

*Control box.

box.

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.

When the lead compressor in each circuit

is started or stopped, that circuit goes through a

cycle to purge the cooler and refrigerant suction lines of

refrigerant.

At shutdown, the

urated suction temperature for that circuit is 10” F (5.5” C)

below the saturated suction temperature when 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.

cycle continues until the sat-

The

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

F (5.5” C) below the cooler

leaving fluid temperature, or reaches

saturated suction tem-

is necessary if the

perature of -15 F (-26 C). No

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The default display is displayed every 2 seconds if there

has been no manual input from the keypad for 10 minutes.

Keypad and Display Module (Also Called

The only function of this module is to allow

the operator to communicate with the processor. It is used

to enter configurations and set points and to read data, per-

or LID)

To return to automatic display, enter a t a n y t i m e .

form tests, and set schedules. This device consists of

key-

Table 6

Keypad and Display Module Usage

pad with 6 function keys, 5 operative keys, 12 numeric keys

(0 to 9, and -), and an alphanumeric g-character LCD

FUNCTION

K E Y S

USE

(liquid crystal display). See

key usage.

3. See Table 6 for

STATUS

For displaying diagnostic codes and

STAT

current operating information about the machine.

HISTORY

previous alarms.

SERVICE

tion information.

For displaying run time, cycles and

For entering specific unit configura-

TEST

proper

For checking inputs and outputs for

operation.

EST

SCHEDULE

schedules for unit operation

For entering occupied/unoccupied

ACCESSING FUNCTIONS AND SUBFUNCTIONS

See

Tables 6 8. Table 7 shows the 6 functions (identified by

name) and the subfunctions (identified by number).

SET POINT

For entering operating set points

S E T

and day/time information.

OPERATIVE

USE

For displaying a non-abbreviated ex-

K E Y S

EXPAND

pansion of the display

CLEAR

For clearing the screen of all displays

UP ARROW

position,

DOWN ARROW

position.

For returning to previous display

For advancing to next display

ENTER

For entering data

KEYPAD OPERATING INSTRUCTIONS (Refer to

Table 9.)

White keys on left side of keypad are shown and oper-

ample: keypad entry means press the

the white key marked

2. The standard display uses abbreviations. Expanded in-

^{ated in these instructions according to th}q^{e following ex-}

, then

formation scrolls through the display whenever

is pressed.

key

Fig. 3

Keypad and Display Module

3. All functions are made up of a group of subfunctions.

To enter a subfunction, first press subfunction number

desired. Then press the function key in which the sub-

function resides. To move within that subfunction, press

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.

the

arrow. For example, a

the Temperature Information subfunction.

enters

4. At any time, another subfunction may be entered by en-

tering the subfunction number, then the function key.

DISPLAY

TUE

EXPANSION

TODAY IS TUE, TIME IS

PM)

5. Prior to starting unit, check leaving fluid set point for

correct setting. Refer to Set Point Function section on

page 39.

CLOCK ON

UNIT IS ON

CLOCK SCHEDULE

C O O L

NUMBER OF STAGES IS 1

ALARMS DETECTED

ALARMS

6. Depending on system configuration, all displays may not

be shown. All displays are shown unless marked with

the following symbol.

AUTOMATIC DISPLAY OPERATION/DEFAULT DIS-

PLAY In this mode, the keypad displays the current time

format), current operating modes, cooling capac-

ity stages, and total number of alarms.

*Must be configured.

For additional unit start-up procedures, see separate In-

stallation, Start-Up and Service Instructions supplied with

unit.

COOL x

MODE

Day of Week

Hour(s)

Minute(s)

DOW

2 8

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Functions and Subfunctions

Table

FUNCTIONS

Status

Schedule

Service

History

Set Point

Test

^TESTl

Run Time

Set Points

(Chiller Fluid)

Automatic

outputs

Override

Clock Set

Period

Log On and

Log Off

Display

Alarm

Display

Compressors

and Unloaders

Version

(Software)

Starts

Reset

Set Points

Factory

Configuration

Alarm

History

Demand

Limit

Set Points

P e r i o d

Field

Configuration

Date and

Time

Set Points

(Current Operating)

Service

Configuration

Period

P e r i o d

Temperatures

Pressures

Analog

Inputs

1 0

outputs

HOLIDAYS

Table 8

Accessing Functions and Subfunctions

KEYPAD

ENTRY

DISPLAY

RESPONSE

DESCRIPTION

OPERATION

To access a function, press

subfunction no and function

name key. Display shows

function

R E S E T

Reset Set Points

Cooling

Reset

Maximum

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.

Cooling

Reference xx

Cooling

Reference xx

Minimum

Cooling

Reference xx

Minimum

When the last element in a

subfunction has been

played, the first element is

repeated.

R E S E T

Reset Set

To move to next subfunction

it is not necessary to use

subfunction number Press

function name key to

display through all

DEMAND

D e m a n d S e t

Points

^SETl

T I M E

Current Time and

Day of Week

subfunctions within a

function and then back

to the first

SET

S E T

Unit Set Points

To move to another function,

either depress function name

key for desired function

(display shows the first

subfunction),

X ALARMS

Rotating Display

Access

ic sub-

function by’using the sub-

function number and the

function name kev.

Capacity Stages

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Table 9

Keypad Directory

STATUS

DISPLAY

COMMENT

KEYPAD ENTRY

Refer to Automatic Display Operation on page 28

Number of Tripped Alarms

A L A R M S

2 ALARMS

ALARM X

Displays Tripped Alarms

Number of Modes in Effect

X MODES

MODE X

3 MODES

Displays Mode in Effect

S T A G E

Capacity

Staging

Information

4 STAGE

Number of Requested Stages

Percent of Total Capacity

Percent Circuit A Capacity

Percent Circuit Capacity

Demand Limit Set Point

S T A G E

C A P T

CAP0 X

L M T X *

LOAD X*

Load Limit Set Point

Circuit A Compressor Relay Status

Circuit B Compressor Relay Status

S M Z

Load/Unload Factor for Compressors

Factor = 1 Unloader Factor = 0 6

S E T P O I N T

Fluid Set Point Information

Set Point

SET POINT

Modified Set Point = Set Point

Reset

M S P

TWX

Cooler Leaving Fluid Temperature

T E M P S

Temperature

Information

TEMPERATURE

EWTX

Cooler Entering Fluid Temperature

Cooler Leaving Fluid Temperature

Circuit A Saturated Condenser Temperature

Circuit A Saturated Suction Temperature

Compressor Al Suction Temperature

Circuit A Suction Superheat

L W T

S C T A

S S T A

CTA X

SHA X

LEGEND

*Must be configured

applicable

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

CCN

E X V

M O P

3 0

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Table 9

Keypad Directory

STATUS

SUBFUNCTION

TEMPERATURE

KEYPADENTRY

DISPLAY

COMMENT

Circuit B Saturated Condenser Temperature

SCTB X

Circuit

Saturated Suction Temperature

S S T B

Compressor

Suction Temperature

C T B

SHB X

Circuit

Suction Superheat

RST X*

Reset Temperature

PRESSURE

Refrigerant System Pressure (psig)

Circuit A Discharge Pressure

Circuit A Suction Pressure

PRESSURE

D P A

S P A

Circuit A Discharge/Suction

Circuit A Oil Pressure Differential

Circuit B Discharge Pressure

x x x x

OPA X

DPB X

S P B

Circuit

Suction Pressure

Circuit B Discharge/Suction

x x x x

O P B

Circuit B Oil Pressure Differential

8 ANALOG

ANALOG

REF X

L M T X *

RST X*

I N P U T

Status of Analog Inputs

Transducer Supply Voltage

Demand 4-20

Signal

Reset 4-20

Signal

Status of Switch Inputs

Dual Set Point Switch

Demand Limit Switch

DL2 X*

3 1

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Table 9

Keypad Directory

STATUS

SUBFUNCTION

10 OUTPUTS

DISPLAY

COMMENT

OUTPUTS

ALMR X

Status of Outputs

Alarm Relay K3

Fan Relay

FRA2 X

Fan Relay K2

Fan Relay K4

Fan Relay K5

FRB2 X

CHWP X*

Cooler Water Pump Relay K6

Unloader Al

ULA2 X*

Unloader

ULB2 X*

Unloader

E X V A

E X V B

EXVA Percent Open

EXVB Percent Open

Hot Gas Bypass Relay Circuit A

Hot Gas Bypass Relay Circuit B

A Output Percent

HGBB X

M M A X *

MMB X

Motormaster B Output Percent

TEST

To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position To operate a test, scroll to desired test

Then, press to start test. Press to stop test.

KEYPAD ENTRY

COMMENT

SUBFUNCTION

OUTPUTS

DISPLAY

OUTPUTS

Test Outputs

8.8.8 8.8.8

Display Check

ALMR X

Energize Alarm Relay K3

Energize Fan Relay Al

Energize Fan Relay A2 K2

FRA2 X

Energize Fan Relay

CHWP X*

EXVA X

Energize Cooler Water Pump K6

Enter Desired EXVA Position

E X V B

Enter Desired

Position

HGBRA X*

HGBRB X*

M M A X *

Energize Hot Gas Bypass Relay A

Energize Hot Gas

Enter Desired

Relay B

A Output Signal

M M B X *

Enter Desired Motormaster B Output Signal

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Keypad Directory

TEST

Table 9

During compressor test, compressors start and run for

10 seconds. Compressor service valves and liquid line

valves must be open. Energize crankcase heaters 24 hours

prior to performing compressor tests.

KEYPAD ENTRY

DISPLAY

COMMENT

SUBFUNCTION

2 COMPRESSORS AND

UNLOADERS

C O M P

Compressor and Unloader Test

Test Compressor Al

Test Compressor

CPA1 X

CPA2 X*

CPA3 X*

CPA4 X*

Test Compressor

CPB3 X*

CPB4 X*

Test Compressor

ULA2 X*

Energize Unloader Al

Energize Unloader

ULB2 X*

SCHEDULE

The Schedule function key

is used to configure the occupancy schedule The clock select subfunction can be used for

unoccupied shutdown or unoccupied setback depending on the cooling set point control configuration. The Schedule function

described is for clock

SUBFUNCTION

1 OVERRIDE

which is the internal clock. Password required for all subfunctions except override.

DISPLAY

OVRD X

COMMENT

KEYPAD ENTRY

Number of Override Hrs (0 4 Hrs)

For example, to extend current occupied mode for 3 hrs, press:

OVRD 3

Extended Occupied Time

2 CLOCK SELECT

CLOCK XX

Type of Clock Control

0 = No Clock, 1 = Clock 1 (Internal)

LEGEND

*Must be configured

applicable.

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

M O P

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Keypad Directory

SCHEDULE

Table 9

DISPLAY

COMMENT

Period Time Schedule

PERIOD

OCC

Occupied

Time

Unoccupied

MON X

M o n d a y F l a g

Tuesday Flag

T U E

WED x

THU X

Wednesday Flag

Thursday Flag

Friday Flag

S A T

Saturday

Sunday

Flag

SUN X

HOL X

Holiday Flag

To toggle between inputs (Yes/No) Press:

4 PERIOD 2

d PER2IODT2 i

5 PERIOD 3 . . . 9 PERIOD 7

P e r i o. d

P e r i o d

T i m e S c h e d u l e

dPER8IODT8 i

10 PERIOD 8

11 HOLIDAYS

HOLIDAYS

DAT

Define Calendar Holidays

Holiday Date

New = Unassigned Holiday Date

DAT

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.

KEYPAD ENTRY

DISPLAY

COMMENT

SUBFUNCTION

L O G O N

Enter Password/Disable Password Protection

1 LOG ON AND LOG OFF

(LOGGEDON

log out as follows:

At this time, configurations may be modified. When finished viewing and/or modifying

LOG OFF

Disable Password Protection

E X I T L O G

Logged Off/Enable Password Protection

VERSION

x x x x x x x x

Software

Information

2 VERSION

Version No. of Software (CESRXX)

Language

Options

See legend on page 30

3 4

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Table 9

Keypad Directory

SERVICE

The next 3 subfunctions provide the ability to modify configurations Refer to separate Installation, Start-Up, and Service Instructions

supplied with unit for further information

on changing configurations.

To change a configuration, enter the new configuration and press

while on the correct configuration.

DISPLAY

COMMENT

KEYPAD ENTRY

3 FACTORY

FACT CFG

Factory Configuration Codes

CONFIGURATION

x x x x x x x x

Configuration Code

4 FIELD

Adjustable Field Configuration

FLD CFG

CONFIGURATION

CCN Element Address

CCN Bus Number

B U S

BAUD X

FLUID X

UNITS X

LANG X

NULA X

NULB X

HGB X

CCN Baud Rate

Cooler Fluid Select

Display Unit Select

Display Language Select

No Circuit A Unloaders

No. Circuit B Unloaders

Hot Gas Bypass Select

Loading Sequence Select

S E Q T

SEQF X

Lead/Lag

Sequence

Select

Oil Pressure Switch Select

Head Pressure Control Method

Select

HEADM X

M M

CSPTYP X

CRTYP X

Cooling Set Point Control Select

Cooling Reset Control Select

External Reset Sensor Select

Demand Limit Control Select

Ramp Load Select

E R T Y P

L S T Y P

RAMP X

LOCK X

Cooler Pump Interlock Select

Cooler Pump Control Select

5 SERVICE

Service Configurations

SRV CFG

CONFIGURATION

x x x x x x x x

Configuration Code

Refrigerant

Pressure Transducer Select

Oil Transducer Set Point

Low Pressure Set Point

Fan Staging Select

T D T Y P

LPS x

FANTYP X

SH X

EXV Superheat Set Point

EXV MOP Set Point

M O P

3 5

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Keypad Directory

Table 9

DISPLAY

COMMENT

KEYPAD ENTRY

SUBFUNCTION

1 RUN TIME

RUN TIME

HR X

Run Time lnformation

Total Hrs Unit Has a Comp Operating

HRA X

HRB X

Circuit

Run Time

Starts

Information

S T A R T S

STARTS

Cycles from Stage 0 to Stage

Circuit A Starts

CYA X

CYB X

Circuit B Starts

Last 5 Alarms

3 ALARM HISTORY

ALARM X

Alarm Description

SET POINT

c h a n g e

value, t h e n

press

a set point, enter new set point

To read a set point, go to proper subfunction and read desired set point To

LOCAL/ENABLE-STOP-CCN switch must be in LOCAL or STOP position,

COMMENT

DISPLAY

SUBFUNCTION

1 SET POINTS

KEYPAD ENTRY

POINT

Jnit Set Point

Chiller Fluid Set Point

Fluid Set Point

H S P A

H S P B

Head

Pressure Set Point Circuit

Head Pressure Set Point Circuit B

Limit

CRAMP X

R E S E T

CRST2 X*

CREF2 X*

Reset Set Points

2 RESET SET POINTS

Cooling Max Reset

Max Reset Occurs at X

Cooling Minimum Reset

Min Reset Occurs at X

or Degree

DEMAND

Demand Set Points

3 DEMAND SET POINTS

Demand Switch

Set Point

DLS2 X*

DMAX X*

RMAX X*

Demand Switch 2 Set Point

4-20

Maximum Demand Limit

Max Demand Limit Occurs at X

4-20

Minimum Demand Limit

Minimum Demand Limit Occurs at X

SHED

CCN

Amount

Date, Time and Day of Week

4 DATE AND TIME

DAY

Day 1 = Mon, 2 = Tues

Hours are displayed in

Sun

time. Decimal point serves as colon.

MM.DD YR

When entering date, enter a decimal

point between entries. Each entry must be two numbers.

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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.

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

Unit is off. LOCAL/ENABLE-STOP-CCN switch is

( R o t a t i n g D i s p l a y )

in OFF position, or LOCAL/ENABLE-STOP-CCN

LOCAL OFF

switch may be in LOCAL position with external ON/

OFF switch in OFF position

(Alarms)

Alarms are messages that one or more

Unit is off due to CCN network command. LOCAL/

CCN OFF

faults have been detected. Each fault is assigned

code num-

ENABLE-STOP-CCN switch is in CCN position.

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.

Unit is off due to internal clock schedule. LOCAL/

CLOCK OFF

ENABLE-STOP-CCN switch is in LOCAL position.

Unit is on. LOCAL/ENABLE-STOP-CCN switch is

in LOCAL position If external ON/OFF switch is used,

it will be in ON bosition.

LOCAL ON

CCN ON

Up to 5 alarm codes can be stored at once. To view them

to enter the alarm displays

Unit is on due CCN command

STOP-CCN switch is in CCN position.

^{in sequence, p}q^ress

to move to the individual alarm dis-

Unit is on due to internal clock schedule or

CLOCK ON pied override function.

CCN switch is in LOCAL position.

plays. Press

^{and then pr}q^ess

after

code has been displayed. The mean-

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

ing of the code scrolls across the screen. See Example

M O D E

level

set

is in SET function)

Example 1

Reading Alarm Codes

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

K E Y P A D

ENTRY

DISPLAY

RESPONSE

MODE 8

COMMENTS

Keypad has not been used for

at least 10 minutes. Alternating

summary display appears on

screen

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

S T A G E S

2 ALARMS

MODE 9

alarms detected

A L A R M S

Load limit is in effect. This indicates that capacity of

a system of units is being limited by a CCN

shed command Due to this limitation, unit may

not be able to produce the desired leaving water

temperature.

A L A R M

First alarm code

MODE 10

MODE II

COOLER LEAVING

FLUID THERMISTOR Explanation of alarm code

F A I L U R E

Not

Second alarm code Cooler

A L A R M 4 2

freeze

protection

Ramp load (pulldown) limiting is in effect. In this mode,

the

leaving water temperature is dropped

COOLER FREEZE

P R O T E C T I O N

Explanation of alarm code

is limited to

predetermined value to prevent com-

MODE 12

MODE 13

pressor overloading, See CRAMP set point in the

SET function in Table

modified, if desired, to any rate from 2 F to 2 F

The

limit can be

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.

Timed override is in effect This is a 1 to 4 hour

temporary override of the programmed schedule,

forcing unit to occupied mode Override can be 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

(Modes)

The operating mode codes are dis-

saturated suction temperature is

C) for

played to indicate the operating status of the unit at a given

time. See Table 10.

water or 30”

(16” C) for brine or more below leav-

MODE 14

ing fluid temperature, and saturated suction tem-

perature is less than 32 F C). If these conditions

persist beyond 10 minutes, circuit is shut down and

fault code 44 or 45 is displayed.

CCN

CarrierComfort Network

To enter the MODES subfunction, depress

and

use the

key to determine if more than one mode ap-

plies. See Example 2 to read current mode with expansion.

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Reading Current Operating Modes

Example 2

(Analog Inputs)

analog inputs, if any. Enter

transducer supply voltage, 4-20

This subfunction displays

KEYPAD

ENTRY

DISPLAY

RESPONSE

, then use the

reset signal can be dis-

. The

COMMENTS

Keypad has not been used for at

least 10 minutes Rotating summary

display appears on screen

TUE

played. This is useful for problem diagnosis prior to using

LOCAL ON

the test function.

C O O L

A L A R M S

( I n p u t s )

This subfunction displays status

There are 2 modes currently in effect

Unit is on by chiller on/off switch

Temperature reset is in effect

2 MODES

(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.

LOCAL ON

M O D E

(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)

can be displayed.

This subfunction displays the capac-

ity stage number. See Tables for compressor load-

(Stage)

and use the

^{ing sequence. To en}q^{ter the STAGE subfunction, press}

to display the stage number.

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.

Additional provides the following information:

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%).

To reach a particular test, enter its subfunction number,

then scroll to desired test by pressing the

key. Press

to terminate or

to start a test. Press

test. Pressing the

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.

exit

key after

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

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.

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

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.

re-enter test function and press the

the component. Components with a timed operating limit

time out normally even if another function is accessed.

key to shut down

Keypad entry

allows the operator to make the

If compressor unloaders are used, at

a compressor is

following checks by using

LID display check.

unloaded and at

a compressor is loaded up.

is 8.8.8.8.8.8.8.8 .

Operation of remote alarm.

(Set Point)

This subfunction displays leaving

Operation of condenser fans.

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 point. 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-

Operation of chilled water pump.

Operation of

To drive EXV fully open, enter

(100% open). To drive EXV fully closed,

(0% open).

ter

Keypad entry.

compressor unloader

accesses the compressor and

tests.

press

and use the

to display modified leaving

chilled water set point followed by leaving water set point

and actual cooler leaving fluid temperature.

During compressor operational tests, compressor starts

and runs for 10 seconds. Compressor service valves must

be open. Energize crankcase heaters 24 hours prior to

performing compressor tests.

(Temperature)

The temperature subfunction dis-

plays the readings at temperature sensing thermistors.

Since test function checks only certain outputs, it is good

practice to also check all inputs and outputs accessible

To read a temperature, enter

, then scroll to de-

key. See Table 9 for the

sired temperature using the

order of readouts.

through the status function. These are located at

and (see Table 9). If keypad is not used

(Pressure)

This subfunction displays suction,

for 10 minutes, unit automatically leaves test function and

resumes rotating display. See Example 3.

discharge and net oil pressure at lead compressor of each

circuit of unit.

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b. The next value displayed depends on how the sched-

ule function has been programmed. (See pages

47.) If dual set point has been selected, the next set

Example 3

Using Test Function

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

point after

has been pressed is the unoccupied

C O M P

Factory/field test of compressors

subfunction of test function

chilled water set point. If single set point or inactive

schedule

been selected in the schedule function,

^haq^s

is pressed, the display shows the

Circuit A, Compressor

test

CPA OFF

CPA ON

then when

modified chilled water set point.

Pressing starts the test:

when the compressor should be running

the display shows CPA1 on

c. The final value displayed when the

is pressed

CPA 1 OFF If the test is allowed to time out (10 sec-

onds) the display will show off

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

CPA 2 OFF Pressing the down arrow key advances

the system to Circuit A, compressor 2 test

11” to 1.1”

This value is not displayed

unless the function is enabled (see Adjustable Field

Configurations on page 45).

NOTE: Once a compressor has been run using the

is not allowed to run again for 30 seconds.

function, it

Reading and

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.

HISTORY FUNCTION

sequent

run time for each circuit.

Keystrokes

and sub-

keystrokes display total unit run time and total

Keystrokes

and subsequent

keystrokes dis-

Example 4

Reading and Changing

Chilled Water Set Point

play total unit starts and the total starts for each circuit.

and subsequent

alarms along with

keystrokes dis-

Keystrokes

play the last

DISPLAY

RESPONSE

KEYPAD

E N T R Y

C O M M E N T S

description of each alarm.

S E T P O I N T

System set points

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.

44.0

Present occupied chilled water

set point is 44 0 F

420

Chilled Water Set Point

chilled water set point is 42 0 F

Water:

Present unoccupied chilled water

set point is 44.0 F

44.0

50.0

38 to 70 F (3.3 to 21 C)

Brine:

Press the D

15 to 70 F (-9.4 to 21 C)

shows new unoccupied chilled

water set point is 50.0 F

Set Point

0.2 to 2.0 F (0.11 to 1.1

R E S E T

Displays the maximum reset and

minimum reset set points The

minimum and maximum reference

reset set points can also be

displayed.

Reset Set Points

Maximum Reset Range:

to 20” F (0” to 11” C)

These set points are not

accessible when reset type has

been configured for NONE in

the service function

Maximum Reset Reference Range:

Return Fluid Reset

to 20” F

(0” to 11”

External Temperature Reset 20 to 125 F

Temperature Reset Based on Return Water

(-6.6 to 51.6

The control system is capable of providing 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.

External Signal Reset 4 to 20

Minimum Reset Reference Range:

Return Fluid Reset to 20” F

(0” to 11”

External Temperature Reset 20 to 125 F

(-6.6 to 51.6 C)

External Signal Reset 4 to 20

Under normal operation, the chiller

a constant

leaving water temperature approximately equal to chilled

water set point. As building load drops from 100% down to

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 F (0” C)

at no load. See Fig. 4.

Demand Limit Set Points

Switch Input:

Step 1

Step 2

0 to 100% Capacity Reduction

External Signal:

Maximum Demand Limit 4 to 20

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

Minimum Demand Limit 4 to 20

Set points are grouped in subfunctions as follows:

be defined as

function of cooler temperature drop, as shown

Displays chiller water and cooling ramp set points.

in Fig. 4. This is a simple linear function that requires 4

pieces of input data for the set function:

a. The first value shown is the occupied chilled water

set point.

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Example

Using Return Water

Maximum Reset Amount (CRST2)

0” to 20” F (0” to 11” C). This is maximum amount leav-

ing chilled water set point is to be increased.

allowable range

Temperature Reset

KEYPAD

ENTRY

DISPLAY

RESPONSE

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.

COMMENTS

Field configuration

subfunction of

service function

FLD CFG

3. Minimum Reset Amount

allowable range

C). This is minimum amount leav-

to F (0” to

C S P T Y P

Scroll past single/dual

ing chilled water set point is to be increased when reset

is initiated.

Display shows no reset

type has been selected

CRTYP 0

4. Minimum Reset Reference (CREFl)

allowable range

Return water temperature

is selected and activated

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

C R T Y P

S E T P O I N T

44.0

System set points

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

ternal Signal (with a loop isolator) Reset.

Present occupied chilled

water set point

Enter new chilled water

set point

45 6

Ex-

Reset set points

maximum reset

R E S E T

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.

C R S T 2

Cooling maximum reset

is 10 F

C R S T 2 1 0

Cooling maximum reset

CREF2 0.0

CREF2 1.0

0 0

reference is 0” F

Cooling maximum reset

reference is 1 F

Cooling minimum reset

Activating reset based on external temperature or

Cooling minimum reset

2.0

4-20

signal is done the same way, except the reference

is 2 F

set point range is 20” to 125” F (-6.6” to 5 1.6” C), or 4 to

Cooling minimum reset

reference is 0” F

CREFl 0.0

8 0

depending on which method was selected at the field

configuration step.

Cooling minimum reset

reference is

8 0

6 0

RESET REFERENCE TEMPERATURE (COOLER EWT-LWT)

Fig.

Cooling Return Water Reset

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Example 6

Changing Reset Type

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-

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.

quires a thermistor

Part No.

located in

the space or outdoor air and wired to terminals as follows

(also see Field Wiring section on page 71):

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

4 in/4 out Module

and

Field configuration

subfunction of

service function

At the field configuration step, select external tempera-

FLD CFG

ture reset by entering

when CRTYP

appears. Then

Scroll past single cooling

set point

C S P T Y P

enter set points as described previously in Example 5. See

Fig. 5.

No reset has been

selected

CRTYP 0

Temperature Reset Based on 4-20

Signal- If desired,

signal. For

Return water temperature

reset is selected and

activated

CRTYP

temperature reset can be based on a 4-20

refer to Field Wiring section on page

proper connections,

71 and Fig. 6.

Reset type is changed to

space or outdoor-air

temperature reset and

activated

CRTYP 2

reset by

entering

^{At th}q^{e field configuration step, select 4-20}

when CRTYP

appears. Then enter set points

Reset type is changed to

as described previously in Example 5. See Fig.

CRTYP 3

CRTYP 0

4-20

signal reset

and activated

Demand Limit, 2-Stage Switch Control This control has

Reset is deactivated

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 0% of

capacity. Capacity steps are controlled by 2 field-supplied

relay contacts connected to the designated chiller terminals.

(See Field Wiring section on page 7 1 and Fig. 6.)

RESET REFERENCE TEMPERATURE

AIR OR

Cooling External Temperature Reset

Fig. 5

4 1

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P O I N T NUMBER OF

FIRST CHANNEL

RET

DO+

LIMIT

C O D E 3 1 2

LEGEND

COMM

PWR

Communications Bus

Power

Switch

NOTE: For specific connection points,

see Fig. 24 29.

(ALARM

(MODE

4 IN/4 OUT Options Module Wiring for Reset, Demand Limit,

Dual Set Point

Fig 6

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.

Table 11

Service Functions

To view and modify configurations, the password must

be entered under the log on subfunction.

KEY FAD

E N T R Y

COMMENT

DISPLAY

F U N C T I O N

Enter Password/

P A S S W O R D

Disable

Password

LOGGED ON Logged On

NOTE: Configurations may be modified at this time. When

finished viewing and/or modifying configurations, log out

as follows:

-Demand Limit, 4-20

Signal

The controls can also

accept a 4-20

signal for load shedding. Input for the

L O G G E D O N

signal are terminals shown below:

Disable

Protection

Password

Externally powered (loop isolator required)

L O G O F F

Positive lead to

Negative lead to

4 In/4 Out Module

Logged Off/

LOG

Enable

Password

Protection

Int erna lly pow ered

Positive lead to

Negative lead to

4 In/4 Out Module

Software

Information

V E R S I O N

xxxxxxxx

Version

of Software

See Field Wiring section on page 71 and Fig. 6.

entering

^{At fiel}q^{d configuration step, select 4-20}

when the LSTYP 0 display appears. See

Language

Options

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.

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2 0

RESET REFERENCE SIGNAL

-20 MA INPUT)

Fig. 7

4-20

Cooling Temperature Reset

Using Demand Limit (4-20

Example

(First Log On As Shown in Table 11)

Example 7A

(First Log On as Shown in Table 11)

Using Demand Limit

KEYPAD

ENTRY

DISPLAY

RESPONSE

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Field configuration subfunction

of service function

Field configuration sub-

function of service function

FLD CFG

ERTYP

LSTYP

Scroll past other elements in

the subfunction

Scroll past other elements

in the subfunction

E R T Y P

LSTYP

is not enabled

is now enabled

is not enabled

is now enabled

for 2-stage switch control

L S T Y P

q ‘n

for 4-20

signal control

Demand Limit set points

subfunction of set point

function

DEMAND

Demand Limit set points

DEMAND

Maximum demand limit is 100%

Maximum demand limit is 90%

D M A X 1 0 0

1 currently set

100

a t 1 0 0 %

D M A X 9 0

reset to 60%

Maximum demand limit

reference is 20

RMAX 20

2 currently set

D L S 2 1 0 0

DLS2 40

a t 1 0 0 %

Maximum demand limit

reference is 15

R M A X 1 5

2 reset to 40%

Minimum demand limit is 0%

Minimum demand limit is 20%

To Disable Demand Limit:

Minimum demand limit

reference is 4

KEYPAD

ENTRY

DISPLAY

COMMENTS

RESPONSE

Minimum demand limit

reference is 6

Field configuration sub-

function of servicefunction

FLD CFG

Scroll past other elements

E R T Y P

L S T Y P

LSTYP

in the subfunction

is enabled for

2-stage switch control

is now disabled

NOTE: Select 3 for Carrier comfort Network (CCN) load limiting

Select

for CCN demand limiting.

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= 90

M A X D E M A N D

DEMAND

SIGNAL (4-20 MA INPUT)

Fig. 8

4-20

Demand Limiting

Off

The service function is

Reading and Changing Time Displav

and displayed in 24-hour time. The day of the week is

tered as a number.

Time is entered

word protected. Therefore, to gain entry to this function,

this password must be entered. Pressing

allows the technician to view, change or enter

tion codes. To log off, perform the following keystrokes:

1 = Mon, 2 = Tue, 7 = Sun, etc.

is used as the colon when entering time. See

The service function is once again

word protected.

Setting Time of Day and

Day of Week

Example 8

Software Information

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.

T h e a n d su b f ions are summarized in

Table

displays the version

KEYPAD

ENTRY

DISPLAY

COMMENTS

RESPONSE

Time display sub-

function of set point

function

T I M E

Current setting is

Monday, 4:00

MON 1600

New setting of

Tuesday,

p m

Configuration Codes

allows entry into

TUE 13 05

is entered

and displayed

the factory configuration subfunction. Under this subfunc-

Current date is

Jan. 1, 1990

tion, there are

groups of configuration codes that are down-

JAN 01 90

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

New setting

April 15, 1990

is entered

APR

display module. Factory configuration codes (groups

through

and displayed

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.

SERVICE FUNCTION

This function allows the

to view and input configuration data. Factory

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.

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Adjustable Field Configurations

Table 13

Factory Configuration Keystrokes

To change a configuration enter the new configuration

Table 12

SERVICE

C O D E

FACTORY

ITEM AND CODES

address

and press

while on the correct configuration.

CCN

001

(Entered by CCN Technician)

S UB-

F U N C T I O N

DISPLAY

COMMENTS

CCN Bus Number

0 0 0

9 6 0 0

0 0 0

9 6 0 0

(Entered by CCN Technician)

F A C T O R Y

C O D E S

CCN Baud Rate

3 FACTORY

FACT CFG

(Entered by CCN Technician)

C F G

Cooler Fluid Select

Standard Models

Water (38 to 70

xxxxxxxx

to 21 C] Set Point)

Medium Brine (15 to 70

f-9 to 21 C] Set Point)

= Brine Models

Unit Select

English

1 = Metric

Configuration

C o d e

Display Language Select

Configuration

C o d e

English

No. Circuit

Unloaders

No Unloaders

One Unloader

Two Unloaders

No.

Unloaders

190-210';

No Unloaders

One Unloader

Two Unloaders

S E R V I C E

S R V C F G

Hot Gas Bypass Select

No Valve

xxxxxxxx

Loading Sequence Select

Equal Circuit Loading

Staged Circuit Loading

Sequence Select

^L1^e=^adA^/Lu^at^gomatic

Pressure Switch Select

Not Used

Air Cooled

Adiustable Field Configurations After logging on, press

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-

Head Pressure Control Type

Not Used

Air Cooled

Head Pressure Control Method

EXV Controlled

Set Point Control for

Both Circuits

tory

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.

Set Point Control for

Circuit A; EXV Control

for Circuit

Set Point Control for

Circuit B; EXV Control

for Circuit

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.

Cooling Set Point

Control Select

Single Set Point Control

External Switch

Controlled Set Point

Clock Controlled

Set Point

Cooling Reset

Select

Control

No Reset

to enter the

Service Configuration Codes Press

Return Fluid Reset

External Temperature

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.

Reset

4-20

Controlled

Reset

External Reset Sensor Select

Thermistor Connected to

Options Module

Obtained Through CCN

Demand Limit Control Select

No Demand Limiting

Two External Switch Input

₌External 4-20

CCN Load Limiting

(Multi-Unit)

CCN

Interface

Ramo Load Select

SCHEDULE FUNCTION This function provides a means

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:

Enabled

Cooler Pump Interlock Select

No Interlock

With Interlock

and

(040-210 and associated modular units)

(225, 250, and 280 units). The chilled

Cooler Pump Control Select

Not Controlled

ON/OFF Controlled

water pump relay starts chilled water pump but compres-

sors do not run until remote chilled water pump interlock

L E G E N D

Carrier Comfort Network

Electronic Expansion Valve

contacts are between

and associated modular units, or between

on 250, and 280 units are closed and

and

*And associated modular units

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.

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Example

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.

Using the Schedule Function

DISPLAY

schedule

override

O V R D

O V R O

C L O C K

in effect

hours override in effect

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.

Override cancelled

Schedule function is inactive

Schedule function is enabled

through local unit clock

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.

Schedule function is enabled

throuah CCN clock 65

C L O C K 6 5

Define schedule period

Start of occupied time

PERIOD

For this example, first

period should stat-t here

so no entry

The schedule consists of from one to

occupied time pe-

riods, 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

Start of unoccupied time

(end of period) For this

period 1 should

day begins at 00

and ends at 24.00. The machine is in

00.00

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-

end at 3:00

Period ends at 3:00

Monday is now flagged no

riod must end at

hours (midnight); a new occupied

period must be programmed to begin at

hours.

for

1 To out

M O N N O

into’ effect on

NOTE: This is true only if the occupied period starts at

(midnight). If the occupied period starts at a time

other than midnight, then the occupied period must end at

hours (midnight) and new occupied period must be

Monday must be flagged

Monday is now fla ged for

period to be in e ect

M O N Y E S

TUE YES

T U E N O

For this example, period

is to be in effect on Monday

only All other days must

checked to be sure that thev

are flagged no. If any day

flagged yes, change to no

programmed to start at

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.

Tuesday is now flagged

no for period

All subfunctions of schedule function are password pro-

tected except the override subfunction,

P E R I O D

Define schedule period

word entry into subfunctions through

is done through service function. See page 44, logging on/

logging off.

occ 00 00 Start of occupied

will start

occ 7 00

00.00

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 learn 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.

Start of unoccupied time

(end of period) For this

example, period 2 should

end at 18:00 (6:00

)

Period

(6:00

ends at 18:OO

)

18 00

Monday is now flagged no

for period 2 To put period 2

into effect on Monday,

M O N N O

MON YES

Monday must be flagged yes

Monday is now flagged for

period

to be in effect

Tuesay is now flagged no

for period 2 To put period 2

into effect on Tuesday,

T U E N O

Tuesday must be flagged

Tuesday is now flagged for

TUE YES

period

to be in effect

For this example, period

is to be in effect only on

Monday

and

Tuesday

All other days must be

checked to be sure that

they are flagged no. If

W E D Y E S

day is flagged yes,

change to no

Wednesday is now flagged

no for period

W E D N O

Carrier Comfort Network

Example

CCN

continued next page.

4 6

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Holiday Schedule Function

Example 10

Example 9

Using the Schedule Function

D I S P L A Y

H O L I D A Y

E N T E R

COMMENT

D I S P L A Y

PROGRAMMING PERIOD 3:

JAN01 02 (Includes Jan

and 2nd)

Define

period

schedule

P E R I O D

occ

Start of occupied

lime

01 (Includes April 17th)

MAY21 01 (Includes May 21 st)

JUL03 01 (Includes July 3rd)

JULO4 01 (Includes July 4th)

SEP07 01 (Includes Sep 7th)

will start

occ 7 00

Start of unoccupied time

(end of period 3). For this

example, period

end at

00 00

21 30

should

p m )

Period 3 ends at

)

Check to be sure that

Monday and Tuesday are

flagged for period

M O N N O

02 (Inclu₂d₇e_ths₎Nov 26th

and

TUE NO

W E D N O

W E D Y E S

T H U R N O

FRI NO

DEC24 02 (Includes

24th

Wednesday

no, change to yes

flagged

and 25th)

02 (includes

and

30th

W e d n e s d a y i s n o w

flagged yes for period

Check to be sure that all

other days are flagged no

MAY25 01 (Includes May 25th)

SAT NO

SUN NO

N E W

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,

00.00.

NOTE: When a day is flagged yes for 2 overlapping peri-

ods, occupied time will take precedence over unoccupied

time. Occupied times can overlap in the schedule with no

consequence.

N E W

NEW (30TH

NEW indicates a holiday that has not been assigned yet.

To extend an occupied mode beyond its normal termina-

tion for a one-time schedule override, program as shown

below:

2 -

3 -

4 -

5 -

8 -

9 -

Holidav Schedule

Press

to schedule up to

30 holiday periods. All holidays are entered with numerical

values. First, the month (01 to

then the day (01 to 3

‘ERIO

then the duration of the holiday period in days.

Examples: July 24 is

25 26 is 12.25.02

If any of the 30 holiday periods are not used, the display

shows NEW.

1 9

See Example 10.

OCCUPIED

UNOCCUPIED

Sample Time Schedule

Fig. 9

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13. Cooler entering or leaving fluid thermistor failure

14. Low transducer supply voltage

TROUBLESHOOTING

The

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-

15. Loss of communications between processor module and

other control modules

16. Low refrigerant pressure

pressors, compressor unloaders, fans,

and other com-

Single Circuit Stoppage

can be caused by the following:

Single circuit stoppage

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

Low oil pressure in lead compressor

2. Open contacts in lead compressor high-pressure switch

3. Low refrigerant pressure

4. Thermistor failure

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.

5. Transducer failure

6. Ground fault in lead compressor indicator (indicator is

Checking Display Codes

To determine how ma-

chine has been programmed to operate, check diagnostic

field-supplied on 040-060, 070

associated modular units)

Hz],

110, and

information

and operating mode displays

If no

ules

follows:

follow procedures in Control Mod-

64. If display is working, continue as

7. High suction superheat

8. Low suction superheat

9. Lead compressor circuit breaker

Stoppage of one

Note all alarm codes displayed,

2. Note all operating mode codes displayed,

3. Note leaving chilled water temperature set point in ef-

fect and current leaving water temperature,

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

250, 280, and associated modular units).

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 be

different because machine is operating to the modified

chilled water set point, If current temperature is equal to

set point, but set point is not the one desired, remember

that if dual set point has been selected in the schedule

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

units)

Hz],

110, and associated modular

function, there are

set points to which the machine can

3. Compressor circuit breaker trip

be operating. Check the programming of schedule func-

tion to see if occupied or unoccupied set point should be

in effect.

Not required to run to meet cooling load requirement

Unit Shutoff

To shut unit off, move LOCAL/

If stoppage occurs more than once as a result of any of

the above safety devices, determine and correct the cause

before attempting another restart.

ENABLE-STOP-CCN Switch to STOP position. Any re-

frigeration circuit operating at this time continues to com-

plete the

cycle. Lag compressors stop immediately,

and lead compressors run to complete

After cause for stoppage has been

corrected, restart is either automatic or manual, depending

Restart Procedure

Complete Unit Stoppage

page can be caused by any of the following conditions:

Complete unit stop-

on fault. Manual reset requires that

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.

1. Cooling load satisfied

2. Remote ON/OFF contacts open

3. Programmed schedule

4. Emergency stop command from CCN

5. General power failure

POWER FAILURE EXTERNAL TO THE UNIT

restarts automatically when power is restored.

Unit

6. Blown fuse in control power feed disconnect

7. Open control circuit fuse

Typical Stoppage Faults and Reset Types

Chilled Water, Low Flow

Manual reset

8. LOCAL/ENABLE-STOP-CCN switch moved to STOP

Chilled Water, Low Temperature Auto reset first time, manual

position

if repeat

9. Freeze protection trip

10. Low flow protection trip

Chilled Water Pump Interlock

Control Circuit Fuse Blown

High-Pressure Switch Open

Low Refrigerant Pressure

Low Oil Pressure

Manual reset

Unit restarts automatically when

power is restored

11. Open contacts in chilled water flow switch (optional)

12. Open contacts in any auxiliary interlock. Terminals that

Manual reset

Auto reset first time, then manual

if within same day

are

from factory are in series with control

switch. Opening the circuit between these terminals places

unit in stop mode, similar to moving the control switch

to STOP position. Unit cannot start if these contacts

are open. If they open while unit is running, unit pumps

down and stops.

Manual reset

Gas Thermostat Open Manual reset

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pressor, energizes alarm light, and displays a code of

3, 4, 5, 6, 7, or 8 depending on the compressor. Compres-

sor locks off; to reset, use manual reset method.

Alarm Codes

Following is a detailed description of

each alarm code error and possible cause. Manual reset of

an alarm is accomplished by moving

STOP-CCN Switch to STOP position, then back to LO-

CAL or CCN position. See Table 14 for listing of each alarm

code.

If lead compressor in

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

terminal strip receives voltage when compressor is not

supposed to be on.

circuit shuts down, the other com-

Code 0

No alarms exist

Codes 1 8 Compressor failure

If DSIO-LV or -EXV relay module control relay feed-

back switch or signal is sensed as open during operation of

a compressor, microprocessor detects this and stops com-

Table 14

Alarm Codes

ACTION TAKEN

B Y C O N T R O L

C K T

D E S C R I P T I O N

No Alarms Exist

PROBABLE CAUSE

DISPLAY

Compressor Al failure

Circuit

shut down

Manual

High-pressure switch trip, discharge gas

thermostat trip, or wiring error

Manual

CPCS Ground Fault Protection

Compressor A2, A3, A4 failure

Compressor

Circuit

Compressor

shut

down

Yes

2, 3,

Compressor

failure

shut down

failure

shut

down

A u t o

Leaving water thermistor failure

Entering water thermistor failure

Compressor Al sensor failure

Unit shut down

Yes

N o

1 0

1 9

2 0

2 1

Thermistor or transducer failure

or wiring error.

Circuit

shut down

Compressor

sensor failure

Reset thermistor failure

Normal set point used

Circuit

shut down

Auto.

A u t o

Auto.

A u t o

2 2

2 3

2 4

2 5

2 6

2 7

Discharge pressure transducer failure, circuit

Yes

N o

N O

Suction pressure transducer failure, circuit

Transducer failure or wiring error

Oil pressure transducer failure, circuit

Unit shut down

N o

A u t o

Unit voltage low or PSI faulty

Chilled water pump inoperative

2 8

2 9

Transducer supply voltage low

Interlock switch oaen

M a n u a l

4-20

reset input failure

Normal set point used

Demand limit ignored

Unit shut down

N o

A u t o

Auto.

3 0

demand limit failure

Wiring error or faulty module

3 2

Loss of communication with DSIO-LV

or improper address

code

Unit shut down

N o

A u t o

3 3

3 4

Loss of communication with DSIO-EXV

Loss of communication with

Not used

Out module

Yes

3 5

3 6

Low refrigerant pressure circuit

Low refrigerant charge, plugged filter

drier, faulty EXV

3 7

Low refrigerant pressure circuit

Low refri erant charge, plugged filter

drier. fau tv EXV

Manual

Faulty EXV, transducer, or thermistor

Faultv EXV, transducer, or thermistor.

3 8

3 9

4 0

M a n u a l

oil pressure circuit

Circuit

shut down

N o

Manual

Low oil level, circuit breaker trip,

faulty EXV, crankcase heater,

or Pressure Transducer

4 1

Low oil level, circuit breaker trip,

fautty EXV, crankcase heater,

transducer

4 2

4 3

Cooler

freeze

protection

Unit shut down

Low water flow or faulty thermistor

Low cooler water flow

Manual

M a n u a l

Chilled water pump failure

or faulty thermistor

Faulty EXV or thermistor

4 4

4 5

Low suction temperature circuit

Circuit

shut down

after 10 minutes

Circuit

afler

shut down

N o

Faulty EXV or thermistor

minutes

4 6

4 7

High suction superheat circuit

Circuit

shut down

Yes

Manual

Low charge, faulty EXV or

thermistor, or plugged filter drier

Low charge, faulty EXV or

thermistor, or plugged filter drier.

Circuit

shut down

M a n u a l

Faulty EXV or thermistor

Faultv EXV or thermistor

4 8

4 9

Low suction superheat circuit

Circuit

shut down

Yes

Circuit shut down

Manual

M a n u a l

C C N

Configuration

error

Illegal

configuration

Unit cannot start

Unit shut down

omitted

5 1

Initial configuration required

Network

command.

Emergency stop by CCN command

Yes

5 2

L E G E N D

*Reset automatic first time, manual if repeated same day

Compressor Protection Control Module

Power Supply

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and circuit start-up follows normal sequence. Cause of

fault is usually a bad thermistor, wiring error or loose

connection.

Possible causes of failure:

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.

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.

DSIO-LV or DSIO-EXV Module Failure If a DSIO-LV

relay module relay fails open or closed, microprocessor

detects this, locks compressor off and indicates an error.

3 . Wiring Errors If a wiring error exists causing CPCS,

CR, or feedback switch not to function properly, micro-

processor indicates an error.

Code 21 Reset thermistor failure (applies only to installa-

tions having external temperature reset)

If temperature measured by this thermistor is outside range

4. Processor (PSIO) Failure

If hardware that monitors

to 240 F (-40 to 116 C), reset function is disabled

feedback switch fails, or processor fails to energize re-

lay module relay to on, an error may be indicated.

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 loose connection.

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.

Code 22 Compressor

discharge pressure

transducer failure

5 . Ground Fault Module on 130-2 10, 225, 250, 280, and

Code 23 Compressor

discharge pressure

associated modular units (CGFA or CGFB) Open

ule contacts are in lead compressor circuits, but ground

fault could be in any compressor in affected circuit.

Ground fault of any 040-l 10 and associated modular unit

compressor (field-supplied accessory on 040-060 and 070,

60 Hz units; standard on 070, 50 Hz and 80-l 10 and as-

sociated modular units) will cause a trip.

Mod-

transducer failure

Code 24 Compressor

failure

suction pressure transducer

Code 25 Compressor

failure

Code 26 Compressor Al oil pressure transducer failure

Code 27 Compressor Bl oil pressure transducer failure

6. Checkout Procedure

Shut off main power to unit. Turn

then step through subfunc-

on control power,

If output voltage of any of these transducers is greater

than 5 v, affected circuit shuts down without going through

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.

tion

code 5 is compressor

step works correctly, then failure code is caused by:

to proper compressor number (i.e., failure

Next, energize the step. If

HPS (high-pressure switch) open

Misplaced feedback wire from and J5 terminals

Ground wire and 24-v feeds reversed on one or more

points on

Code 28

Low transducer supply voltage

If transducer supply voltage is less than 4.5 v or greater

than 5.5 v, unit shuts down without going through

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-

Compressor Alarm Circuit

alarm circuit, processor closes contacts between

nals 2 and 3 to start compressor. See Fig.

ties shown to left of 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

tween 2 and 3 on J4 should be closed, causes a code 1

alarm.

For compressor Al

termi-

Safe-

when contacts be-

ance, check to be sure the transformer supplying

is not

grounded. Grounding the supply transformer can result in

serious damage to the control system.

Terminal 2 on

is the other leg of the compressor Al

Code 29 Chilled water pump interlock switch open

(applies only if unit is configured for use with

a chilled water pump interlock).

feedback channel. It is connected to the 24-v common.

NOTE: Similar connections for each compressor can be

lowed on the unit wiring diagrams located on the unit.

Code can occur under any of these conditions:

Code 9

Leaving water thermistor failure

1. Interlock switch fails to close within o n e minute after

chilled water pump starts

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

2. Interlock switch opens during unit operation

3. Interlock voltage is detected, but unit is not configured

for interlock

going through a normal

Reset is automatic if tem-

perature returns to the acceptable range, and unit start-up

follows normal sequence. Cause of fault is usually a bad

thermistor, wiring error, or loose connection.

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

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 19

Code 20

Compressor Al suction sensor failure

Compressor 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

Other circuit continues to run. Reset is

automatic if temperature returns to the acceptable range,

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ginning of

F (5.5” C) below leaving water

Code 30 Reset input failure (4 to 20

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

Code 31 Demand limit input failure (4 to 20

These codes apply only if unit is configured for these

functions. If

signal is less than 4 or more than

shuts down without

Reset is manual with LOCAL/

20 reset or demand limit function is disabled and unit

ENABLE-STOP-CCN Switch, and start-up follows normal

functions normally. If

range, function is automatically enabled.

signal returns to the acceptable

sequence.

Possible causes for this alarm are

ducer or a faulty EXV.

bad thermistor or trans-

Code 32 Loss of communication with compressor

relay module (DISO-LV)

Code 33 Loss of communication with EXV relay

Code 40 Low oil pressure, Circuit A

Code 41 Low oil pressure, Circuit

module (DSIO-EXV)

If communication is lost with either of these modules,

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-

unit shuts down without

This alarm resets auto-

matically when communication is restored. The unit starts

up normally after alarm condition is reset. Probable cause

of condition is a faulty or improperly connected plug, wir-

ing error, or faulty module.

ing through

process, Reset is manual with LOCAL/

ENABLE-STOP-CCN switch, and start-up follows normal

sequence. Factory configured differential oil pressure is

6 psig.

Loss of communication can be attributed to a grounded

transformer with a secondary voltage of 21

supplying

Possible causes of fault are faulty compressor, EXV, crank-

case heater or transducer, refrigerant overcharge, insuffi-

cient oil charge, or tripped circuit breaker.

the PSIO, DSIO-LV, or 4 IN/4 OUT modules; the

transformer supplying the DSIO-EXV module; or the

transformer supplying PS

for the transformers. These

Code 42 Cooler freeze protection

transformers should not be grounded, or serious damage to

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

controls can result. Check to be sure the

are

not grounded.

point for brine, unit shuts down without

Chilled

NOTE: If a blank

module is downloaded without be-

water pump continues to run if controlled by chiller con-

ing connected to the modules DSIO, this alarm is

energized.

trols. Reset is automatic when leaving water temperature

reaches

F (3” C) above set point, providing there has

Code 34 Loss of communication with 4 In/4 Out module

This applies only if one or more of the following options

are used:

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 (1.7” C) or more below leaving water tem-

perature for more than one minute, unit shuts down without

Chilled water pump also shuts down. Reset is

manual with LOCAL/ENABLE-STOP-CCN switch, and

start-up follows normal sequence.

external temperature reset

4-20

temperature reset

external switch controlled dual set point

switch controlled demand limit

4-20

demand limit

hot gas bypass

If communication is lost with 4 IN/4 OUT module, the

unit shuts off automatically, after finishing

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.

Reset

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.

Loss of communication can be attributed to a grounded

transformer with a secondary voltage of 21

the PSIO, DSIO-LV, or 4 IN/4 OUT; the

former supplying the DSIO-EXV module, or the

supplying

trans-

Code 44 Low cooler suction temperature, Circuit A

Code 45 Low cooler suction temperature, Circuit B

former supplying PS

should

for the transformers. These transformers

be grounded, or serious damage to controls can

If saturated suction temperature is less than 32 F (0°C)

result. Check to be sure the transformers are not grounded.

and is 20” F (11” C) for water or 30” F

C) for brine or

Code 36 Low refrigerant pressure, Circuit A

Code 37 Low refrigerant pressure, Circuit B

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

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

without

Reset is manual with

down without going through the

process. Reset is

STOP-CCN switch, and start-up follows normal sequence.

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

Possible causes of fault are low refrigerant charge, 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, unit shuts down after normal

process.

Reset is manual with LOCAL/ENABLE-STOP-CCN switch,

and start-up follows normal sequence.

The

process is terminated when saturated suc-

tion temperature is 10” F (5.5” C) below temperature at

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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

Possible causes of fault are low refrigerant charge, plugged

filter drier, or a faulty EXV or thermistor.

Code 48 Low suction superheat, Circuit A

Low suction superheat, Circuit B

Code 49

groups must be entered under s u b f u n c t i o n . G r o u p s

If EXV is at minimum position, suction superheat is less

than

F (5.5” C) or saturated evaporator temperature is

7 and 8 must be entered under s u b f u n c t i o n .

greater than MOP (maximum operating pressure) for more

than

minutes, affected circuit shuts down after going through

Enter each group, then press the

key. Use the

process, Reset is manual with

down arrow after each group to bring up the next

empty screen. Unit should start after factory and field con-

figurations are correctly entered.

STOP-CCN switch, and start-up follows normal sequence.

Possible causes of fault are faulty EXV or thermistor.

Code 50 Illegal configuration

The usual cause of this fault is replacement of the pro-

cessor module. Refer to instructions accompanying the re-

placement module.

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 52 Emergency stop by CCN command.

Code 51 Initial configuration required

Unit goes through normal shutdown when this command

is received, and goes through normal start-up when

mand is cancelled.

LEGEND

STANDARD:

040-060 50 Hz

040-070 60 Hz

STANDARD:

ACCESSORY:

070 50

Contactor

Circuit Breaker

Communications Bus

Compressor Protection

040-060 50 Hz

040-070 60 Hz

CR’S

C O M M

Control

Module

D G T

Compressor Contactor Relay

Discharge Gas Thermostat (Optional)

Relay Module (Low Voltage)

HPS

High-Pressure Switch

Low

Plug

P o w e r

S n u b b e r

PWR

SNB

Terminal

Block

TRAN

Transformer

Unloader

Fig.

24-V Safety Circuit Wiring (040-070)

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CONTROL

24VAC

O N D A R

LEGEND

Contactor

Communications Bus

Compressor Protection Control Module

Discharge Gas Thermostat (Optional)

Relay Module (Low Voltage)

l-tigh-Pressure Switch

Low Voltage

DGT

HPS

Plug

PWR

Power

Terminal Block

Transformer

Unloader

Fig.

24-V Safety Circuit Wiring (080-110 and Associated Modular Units)

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LEGEND

Ground Fault Module

Communications Bus

Compressor Contactor Relay

Relay Module (Low Voltage)

High-Pressure Switch

Low Voltage

CGF

SNB

Plug

Snubber

Terminal Block

Transformer

TRAN

Unloader

24-V Safety Circuit Wiring (130-210 and Associated Modular Units)

Fig.

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LEGEND

Contactor

Ground Fault Module

C o m m o n

C G F

Control

Relay

Discharge Gas Thermostat (Optional)

Relay Module (Low Voltage)

Electronic Expansion Valve

High-Pressure Switch

D G T

E X V

H P S

Low Volta

Normally

Plug

Reset Button

Terminal

Board

24-V Safety Circuit Wiring (225, 250, and 280 Units)

Fig.

5 5

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CHECKOUT PROCEDURE

agnose and correct EXV problems.

Follow steps below to di-

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.

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

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 motor and lead screws,

760 discrete steps of motion are obtained. The large num-

ber of steps and long stroke result in very accurate control

of refrigerant flow.

subfunction of test function by pressing

, then

advance to EXVA test by pressing

times. Press

The driver should drive the circuit

EXV

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

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.

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.

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

sure EXV cables are not crossed.

to be

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

E X V D R I V E R

BOARD

limiting feature enables the 30G

II chillers to

operate with up to 95 F (35 C) entering water temperatures

during start-up and subsequent pull-down.

STEPPER

‘ D C )

O R I F I C E

ASSEMBLY

(INSIDE

EXV

Electronic Expansion Valve

PISTON

Fig. 12

EXV Cable Connections to

SLEEVE)

EXV Driver Module,

3. Check resistance of EXV motor windings. Remove plug

at terminal strip and check resistance between com-

mon lead (red wire, terminal D) and remaining leads,

A, B , C, and E (see Fig.

25 ohms 2 ohms.

Resistance should be

Control of valve is by microprocessor. A thermistor and

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.

Fig. 11

c Expansion Valve (EXV)

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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.

Because the

are 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 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.

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

to initiate test. With

cover lifted off EXV valve body, observe operation

of valve motor and lead screw. The motor should

turn counterclockwise, and the lead screw should move

up out of motor hub until valve is fully open. Lead

screw movement should be smooth and uniform from

4. The EXV test can be used to drive EXV to any desired

position. When EXV opens, the metering slots begin to

provide enough refrigerant for operation at these steps:

step 60 for sizes 040-210 and associated modular units,

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.

for sizes 225, 250, and 280. This is fully closed

position when circuit is operating. The fully open posi-

tion is 760 steps.

5. Check thermistors and pressure transducers that control

EXV. Check thermistors and pressure transducers that

control processor output voltage pulses to

See

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

Fig, 13 for locations.

Circuit A

ducer SPTA

Circuit B

Thermistor T7, Suction Pressure Trans-

Thermistor T8, Suction Pressure Trans-

ducer SPTB

a. Use temperature subfunction of the status function

to determine if thermistors are reading

correctly.

b. Check thermistor calibration at known temperature

by measuring actual resistance and comparing value

measured with values listed in Tables 15 and 16.

c. Make sure thermistor leads are connected to proper

pin terminals at terminal strip on processor mod-

ule and that thermistor probes are located in proper

position in refrigerant circuit. See Fig. 14 and 15.

opening stroke,

hard pulse is felt momentarily. 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.

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-

d. Use the pressure subfunction of the Status function

ing any percentage from 0 (

movement.

to 100 to initiate

(

to determine if pressure transducers are

reading correctly. Connect a calibrated gage to lead

compressor suction or discharge pressure connection

to check transducer reading.

If operating problems persist after reassembly, they

may be due to out-of-calibration thermistor(s) or inter-

mittent connections between processor board terminals

and EXV plug. Recheck all wiring connections and volt-

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

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.

When above checks have been completed, check ac-

tual operation of EXV by using procedures outlined

in Step 5.

6. Check operation of

a. Close liauid line service valve of circuit to be checked,

and run

in that circuit to pump down low side of

Repeat test step 3 ensure all refrigerant

has been pumped from low side.

NOTE: Be sure to allow compressors to run for the

full period.

the test step (

for lead

b. Turn off compressor circuit breaker(s). Close com-

pressor discharge service valves and remove any re-

maining refrigerant from low side of system.

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MUFFLERS

C O M P R E S S O R S

FILTER

D R I E R

CIRCUIT

CIRCUIT A

LEGEND

Discharge Pressure Transducer

Oil Pressure Transducer

Suction Pressure Transducer

Thermistor Number

DPT

Thermistor and Pressure Transducer Locations

Fig. 13

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LEAVING

W A T E R / B R I N E

THERMISTOR

C O O L E R

F L U I D

B A F F L E

ENTERING

W A T E R / B R I N E

C O N N E C T I O N

A I R

VENT

SUCTION

C O N N E C T I O N

D R A I N

C O N N E C T I O N

C O O L E R

TUBE

(TYPICAL)

L E A V I N G

W A T E R / B R I N E

C O N N E C T I O N

ENTERING

W A T E R / B R I N E

THERMISTOR

Fig. 14

Thermistor Locations

(Circuits A and B, Lead Compressor Only)

THERMISTOR

W E L L

JACKETED

C A B L E

S E N S O R

TUBE

JACKETED

COUPLING

A C C E S S O R Y

NOTE: BEND

FOR INSERTION

INTO WELL

(76)

F E R R U L E S

INSIDE

(4 8) DIA

(6.4)

COUPLING

REFRIGERANT TEMPERATURE SENSOR (T7, T8 040-210 AND

ASSOCIATED MODULAR UNITS)

WATER-SIDE TEMPERATURE SENSOR (Tl, T2,

(T7, T8 225, 250, 280)

ALL UNITS),

Thermistors

Fig. 15

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Pressure Transducers

TWO

of pressure trans-

a low pres-

All thermistors are identical in their tem-

perature vs. resistance performance. Resistance at various

temperatures are listed in Tables 15 and 16.

Thermistors

ducers are used on 30G

sure transducer and a high pressure transducer. The low

pressure transducer is identified by

white dot on the body

LOCATION

shown in Fig. 13.

General location of thermistor sensors are

of the transducer, and the high pressure transducer by a red

dot. See Fig. 16.

Cooler Leaving Water Thermistor

is located in

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

leaving water nozzle. The probe is immersed directly in the

All thermistor connections are made through a

coupling. See Fig. 15. Actual location is shown in Fig. 13

and 14.

Cooler Entering Water Thermistor

cooler shell in first baffle space near tube bundle. Ther-

mistor connection is made through a coupling. See

T2 is located in

to 5 vdc.

TROUBLESHOOTING If transducer is suspected of be-

ing faulty, first check supply voltage to transducer. Supply

Fig. 15. Actual location is shown in Fig. 13 and 14.

Compressor Suction Gas Temperature Thermistors

and

voltage should be 5 vdc

v. If supply voltage is cor-

T7 and

are located in lead compressor in each

rect, compare pressure reading displayed on keypad and dis-

circuit in suction passage between motor and cylinders, above

oil pump. They are well-type thermistors on 040-210 and

associated modular units, or ferrule-type on 225, 250, 280

units. See Fig. 13 and 14.

play module against pressure shown on a calibrated pres-

sure gage. If the

pressure readings are not reasonably close,

replace pressure transducer.

TRANSDUCER REPLACEMENT

THERMISTOR REPLACEMENT (Tl , T2, T7,

pressor and Cooler)

(Com-

Transducers are installed directly in the refrigerant cir-

cuit. Relieve all refrigerant pressure using standard re-

frigeration practices before removing.

Thermistors are installed directly in fluid or refrigerant

circuit. Relieve all refrigerant pressure using standard

refrigerant practices or drain fluid before removing.

1. Relieve refrigerant pressure using standard refrigeration

practices.

Proceed as follows (see Fig. 15):

2. Disconnect transducer wiring at transducer by pulling

up on locking tab while pulling weather-tight connection

pfug from end of transducer. Do not pull on trans-

ducer wires.

To replace sensors

T2, T7

and

1. Remove and discard original thermistor and coupling.

3. Unscrew transducer from

male flare fitting. When

IMPORTANT: Do not disassemble new coupling.

Install as received.

installing new pressure transducer, do not use thread

sealer. Thread sealer can plug transducer and render it

inoperative.

2. Apply pipe sealant to

NPT threads on replace-

4. Insert weathertight wiring plug into end of transducer

until locking tab snaps in place.

ment coupling and install in place of original. Do not

use packing nut to tighten coupling. This damages fer-

rules (see Fig. 15).

5. Check for refrigerant leaks.

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

SAE FEMALE FLARE

finish tightening

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

(040-210 and associated

modula r unit s):

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.

WHITE DOT-LOW PRESSURE TRANSDUCER

RED DOT -HIGH PRESSURE TRANSDUCER

Society of Automotive Engineers

SAE

Fig. 16

Pressure Transducer

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Table 1 5

Thermistor Temperature

vs Resistance/Voltage Drop;

VOLTAGE

D R O P ( V )

RESISTANCE

(OHMS)

TEMPERATURE

VOLTAGE

D R O P ( V )

RESISTANCE

(OHMS)

TEMPERATURE

VOLTAGE

D R O P ( V )

( O H M S )

98010

94707

91522

88449

85486

82627

79871

77212

74648

72175

69790

67490

65272

63133

61070

59081

57162

55311

53526

51804

5 0 1 4 3

48541

46996

45505

44066

42679

4 1 3 3 9

40047

38800

37596

3 6 4 3 5

3 5 3 1 3

34231

5781

1 6 7

1 6 8

1 6 9

1 7 0

1 7 1

1 7 2

1 7 3

1 7 4

1 7 5

1 7 6

1 7 7

1 7 8

1 7 9

1 8 0

1 8 1

1 8 2

1 8 3

1 8 4

1 8 5

1 8 6

1 8 7

1 8 8

1 8 9

1 9 0

1 9 1

1 9 2

1 9 3

1 9 4

1 9 5

1 9 6

1 9 7

1 9 8

1 9 9

200

201

7 1 9

- 24. 0

- 23. 0

- 22. 0

- 21. 0

- 20. 0

4818

4814

4806

4. 800

4793

4786

4779

4772

4764

4. 757

4749

4740

4734

4724

4715

4705

4696

4. 688

4676

4666

4657

4648

3. 064

3034

3005

2977

2. 947

2. 917

2884

2857

2. 827

2797

2766

2738

2708

2679

0824

0. 810

0. 797

0. 783

0770

0758

0745

0734

0722

0. 710

0. 700

0. 689

0678

0668

0659

7 0 5

5637

5497

5361

5 2 2 9

5101

4976

4855

4 7 3 7

4622

4511

4403

4 2 9 8

4196

4096

4000

3906

3814

3 7 2 6

3640

3556

3474

3395

3 3 1 8

3243

3170

3099

3031

6 7 7

6 6 3

6 5 0

6 3 8

6 2 6

6 1 4

-18.0

-17.0

-16.0

15.0

14.0

-13.0

-12.0

6 0 2

5 9 1

5 8 1

5 7 0

5 6 1

5 5 1

5 4 2

5 3 3

5 2 4

5 1 6

5 0 8

5 0 1

4 9 4

487

10.0

-9.0

- 8. 0

- 7. 0

- 6. 0

- 5. 0

- 4. 0

650

2622

2593

2563

2533

2505

2. 476

2447

2417

2388

2360

2332

2. 305

2277

649

0640

0632

0. 623

0. 615

0607

0600

0592

0. 585

0579

0572

0566

0560

0554

0548

0542

-l:o

0 . 0

4' 613

4602

4592

4579

4. 567

4554

4540

4527

4. 514

4. 501

4487

4472

4457

4442

4427

4413

4397

4. 381

4366

4348

4. 330

4313

4. 295

4278

4258

4241

4223

4202

4184

4. 165

4145

4125

4103

4082

4. 059

4037

4017

3994

3. 968

3. 948

3927

3902

3. 878

3854

3828

3805

3781

3757

3729

3705

3. 679

3653

3627

3600

3. 575

3547

3520

3493

3464

3437

3409

3382

3. 353

3. 323

3295

3. 267

3238

3210

9 6

4 6 7

4 6 1

4 5 6

4 5 0

4 4 5

4 3 9

4 3 4

4 2 9

424

4 1 9

4 1 5

4 1 0

4 0 5

4 0 1

3 9 8

3 9 1

3 8 6

3 8 2

3 7 7

3 7 2

3 6 7

361

2964

2898

2835

2773

2713

2655

2597

2542

2488

2436

251

5: o

2217

2189

2. 162

2136

2107

2080

2053

2028

1 0 2

8: 0

9. 0

10. 0

1 1 . 0

1 2 . 0

1 3 . 0

14. 0

33185

3 2 1 7 6

31202

1 0 5

1 0 6

0526

0. 520

0515

0. 510

202

2 0 3

204

205

2 0 6

2 0 7

2 0 8

3 0 2 6 0

29351

2 8 4 7 3

2 7 6 2 4

26804

26011

1 0 9

1 1 0

1 1 1

1 1 2

001

973

1. 946

919

2286

2239

2192

2147

2103

2060

2018

1 9 7 7

1 9 3 7

1 8 9 8

1 8 6 0

1 8 2 2

1 7 8 6

1 7 5 0

1 7 1 5

1 6 8 0

1 6 4 7

494

1 6 . 0

1 7 . 0

1 8 . 0

1 9 . 0

20. 0

21. 0

22. 0

23. 0

24. 0

25. 0

26. 0

27. 0

28. 0

29. 0

30. 0

31 .o

32. 0

33. 0

34. 0

35. 0

36. 0

37. 0

38. 0

39. 0

40. 0

41. 0

42. 0

43. 0

44. 0

45. 0

46. 0

47. 0

48. 0

49. 0

50. 0

51. 0

52. 0

53. 0

54. 0

55. 0

56. 0

57. 0

58. 0

59. 0

60. 0

0488

2 5 2 4 5

2 4 5 0 5

2 3 7 8 9

2 3 0 9 6

2 2 4 2 7

2 1 7 7 9

2 1 1 5 3

2 0 5 4 7

1 9 9 6 0

1 9 3 9 3

1 8 8 4 3

18311

1 7 7 9 6

1 7 2 9 7

1 6 8 1 4

1 6 3 4 6

1 5 8 9 2

1 5 4 5 3

1 5 0 2 7

1 4 6 1 4

1 4 2 1 4

1 3 8 2 6

1 3 4 4 9

1 3 0 8 4

1 2 7 3 0

1 2 3 8 7

1 2 0 5 3

1897

1870

1.846

1.822

1792

1 1 4

1 1 5

1 1 6

1 1 7

1 1 8

1 1 9

1 2 0

1 2 1

2 1 0

211

0471

0465

2 1 2

213

2 1 4

2 1 5

2 1 6

217

2 1 8

2 1 9

2 2 0

221

459

771

0. 453

3 5 6

3 5 0

1. 748

1724

1. 702

1676'

1653

0. 446

0439

0432

3 4 4

3 3 8

0. 425

3 3 2

3 2 5

3 1 8

311

3 0 4

2 9 7

2 8 9

2 8 2

1 2 3

1 2 4

1 2 5

1 2 6

127

1 2 8

1 2 9

1 3 0

1 3 1

132

1 3 3

1 3 4

1 3 5

136

1 3 7

1 3 8

139

0417

630

607

585

409

0401

0393

0384

0375

0366

222

2 2 3

224

2 2 5

1562

1538

1496

1474

1453

1. 431

408

517

1 5 8 2

1 5 5 0

1 5 1 9

1 4 8 9

459

1 4 3 0

1401

1 3 7 3

1 3 4 5

1 3 1 8

1291

1389

1369

1348

327

1308

1291

289

1 1 7 3 0

1 4 0

1 2 6 5

1 1 4 1 6

1 4 1

1 2 4 0

1 1 1 1 2

1 0 8 1 6

1 0 5 2 9

1 0 2 5 0

9 9 7 9

9717

9461

9 2 1 3

8973

8739

8511

1 4 2

1 4 3

1 4 4

1 4 5

1 4 6

147

1 4 6

1 4 9

1 5 0

1 5 1

1 5 2

1 5 3

1 5 4

269

250

1 2 1 4

1 1 9 0

1 1 6 5

1141

1 1 1 8

1 0 9 5

1 0 7 2

1 0 5 0

1 0 2 9

1 0 0 7

986

1230

1192

211

155

136

118

100

1. 082

064

965

8291

8076

7 8 6 8

7 6 6 5

7 4 6 8

7277

7091

047

0 2 9

945

925

156

1 5 7

1 5 8

159

1 6 0

1 6 1

1 6 2

163

1 6 4

1 6 5

166

1. 012

906

995

887

62. 0

63. 0

64. 0

65. 0

66. 0

67. 0

68. 0

69. 0

0978

868

962

850

6911

0945

832

929

6735

6564

6399

6238

6 0 8 1

5929

815

798

782

765

750

734

0914

898

181

0883

0868

0853

3152

3123

6 1

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Table 16

Thermistor Temperature

vs Resistance/Voltage Drop; Flotronic’” II

TEMPERATURE

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

TEMPERATURE

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

168230

157440

147410

138090

129 410

121 330

113810

106 880

100 260

94165

- 4 0

- 3 9

- 3 8

- 3 7

- 3 6

- 3 5

- 3 4

- 3 3

- 3 2

-31

- 3 0

- 2 9

- 2 8

- 2 7

- 2 6

- 2 5

- 2 4

- 2 3

- 2 2

-21

4.896

1 . 9 4 4

1898

1 . 8 5 2

1 . 8 0 7

1 . 7 6 3

1 . 7 1 9

1 . 6 7 7

1635

1594

1553

1513

1474

1436

1 . 3 9 9

1 . 3 6 3

1 . 3 2 7

1. 291

272

2184

4 6

4 7

4 8

4 . 8 7 4

4 . 8 6 6

8 5 7

8 4 8

8 3 8

871

801

734

4.828

4.817

4.806

1670

1609

88 480

550

493

439

387

337

290

244

200

158

118

079

041

794

83 170

78125

73 580

69 250

4 . 7 8 2

4.769

4.755

4.740

725

4710

4.693

4.676

57 875

54 555

5 1 4 5 0

48 536

45 807

43 247

40 845

38 592

38 476

34 489

1 . 2 5 8

6 2

6 5 7

639

619

5 9 8

- 2 0

- 1 9

- 1 8

- 1 7

- 1 6

- 1 5

- 1 4

- 1 3

- 1 2

-11

1 . 1 2 9

1006

9 7 1

4 . 5 7 7

1040

1012

0. 984

9 3 8

9 0 6

8 7 6

8 3 6

8 0 5

7 7 5

7 4 7

719

693

6 6 9

645

6 2 3

602

583

5 6 4

547

5 3 1

516

502

4 8 9

477

466

456

446

436

427

4 1 9

4 1 0

402

393

385

376

367

3 5 7

3 4 6

3 3 5

3 2 4

312

554

4 . 5 3 1

4 . 5 0 7

4482

4 . 4 5 6

4 . 4 2 8

4400

4371

4341

4310

4. 278

4. 245

4 . 2 1 1

4 . 1 7 6

4 . 1 4 0

4 . 1 0 3

4 . 0 6 5

4026

3. 986

3. 945

3. 903

3860

3816

3 . 7 7 1

3726

621

949

0. 920

892

30 866

29 216

27 633

26 202

24 827

23 532

22313

21 163

20 079

19 058

18 094

17184

16 325

15515

14749

14026

13 342

12 696

12085

506

- 1 0

0. 865

0 . 8 3 8

0813

- 7

789

7 8

7 9

8 0

0765

0743

0722

0702

0. 683

0665

0648

0 . 6 3 2

0. 617

0. 603

0. 590

0. 577

0. 566

0555

0545

0. 535

0. 525

0. 515

0 . 5 0 6

0 . 4 9 6

0 . 4 8 6

0 . 4 7 6

0466

0454

0 . 4 4 2

- 2

- 1

959

1 0 4 4 1

949

680

3. 633

3. 585

3. 537

3. 487

3438

3387

3 . 3 3 7

3285

3234

3 . 1 8 1

3 . 1 2 9

3. 076

3 . 0 2 3

2. 970

2 . 9 1 7

2 . 8 6 4

2 . 8 1 0

2. 757

2. 704

2 . 6 5 1

2. 598

2. 545

2. 493

2 . 4 4 1

2 . 3 8 9

2337

2 . 2 8 6

2236

2 . 1 8 6

2 . 1 3 7

2087

2 . 0 3 9

1. 991

9485

044

627

231

855

499

161

101

102

840

536

246

971

429

104

105

106

107

0. 416

0401

0386

0370

710

461

285

225

000

786

583

4389

204

028

861

701

549

404

266

3134

008

888

773

663

559

459

363

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DISCHARGE

PRESSURE

TRANSDUCER*

THERMISTOR*

ENTERING

CYLINDERS

REFRIGERANT

TEMPERATURE

*Lead compressor only

SUCTION

PRESSURE

EQUALIZER

LINE

OIL

PRESSURE

SIGHT GLASS

(EACH COMPRESSOR)

TRANSDUCER*

Fig. 17

Lead Compressor Transducer and Thermistor Locations

6 3

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Control Modules

Turn controller power off before servicing controls. This

ensures safety and prevents damage to controller.

PROCESSOR MODULE

(SIO), LOW-VOLTAGE

4 IN/4 OUT 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

front surface of the

(light emitting diodes) on the

and on the top horizontal sur-

face of the

and SIO.

RED LED Blinking continuously at a to

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

module, if the light is blinking at a rate of twice per sec-

ond, the module should be replaced.

GREEN LED On a

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.

(Processor Module)

Proper addresses are:

01 (different when CCN

connected)

DSIO (Relay Module)

DSIO (EXV Driver Module)

(4 In/4 Out Module)

modules indicate communication failure, check COMM

plug on

module for proper seating. If a good connec-

tion is assured and condition persists, replace

module.

ADDRESS

SELECTOR

If only DSIO or

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

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

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

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 sys-

tem does not work.

Fig. 18

Selector Switch Locations

Module Address

relay module, and keypad and display module are all pow-

ered from a common power source which connects

to terminals 1 and 2 of power input strip on each module. A

separate source of power is used to power options

module through terminals 1 and 2 on power input strip. A

II Chillers, processor module, low-voltage

separate source of 12.5

power is used to power EXV

driver module through terminals 1 and 2 on power input

strip.

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LOW VOLTAGE RELAY MODULE (DSIO) (Fig.

Inputs on strip are discrete inputs (ON/OFF).

power is applied across the 2 terminals in a

Inputs

When

channel it reads as on signal. Zero v reads as an off signal.

Outputs

Terminal strips J4 and

are internal relays whose

signal from micro-

coils are powered-up and powered-off by

processor. The relays switch the circuit to which they are

connected. No power is supplied to these connections by

DSIO module.

(LID) (4

DRIVER)

S E N S O R B U S C O N N E C T O R

Sensor Bus Wiring

(Communications)

Fig.

PROCESSOR MODULE (PSIO) (Fig. 20)

Each input channel has 3 terminals; only 2 of the

RED STATUS LIGHT

Inputs

AND

ARE

(C)

terminals are used. Application of machine determines which

terminals are used. Always refer to individual unit wiring

for terminal numbers.

NEL I2

Outputs

Output is 24 vdc. There are 3 terminals, only 2

of which are used, depending on application. Refer to unit

wiring diagram.

RELAYS

NOTE: Address switches (see Fig. 20) must be set at 01

(different when CCN connected).

C H A S S I S

G R O U N D

-( REAR)

N E T W O R K

COMMON

(FORWARD)

S E N S O R B U S

A D D R E S S A D J U S T M E N T

(NOT SHOWN) ON UNDERSIDE

C O N N E C T O R

A D D R E S S

S W I T C H E S

LEGEND

Communications Bus

Normally Closed

Open

Fig. 21

Low-Voltage Relay Module

I-

Power

Fig. 20

Processor Module

6 5

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OUT MODULE (SIO) (Fig. 22)

4 In/4 Out mod-

ule allows the following features to be utilized:

Temperature Reset by outdoor air or space temperature.

A remote thermistor (Part No,

quired.

is also re-

NOTE: This accessory is not required for return water

P W R

temperature reset.

2. Temperature Reset by remote 4-20

signal.

3. Demand Limit by remote 2-stage switch.

4. Demand Limit by remote 4-20

5. Dual Set Point by remote switch.

The options module is standard on

signal

ADDRESS

S W I T C H E S

and

associated modular chillers and is available as a

field-installed accessory on

Flotronic II chillers.

250, and 280

Remember to reconfigure the chiller for each feature se-

lected (see Table 13). For temperature reset, demand limit,

and dual set point, desired set points must be entered through

keypad and display module (see Set Point Function section

on page 39).

See Table 17 for overall troubleshooting information.

LEGEND

Communications Bus

Power

Fig. 22

Out Module

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Troubleshooting

Table

SYMPTOMS

CAUSE

REMEDY

COMPRESSOR DOES

NOT RUN

Power line open

Reset circuit breaker

Control fuse open

Check control circuit for ground or short.

Replace fuse

High Pressure Switch (HPS)

tripped

Move LOCAL/ENABLE-STOP-CCN switch to STOP

position then back to RUN or CCN position.

Tripped power breaker

Check the controls. Find cause of trip

and reset breaker

Loose terminal connection

Improperly wired controls

Low line voltage

Check connections

Check wiring and rewire.

Check line voltage. Determine location

of voltage drop and remedy deficiency

Compressor motor defective

Check motor winding for open or shot-t.

Replace compressor if necessary.

Seized compressor

Loss of charge

Replace compressor.

Repair leak and recharge

Replace transducer.

COMPRESSOR CYCLES OFF

ON LOW PRESSURE

Bad transducer

Add

refrigerant.

Low refrigerant charge

COMPRESSOR SHUTS DOWN

High-pressure control erratic in action

Compressor discharge valve partially closed

Condenser fan(s) not operating

Replace control

Open

or replace if defective.

Check wiring. Repair or replace motor(s)

if defective.

Condenser coil

Clean coil.

UNIT OPERATES LONG OR

CONTINUOUSLY

Low refrigerant charge

Control contacts fused

Add

refrigerant,

Replace control

Clean or replace

plugged or plugged expansion

valve or filter driver

Defective insulation

Service load

Replace or repair.

Keep doors and windows closed.

Check valves. Replace if necessary.

Support piping as required

Piping vibration

SYSTEM NOISES

Expansion valve hissing

Add

refrigerant.

Check for plugged liquid line filter drier.

Check valve plates for valve noise.

Replace compressor (worn bearings).

Check for loose compressor

Compressor noisy

bolts.

Repair leak.

COMPRESSOR LOSES OIL

FROSTED SUCTION LINE

Leak in system

Mechanical damage (blown piston or

broken discharge valve)

Repair damage or replace compressor.

Crankcase heaters not energized

Replace heaters, check wiring and

crankcase heater relay contacts.

durina

shutdown

Check cooler and compressor thermistors.

Test EXV.

Expansion valve admitting excess

refrigerant

Shortaae of refriaerant due to leak

Shutoff valve partially closed or restricted

Burned out coil

Repair leak and recharge

Open valve or remove restriction.

Replace coil

HOT LIQUID LINE

FROSTED LIQUID LINE

COMPRESSOR DOES NOT

UNLOAD

Replace

valve

Defective capacity control valve

Miswired

solenoid

Rewire correctly.

Replace spring

Rewire correctly

Weak, broken, or wrong valve body spring

Miswired

solenoid

DOES NOT

Defective capacity control valve

Replace

valve.

Plugged strainer (high side)

Clean or replace strainer.

Clean or replace the necessary parts.

Stuck or damaged unloader piston or

piston ring(s)

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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.

ACCESSORY UNLOADER INSTALLATION

Some of the 30G II units come standard with

unloader(s), and many permit additional unloader(s) to be

added if desired. See Table 18.

Wire the secondary side of transformer to DSIO-LV

IMPORTANT: Accessory hot gas bypass cannot be

installed with accessory unloaders on units with more

than 4 compressors.

and a jumper from DSIO-LV

Wire the secondary common to

to DSIO-LV

Connect

the transformer ground to ground hole supplied near the

transformer. These connections provide DSIO with nec-

essary power to energize the solenoid coils.

If accessory unloaders are desired, an accessory unloader

package is used. Package includes

suction cutoff unloader

3. When all connections are made, check for proper wiring

and tight connections. Replace and secure inner panel.

Restore power to unit.

head package. The 24-v coil in the package can be used for

040-l 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.

4. 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

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-

CCN switch must be in the STOP position, and the ser-

vicer must log on to the processor.

a. Press

Keypad LCD displays the word

a d LaCD

Keypad LCD

ply a

vdc (part number

unloader relay

PASSWORD.

Enter d

LOGGEDON.

and wire (90” C or equivalent).

. p K e y p

Table 18 Standard and Accessory Unloaders

NO. OF ACCESSORY

To change configuration, press

displays FLD CFG.

d. If an additional unloader was added to compressor

Circuit

or2

Al, press until NULA 1 appears in keypad dis-

play. Press for the number of unloaders on

circuit A. Keypad display now reads NULA 2.

If an additional unloader was added to compressor

*And associated modular units

1, press

until NULB

appears in keypad dis-

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.

play. Press

for the number of unloaders on

circuit B. Keypad display now reads NULB 2.

Key-

When configuration is complete, press

pad display reads LOGGEDON. Press

until

. Keypad dis-

2. For ease of installation, factory-supplied wiring for the

additional unloader is provided in the compressor

harness.

pad display reads LOG OFF. Press

play reads EXIT LOG.

5. Using test function, check unloaders. Press

Install the additional unloader cylinder head on the lead

Key-

compressor, Al or

according to instructions pro-

vided by the compressor manufacturer in the accessory

pad display reads OUTPUTS. Press

until display

package.

reads ULA

OFF. Press

Relay energizes. Press

until reads

4. Continue installation per either 040-l 10, 130 (60 Hz)

units or 130 (50 Hz), 150-210, 225, 250, and 280 units

section as appropriate.

and relay deenergizes. Press

ULB2 OFF. Press

. Relay energizes. Press

^displayq

0 4

10, 130 (60 Hz) UNITS (and associated modular units)

and relay deenergizes.

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.

6. When unloader check has been performed, return LOCAL/

ENABLE-STOP-CCN to proper position. Close and se-

cure control box door.

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 panel.

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SC H E M A T I C

FROM

CONTROL SCHEMATIC

TRAN

080-110

Hz) and 130 (60

L E G E N D

Contactor

Compressor Protection Control System

Control Relay

Module

Terminal Block

Transformer

Unloader

Low oltage

Fig. 23

Accessory Unloader Control Wiring

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130 (50 Hz), 150-210, 225, 250, AND 280 UNITS (and

To change the configuration, type

keypad LCD will display “FLD CFG.” Press

until either 0” or “NULA is displayed

(depending on the number of unloaders provided as

standard), Then press (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

and the

associated modular units)

Install control wiring. The minimum wire size for

stallation is 16

(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 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.

to get to the

NULB display, and change this setting in the same

manner as with circuit A.

Wire the control side. Wire the URA coil in series be-

tween

and

19 of the 4 IN/4 OUT module with

the wires provided. Wire the URB coil in series be-

d. Once the configuration is complete, press

tween

and

of the same module with the wires

and the keypad LCD will display “LOGGEDON,”

provided.

Press

until the keypad LCD display reads “LOG

Locate the black wire in the control harness originating

from 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

OFF.” Press

and the keypad LCD will display

“EXIT LOG.”

Once the unloader heads are installed, the unit is checked

for leaks, and the system is prepared for operation per

URA-NO to

For an extra unloader on circuit

connect the wire labeled HGBPR-B-COM to

COM, and the wire labeled HGBPR-B-NO to

NO. Connect the wire from URB-NO to

instructions for the compressor unloader head instal-

lation, check the output of the relays using the test func-

tion as follows:

the

3. Wire in the solenoid valves.

a. Press

and the display will read

NOTE: Wires external to the control box must be run in

conduit

b. Press the

to scroll down until the display reads

Terminal blocks are provided for easy field wiring. Use

“CPA1 OFF.”

one of the isolated

(22-mm) holes in the side of

c. Press

, and the compressor should start.

the compressor electrical box with a strain relief to run

the wires to the solenoid coil. Connect URA between

d. Press

and the compressor should stop.

and

Connect URB between

and

e. Press

f. Press

until the display reads

OFF.”

Check all of the electrical connections for proper

location and tightness, and replace and secure the elec-

trical box of the compressor,

c l

, and the solenoid should energize.

and the solenoid should deenergize.

and keys to check the remainder of

g. Press

4. Configure the microprocessor, Once the relays are mounted

in the control box, the microprocessor must be config-

h. Use the

ured for the unloader option. ‘To do so:

the unloader coils.

a. Be sure the LOCAL/ENABLE-STOP-CCN switch is

in the STOP position.

6. Once the check has been performed, return the LOCAL/

ENABLE-STOP-CCN switch to the proper position.

b. Log into the processor and enter the service func-

tion using the keypad and display module.

7. Close and secure the control box door.

8. Start the unit and confirm that the chiller operates

Type

. The keypad LCD will display

properly.

“PASSWORD.” Enter

and the

keypad LCD will display “LOGGEDON.

LEGEND

Terminal Block

Transformer

COM

Communications Bus

Hot Gas Bypass Relay

Unloader

Normally

Open

Unloader Relay

S n u b b e r

Unloader Wiring, 130 (50 Hz), 150-210, 225, 250, 280

Fig. 24 - Flotronic’”

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- - - ‘ I

S W I T C H

211

- - - - - - - - m - w - - - - - - -

- - -^OUT-^PUT- I - - - - - - - - - - - - - - - - Y - -

4-20

LEGEND

Switch

Transformer

Unloader Relay

Contactor

Circuit Breaker

COMM

Communications Bus UR

Accessory Unloader Control Wiring, 130 (50 Hz),

280

Fig. 25

FIELD WIRING

Refer to Fig, 26 36 for field wiring.

O U T

T B 7

M O D U L E

STAGE

- - - - - - - - - - -

STAGE

e m - - -

- - -

H -

STAGE2

Terminal Block

N O T E S :

NOTE: Contacts must be rated for dry circuit application, capable of

Requires accessory options module package.

2 Contacts must be rated for dry circuit application, capable of re-

reliably switching a 5 vdc,

to 20

load

liably switching a 5 vdc, 1

to 20

load

Demand Limit

Two External Switch

Fig. 26A

Inputs,

Two External Switch

250, 280 Units

Demand Limit

Inputs,

Fig. 26B

and Associated Modular Units

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FIELD SUPPLIED

LOOP ISOLATOR

EXTERNAL

POWER

AND ASSOCIATED MODULAR UNITS

AND ASSOCIATED MODULAR

FIELD SUPPLIED

LOOP ISOLATOR

T B - 7

FLOTRONIC II UNITS

l-E-11

Terminal Block

FLOTRONIC II UNITS

NOTE: The

sory options module package for this feature

Flotronic’” II units require the acces-

Terminal Block

NOTE: The

Flotronic II units require the acces-

sory options module package for this feature.

Fig. 27

Demand Limit

4-20

Signal

(Externally Powered)

Fig. 30

Remote Reset from 4-20

Signal

(Externally Powered)

OUT

MODULE

SIGNAL

GENERATOR

AND ASSOCIATED MODULAR UNITS

TB-11

TB-7

FLOTRONIC II UNITS

Terminal Block

NOTE: The Flotronic II units require the acces-

sory options module package for this feature

NOTE: The

sory options module package for this feature.

Flotronic II units require the acces-

Demand Limit

(Internally Powered)

4-20

Signal

Fig. 31

Remote Reset from 4-20

Signal

Fig. 28

(Internally Powered)

IN/4 OUT

REMOVE JUMPER

CONTACTS

M O D U L E

- -

REMOTE THERMISTOR

AND ASSOCIATED MODULAR UNITS

JUMPER

- - - -

TB-7

- - - -

10 TE7

TB-11

FLOTRONIC I UNITS

FLOTRONIC II UNITS

Terminal Block

N O T E S :

1 The

Flotronic II units require the accessory op-

tions module for this feature.

2. Contacts must be rated for dry circuit application, capable of

NOTE: The

Flotronic II units require the acces-

sory options module package for this feature.

switching a 5 vdc, 1

to 20

load

Remote Reset from Space or

Outdoor-Air Temperature

Fig. 29

Remote On/Off

Fig. 32

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(CWFS)

OUT

M O D U L E

TB-6

S W I T C H

I - -

AND ASSOCIATED MODULAR UNITS

FLOTRONIC

Chilled Water Pump Interlock

Chilled Water Flow Switch (not required

protection is provided by Flotronic II controls)

Terminal Block

UN ITS

FLOTRONIC’” II UNITS

CWFS

low flow

T B

Terminal Block

T B

NOTE: The

sory options module for this feature

Flotronic II units require the acces-

NOTE: Contacts must be rated for dry circuit application, capable of

reliably switching a 5 vdc,

to 20

load.

Fig. 33

Remote Dual Set Point Control

Fig. 36

Interlocks

REPLACING DEFECTIVE

PROCESSOR MODULE

The replacement part number is printed on a small label

on front of the

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-

T5-3

AND

MODULAR UNITS

ule. Therefore, when ordering

replacement processor mod-

ule (PSIO), specify complete replacement part number,

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.

FLOTRONIC II UNITS

Chilled Water Pump

Terminal Block

T B

Electrical shock can cause personal injury, Disconnect

all electrical power before servicing.

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

Installation

1. Verify the existing

module is defective by using

the procedure described in the Control Modules sec-

tion on page 64.

ALARM

SHUTOFF

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

S W I T C H

TB-3

I -

procedure. If checklist does not exist, fill out the

T 8 - 3

and

configuration code sections on

new check-

list. Tailor the various options and configurations as

needed for this particular installation.

AND ASSOCIATED MODULAR UNITS

3 . Check that all power 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.

TB-5

FLOTRONIC II UNITS

Terminal

Block

4 . Remove defective

by removing its mounting screws

with a Phillips screwdriver, and removing the module

from the control box, Save the screws for later use.

NOTE: The maximum load allowed for the alarm circuit is 125 va

sealed, 1250 va inrush at 115 or 230 v

5 . Use a small screwdriver to set address switches and

Fig. 35

Remote Alarm

S2 on the new

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

above.

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while displaying CODE 6. The display returns in ap-

proximately 15 seconds.

8. Reinstall all 6 wire connectors and the green ground

wire.

NOTE: Codes with leading zeros in the configuration

will be displayed starting with the first number greater

than zero.

9. Carefully check all wiring connections before restoring

power.

10. Verify the LOCAL/ENABLE-STOP-CCN switch is in

STOP position

14. Press

to verify each item is configured as needed

11. Restore control power. Verify the red and green lights

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-

on top of

and front of each DSIO module re-

spond as described in Control Modules section on

page 64. The keypad and display module

or LID)

should also begin its rotating display.

dering the replacement

module. It is strongly sug-

gested that the Start-Up Checklist for

II Chiller

12. Using the keypad and display module, press

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.

to verify that the software version number matches the

ER (engineering requirement) number shown on the

label.

After completing the configuration steps outlined above,

13. Press

to verify that the 6 factory configuration

restore main power and perform a unit test as

codes (CODE 1 through CODE 6) exactly match the

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 codes.

scribed in

and

sections on page 38.

Complete this procedure and restore chiller to normal

operation by returning the

CCN switch to desired position.

If any changes are required, the

display becomes

blank and reconfigures itself after pressing the

key

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1994

Carrier

Corporation

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

Book 2

T a b

P C 9 0 3

Catalog No 563-015

Printed in

Form

Pg 76

l-94

Replaces:

T ,

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