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30GB040-070 Flotronic™Reciprocating Liquid Chillers

HEATING & COOLING





Installation, Start-Up and Service Instructions

50Hz and 60 Hz, Domestic and Export

CONTENTS



Page INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . .. I

SAFETY CONSIDERATIONS .

INSTALLATION 1-7

Rigging.................................... I

Placing the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 Adjust Compressor Mounting. . . . . . . . . . . . . .. 3 Connect Chilled Water Piping. . . . . . . . . . . . . .. 3 Check Water Treatment and Preparation

for Winter " . . . . . . . . . . .. 3

Make Electrical Connections. . . . . . . . . . . . . . .. 5

• POWER SUPPLY

• FIELD POWER CONNECTIONS

Install Accessories. . . . . . . . . . . . . . . . . . . . . . . . .. 7 • ELECTRICAL

PRE-START-UP 7-12

System Check (Steps 1-9). . .. .. . . .. .. . . . . .. .. 7

Quick Test (Step 10) " .. . . . . . . . . .. 7

START-UP AND OPERATION 12-17

Digital Display Action 12

Actual Start-Up " 14

Operating Limitations 14

Operation Sequence IS

Start-Up Check List (4-pg insert) CLl-4

SERVICE 18-24

Diagnostics and Troubleshooting 18

Refrigerant Circuit 18

Electronic Components. . . . . . . . . . . . . . . . . . . .. 18

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18

Access for Servicing. . . . . . . . . . . . . . . . . . . . . . .. 18

• COMPRESSOR SECTION

• CONDENSER FANS

• UNIT CONTROL BOX

• COOLER SECTION

Cooler Freeze-Up Protection 19

• COOLER HEATERS

Servicing the Cooler. . . . . . . . . . . . . . . . . . . . . . .. 19

Refrigerant Feed Components 20

Thermistors 21

Safety Devices 23

Relief Devices 24

Other Safeties 24

INTRODUCTION



These instructions cover the installation, start-up and service of the 30G B040-070 Flotronic'" liquid chillers and the units with factory-installed options (FlOP).

The Flotronic chillers are equipped with electronic expansion valves and the FlOP units have the conventional thermostatic expansion valves and liquid line solenoid valves. Differences in Quick Test procedures and operation sequence should be carefully noted when following these instructions.

IMPORTANT: This equipment generates, uses and can radiate radio frequency energy and if not installed and used in accordance with these instructions may cause radio interference. It has been tested and found to comply with the limits of a Class A computing device as defined by FCC regulations, Subpart J of Part IS, which are designed to provide reasonable protection against such interference when operated in a commercial environment.

SAFETY CONSIDERATIONS

Installation, start-up and servicing of this equipment can be hazardous due to system pressures, electrical components and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start-up and service this equipment. -

Untrained personnel can perform basic maintenance functions of cleaning coils. All other operations should be performed by trained service personnel.

When working on the equipment, observe precautions in the literature, 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 bulky equipment.

ELECTRIC SHOCK HAZARD.

Open all remote disconnects before servicing this equipment.

INSTALLATION

Rigging - These chillers are designed for overhead rigging only. For this purpose, the transverse base channels extend beyond the sides, with holes provided in end plates to attach cables or hooks (see rigging label on unit). Use a spreader {rame above the unit to keep cables vertical and awaJ' from the sides. As further protection for the coil faces, plywood sheets may be placed against the sides of the unit, behind the cables. Run the cables to a central suspension point so that the angle from the horizontal is not less than 45 degrees. Raise and set unit down carefully.

DOMESTIC UNITS - These chillers are shipped without skids. If, at the jobsite, overhead rigging is not possible, place chiller on skid or pad for rolling or dragging. When rolling, use minimum 3 rollers. When dragging, pull the pad. Do not apply force to the unit. When in final position, raise from above to lift unit off the pad.

Tab 5c

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

Book 2 PC111 Catalog No 533-001 PrintedinUSA Form30GB-35SIM Pg1 2-89 Replaces: 30GB-31SIM

For replacement Items use Carrier Specified Paris

30GB040,045,046,050,055.0r,n.~70

(2) REMOVABLE

SEE TABLE PANELS IN END

CLEARANCE CLEARANCE /

--- SEE TABLE A ·1

FOR COOLER REMOVAL

-lOr 101 ror--lOI- -I---~-

r ~~® !~!

M"u~~ ~~ I]

MTG HOLES tt_ I t: SEE TABLE -

-- 1~2r F ~ CLEARANCE

1----1----- G 11'ts"

SEE TABLE MTG HOLES ~

OVERHEAD CLEARANCE CLEARANCE

MUST BE UNRESTRICTED +

REMOVABLE PANEL

COOLER END VIEW



TOP VIEW

E

040,046

DIMENSIONS - It-in. (mm)



SIDE VIEW

UNIT 30GB

045,050,055,060 070

Length Cabinet Width

Overall Width (Base Channels) Overall Height

Mounting Holes ~ (Width) Mounting Holes ~(Length, Inner) Mounting Holes ~(Length, Outer) Lifting Holes ~

Height to Power Connection

Height to Control Power Connection Height to Water Nozzles ~

Water Nozzles, Between ~

Water Nozzle Location ~

A 11-10% (3616) B

C

D 4-83/'6 (1427) I

F 8- 2% (2499) G 10- 7% (3235)

H 9- 4% (2867)

J 3-5'3/'6 (1062)

K 2-7% (807)

L

M

N

13-7% (4163) 7- 0% (2146)

7 - 63/'6 (2291)

5-8%2 (1730) I 7- 4% (2233) 7 - 3% (2213)

10-0'12 (3061) 12-5% (3797) 11-3 (3429)

4-53;" (1365) I 6-1 (1854)

3-7"/'6 (1094) 4-11'.4 (1055)

1- 913/'6 (554)

0- 4% (117)

2-10% (867)

Minimum Clearances

Compressor End

Opposite End (Cooler Removal) Sides

6-0 (1829) 7-5 (2261) I 7-6 (2286) 5-0 (1524)

10-4 (3150) 7-0 (2134)

®

Fig. 1 - Dimensions

2





EXPORT UNITS - All units are mounted on skids and crated for shipping. At the jobsite, leave unit on the skid until it is in final position. While on the skid, the unit can be rolled or skidded on the floor, with force applied to the skid, not the unit. When the skid is removed, the unit must be handled by overhead rigging as described above. If it is necessary to remove the skid before the unit is in final position, and it can be dragged, it should be placed on some kind of large pad and dragged by the pad. Do not apply force to the unit. When in final position, raise from above to lift unit off the pad.

Placing the Unit - Locate so that condenser airflow is unrestricted on all sides and above. Be sure to provide clearance all around for servicing as shown in Fig. 1. The unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points. The weight distribution is based on support points shown in Table I. Bolt securely to pad(s) when unit is positioned and leveled.

If the vibration isolators are required for a particular installation, the weight distribution shown in Table I will aid in making the proper selection.

Adjust Compressor Mounting - As shipped, each compressor is held down by special self-locking bolts and plain lockwashers. After unit is installed, remove the self-locking bolts one at a time and reassemble with flanged washers and neoprene snubbers as shown in Fig. 2. The flanged washers and neoprene snubbers are shipped in a cloth bag tied to one of the compressor feet. Tighten all 4 bolts, then loosen each until the flanged washer can be moved sideways with finger pressure.

Connect Chilled Water Piping - Viewing the cooler from the end opposite the compressors, the return (inlet) water connection is on the left and leaving (supply) water connection is on the right (Fig. 3). To isolate the cooler for servicing, shutoff valves should be field installed in the leaving and return water lines, as near the cooler as possible.

At the highest point in the chilled water circuit, install an air-trap vent.

Table 1 - Weight Distribution. Ib (kg)

UNIT 30GB

4

040 3780 (1715) 1255 (569) 1255 (569) 635 (288) 635 (288)
045 4250 (1928) 1385 (628) 1385 (628) 740 (336) 740 (336)
055 4800 (2177) 1528 (693) 1528 (693) 872 (396) 872 (396)
060 4900 (2223) 1578 (716) 1528 (693) 922 (418) 872 (396)
070 6200 (2812) 1974 (895) 1974 (895) 1126 (511) 1126 (511) 50 Hertz

040 3780 (1715) 1255 (569) 1255 (569) 635 (288) 635 (288)
046 3860 (1751) 1315 (597) 1275 (578) 635 (288) 635 (288)
050 4330 (1964) 1425 (646) 1425 (646) 740 (336) 740 (336)
055 5060 (2295) 1618 (734) 1578 (716) 932 (423) 932 (423)
070 6280 (2849) 2014 (913) 201" (913) 1123 (509) 1123 (509) 4

2

~ ,......-,
CONDENSER
@ ® @ a::
0
~z
5 wQ
* *
@ @ ® 11:1-
a.U
::;:w
OW
6 U
* *
CONDENSER
'-----' L.....::f 3

'Only 4 fans on 30GB040 and 046

SNUBBER FLANGED WASHER

NEOPRENE SNUBBER

COMPRESSOR FOOT

ISOLATION SPRING

Fig. 2 - Compressor Mounting

After field piping has been completed, all piping that is exposed to low ambient temperature should be wrapped with electric heating tape with a rating suitable for the area ambients, and covered with a suitable thickness of closed cell insulation. Bring the power for the heating tape(s) from a separate fused disconnect. Identify the disconnect as the power source for the pipe heater(s), with emphasis that it must never be turned off except when the unit is being serviced.

A drain connection is located at the end of the cooler opposite the compressors (see Fig. I and 3).

Check Water Treatment and Preparation for Winter

W ATER TREATMENT - If the unit is on year-round operation, add sufficient ethylene glycol to the chilled water to prevent freezing under the operating ambient conditions.

Consult the local water authority on the characteristics of the area water and add a recommended inhibitor to the chilled water.

UNIT

LEAVING CHILLED WATER

THERMISTOR. TI

RETURN CHILLED WATER

THERMISTORS

130GB070 SHOWN I

Fig. 3 - General View; End Opposite Compressors

3

Table 2 - Physical Data; 60 Hz

UNIT 30GB 040 045 055 060 070
APPROX OPER WT [Ib (kg)) 3780 (1715) 4250 (1928) 4800 (2178) 4900 (2223) 6200 (2813)
REFRIG CHARGE, R-22 * Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 1 (L) Ckt 2 (R)
6~~~1 Clear Glass [Ib (kg)] 40 (18 1) 40(181) 60 (27 2) 38 (172) 71 (322) 65 (295) 85 (386) 65 (295) 106 (481) 71 (322)
181 (82) 18 1 (82) 181 (82) 181 (8.2) 181 (82) 181 (82) 20 (9.1) 20 (9.1) 481 (218) 32.2 (14.6)
COMPR, Type ... Rpm (Rls) Reciprocating, Semi-Hermetic 1750 (292)
• Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 1 (L) Ckt 2 (R)
06Et A250 2250 F275 2250 F275 6275 A299 6275 6275 A250 F275
Compr No .... CyI/Compr 2. 4 1 4 2 6 1 4 2 6 1 .. 6 2 6 1 6 1 6 2. 4 3 6
Oil Charge/Compr 14 (66) 14 (66) 19 (9) 14 (66) 19 (9) 19 (9) 19 (9) 19 (9) 19 (9) 14 (66) 19 (9)
[pt(LlH
COND FANS, Type 4 .. 26 (660) I I Propeller, Direct Drive
No .... Dla [in. (mm)) 6 .26 (660) 6 .. 26 (660)1' 3 .. 30 (762) 3 .. 26 (660) 6. 30 (762)
Speed [Rpm (Rls)) 1080 (18) 1080 (18) 1080 (18) 1080 (18) 1080 (18) 1140 (19)
Total Airflow [Cfm (Lis)] 26,000 (12269) 39,000 (18404) 39,000 (18404) 27,000 (12747) 19,500 (9206) 58,800 (27748)
No. Blades 4 4 4 3 4 3
COND COILS, No .... Type 2 Vertical, Plate Fin
Tube Dla [In. (mm)) % (9.5) V, (12.7) Y, (12.7) V, (12.7) V, (12.7) V, (12.7)
Tube Length [In. (mm)) 115 (2921) 138 (3505) 138 (3505) 138 (3505) 138 (3505) 138 (3505)
Flns/ln. (Fin Pitch, mm) 170 (1 49) 175 (145) 142 (179) 150 (169) 14.2 (1 79) 155 (164)
Rows 3 2 3 4 3 3
Face Area [ft' (m')] Ckt1 )1 Ckt2 Ckt 1 )1 Ckt 2 Ckt 1 )~ Ckt 2 Ckt 1 Ckt 2 Ckt 1 1 Ckt 2
38 33 (3 56) 38 33 (3 56) 43125 (4 0) 71 875 (668) 575 (534) 575 (534) 57.5 (534) 57.5 (5.34) 95.83 (8.9) 57.5 (5.34)
COOLER, No .... Type 794 One Direct Expansion, Shell and Tube
ModeI10HA400--- I 824 I 824 I 934 I 854
No. Refrlg Circuits 2 2 2 2 2
Net Water Vol [gal. (L)] 154 (583) 17 7 (670) 177(670) 17 7 (670) 236 (893)
Max Design Working Refrigerant Side: 235 (1620); Water Side: 150 (1034)
Pressure [pslg (kPa)]
WATER CONNECTIONS
Inlet and Outlet (In. MPT) 3 3 3 3 3
Drain (in. MPT) % % % % % *L and R are left and right circuits, viewed from compressor end tPrefix: 2, 6 = one electric unloader; A,F = no unloader

tSee Oil Charge for Carrier-approved compressor oil

Table 3 - Physical Data; 50 Hz

UNIT 30GB 040 046 050 055 070
APPROX OPER WT [Ib (kg)) 3780 (1715) 3860 (1751) 4330 (1964) 5060 (2295) 6280 (2849)
REFRIG CHARGE, R-22 . Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 1 (L) Ckt 2 (R)
Total [Ib (kg)] 40 (181) 40 (18 1) 44 (20) 30 (13.6) 54 (24.5) 54 (24.5) 65 (295) 65 (29.5) 106 (48 1) 71 (322)
Over Clear Glass 18.1 (82) 181 (82) 145 (66) 10 (4.5) 8 (3.6) 8 (3.6) 26.2 (11.9) 29.5 (13.4) 48.1 (21.8) 32.2 (14.6)
COMPRESSOR, Type ... Rpm (Rps) Reciprocating, Semi-Hermetic 1450 (24)
. Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 2 (L) Ckt 1 (R) Ckt 1 (L) Ckt 2 (R)
06Et A250 2250 F275 2250 F275 6275 F299 6275 6275 A275 F275
Compr No .... CyI/Compr 2 .. 4 1 .. 4 2 6 1 .. 4 2 .6 1 .6 2 .6 1 6 1 .6 2 .6 3 6
Oil Charge/Compr [pt (L)]t 14 (66) 14 (66) 19 (9) 14 (66) 19 (9) 19 (9) 19 (9) 19 (9) 19 (9) 19 (9) 19 (9)
CONDENSER FANS, Type Propeller, Direct Drive
No .... Dia [in. (mm)] 4 ... 26 (660) 4 ... 26 (660) 6 ... 26 (660) 6.30 (762) 6 .. 30 (762)
Speed [Rpm (Rls)] 920 (153) 870(145) 870 (145) 900 (15) 900 (15)
Total Airflow [Cfm (Lis)] 21,600 (10193) 26,000 (12269) 39,000 (18404) 45,000 (21 236) 60,000 (28326)
No. Blades 4 4 4 3 3
COND COILS, No .... Type 2 Vertical, Plate Fin
Tube Dia [in. (mm)] % (95) % (9.5) Y, (12.7) V, (12.7) V, (12.7)
Tube Length [in. (mm)] 115 (2921) 115 (2921) 138 (3505) 138 (3505) 138 (3505)
Fins/ln. (Fin Pitch, mm) 17 (1 49) 17 (1 49) 155(164) 15 5 (1 64) 155 (1 64)
Rows 3 3 2 3 3
Face Area [ft' (m')] Ckt 1 II Ckt 2 Ckt 1 r Ckt 2 Ckt 1 J Ckt 2 Ckt 1 If Ckt 2 Ckt 1 I Ckt 2
38.3 (3.6) 38.3 (3.6) 27.5 (2.5) 49.51 (4.6) 57.5 (5.34) 57.5 (5.34) 57.5 (5.34) 57.5 (5.34 95.83 (8.9) 57.5 (5.34)
COOLER, No .... Type One Direct Expansion. Shell and Tube
ModeI10HA400--- 924 I 924 I 934 I 934 I 944
No. Refrig Circuits 2 2 177 T67 0) 177 T67.0) 2
Net Water Vol [gal. (L)] 154(583) 154(583) 236 (893)
Max Design Work. Press. Refrigerant Side: 235 (1620); Water Side: 150 (1034)
[psig (kPa)]
WATER CONNECTIONS
Inlet and Outlet (In. MPT) 3 3 3 3 3
Drain (in. MPT) % % % % % *L and R are left and right circuits, viewed from compressor end tPrefix: 2,6 = one electric unloader; A,F = no un loader

tSee Oil Charge for Carrier-approved compressor oil

4



t



PREP ARA nON FOR WINTER - Do not shut off control power disconnect during off-season shutdown.

At the end of the cooling season, drain the water from the system. Replace the drain plug and put 2 gallons (8 liters) of ethylene glycol in the cooler to prevent freezing of residual water. Remove the plug on top of the leaving chilled water nozzle to add the glycol. At the beginning of the next cooling season, refill the cooler and add the recommended inhibitor.

Make Electrical Connections

POWER SUPPLY - Electrical characteristics of available power supply must agree with unit nameplate rating. Supply voltage must be within the limits shown in Tables 4 and 5.

IMPORT ANT: Operation of unit on improper supply voltage or with excessive phase imbalance constitutes abuse and may affect Carrier warranty.

Refer to Operation Limitations section for information on power supply.

FIELD POWER CONNECTIONS - All power wiring must comply with applicable local and national codes. Install field-supplied branch circuit fused disconnect(s} of a type that can be locked OFF or OPEN. Disconnect(s} must be located within sight from and readily accessible from the unit in compliance with NEC Article 440-14.

Main Power - Power entry is single point (only one end of unit). Bring the wires into the unit through the side

Table 4 - Electrical Data (60 Hz)

UNIT COMPRESSORS FAN MOTORS
UNIT Volts RLA (ea) I LRA (ea) Total MTA Total FLA (ea)
30GB Supplied' MCA MOCP ICF Compressor No. CB No. kW Fan No. MTAt
Nameplate (Fuse) (no.) 1,3,5 I 2,4,6t (FCB)
Min Max 1 2 1 2 1 2
208 187 229 182 250 499 728 728 345 345 106 106 46 21
230 207 253 172 225 499 684 684 345 345 106 106 27 46 21
040 380 342 418 104 125 287 390 390 191 191 54 54 46 21
460 414 506 82 110 246 324 324 173 173 50 50 (4) 23 14
575 518 633 62 90 181 269 26.9 120 120 42 42 1.8 14
208 187 229 234 300 547 728 1064 345 506 106 166 46 ;11
230 207 253 229 300 547 684 1064 345 506 106 166 4.0 46 21
045 380 342 418 143 200 322 390 640 191 280 54 89 46 21
460 414 506 105 150 166 324 468 173 253 50 73 (6) 23 14
575 518 633 88 125 198 26.9 40.4 120 176 42 63 1.8 14
208 187 229 267 350 746 1064 106.4 506 506 166 166 46 21
230 207 253 267 350 746 1064 1064 506 506 166 166 4.0 46 21
055 380 342 418 168 250 436 640 640 280 280 89 89 46 21
460 414 506 119 150 360 468 468 253 253 73 73 (6) 23 14
575 518 633 102 125 268 40.4 404 176 176 63 63 1.8 14
208 187 229 327 450 792 1064 1473 506 690 166 222 46 77 35
230 207 253 327 450 792 1064 1473 506 690 166 222 6.1 46 77 35
060 380 342 418 200 250 473 640 890 280 382 89 125 (6) 46 77 21
460 414 506 145 200 374 468 656 253 345 73 90 23 33 18
575 518 633 119 150 282 40.4 52.6 176 276 63 82 1.8 2.6 14
208 187 229 360 450 720 1100 728 506 345 166 106 66 35
230 207 253 347 450 720 1064 684 506 345 166 106 9.3 66 35
070 380 342 418 226 250 405 640 390 280 191 89 54 (6) 36 14
460 414 506 160 200 350 485 324 253 173 73 50 30 35
575 518 633 132 150 258 404 269 176 120 63 42 24 18 •

Italics denote 60-Hz export unit (not for sale in USA)

CB FCB FLA Hp ICF

- Circuit Breaker (Compressors)

- Fan Circuit Breaker

- Full Load Amps (Fan Motors)

- Horsepower

- Maximum Instantaneous Current Flow during starting (the

point in the starting sequence where the sum of the LRA for the starting compressor, plus the total RLA for all running compressors, plus the total FLA for all running fan motors is maximum)

- Total condenser fan motor power input

- Locked Rotor Amps

- Minimum Circuit Amps (for wire sizing) Complies with NEC

Section 430-24

kW LRA MCA

LEGEND

MOCP - Maximum Overcurrent Protective Device Amps MTA - Must Trip Amps (Circuit Breaker)

NEC - National Electrical Code

RLA - Rated Load Amps (Compressors)

'Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum

limits .

tNo 5 and 6 do not apply on 30GB040

tAil fan motors are protected by a single circuit breaker Fan motor power: 230-1-60 on 380 v units; unit volts - 1-60 on all other units

Table 5 - Electrical Data (50 Hz)

UNIT COMPRESSORS FAN MOT! RS
UNIT Volts RLA (ea) LRA (ea) Total MTA
30GB Supplied' MCA MOPA ICF Compressor No. CB No. Total FLA MTAt
(Fuse) kW (ea) (FCB)
Nameplate Min Max 1 2 1 2 1 2
040 87 110 220 36 36 173 173 50 50 2.4 2.7 14
046 112 150 307 36 53 173 253 50 73 2.4 4.5 18
050 129 175 333 53 53 253 253 73 73 3.7 4.5 4.5
400 342 440
055 151 200 412 53 68 253 345 73 95 6.0 2.1 2.1
1,2,3 1,2,3 1,2,3
070 186 225 372 53 253 73 60 21 21 5

at the compressor end as shown in Fig. 1. Field wiring connections are shown in Fig. 4. Also, refer to unit wiring diagrams.

All units may use copper, copper-clad aluminum or aluminum conductors at all voltages. Size 060 (208/ 230 v) requires copper conductors only. The maximum wire size accepted per terminal block is 500 MeM.

On 208-230/3/60 Units

30GB040,045,055,060 have one terminal block, with 3 conductors from the fused disconnect.

30GB070 has 2 terminal blocks and requires 6 parallel conductors from the fused disconnect.

r-----

I 11----

:: ,---

~J I I ~ _ _j 1

~--_j

o

~- -- -- -- -- ~ EQUIP GND

....J

ti!- - - - ~ NEUTRAL *380V AND 400V ONLY

30GB040-060

60 Hz: All Voltages 50 Hz 400 Volts

30GB070

60 Hz 380, 460, 575 Volts 50 Hz 400 Volts

*040, 045, 055 at 380 V 040, 046, 050 at 400 V 060 at 380 V

On 380/3/60 Units

30GB040,045,055,060 have one terminal block with 4

conductors from the fused disconnect. '

30GB070 has one terminal block, with 3 conductors from the fused disconnect.

On 460,575/3/60 Units

30GB040 through 070 have one terminal block, with 3 conductors from the fused disconnect.

1-Ir--- 11,_-

II ~_J II I~ E- ~=:!J

IIF Illl~ Il- "liIL

IlL-=-

I L - - -rn EQUIP GND

L__ -- -- ~EQUIP GND

30GB070

MAIN POWER

208 and 230 Volts 60 Hz

EQUIP GND

,-----[]QJ

<!l I

z I

1i: I r--~-_j I

a:: I

~ _J

o

~-,

.J I !:! I

1J.. I

I I I

L _

A - Alarm

CWFS - Chilled Water Flow Switch

CWP - Chilled Water Pump Starter Auxiliary

Contacts

TB - Terminal Block

NOTE. Remove ORN jumper between terminals 4and 5 on TB2 when installing interlocks

115-1-60 all 60 Hz units except 380 V

230-1-60: 60 Hz units, 380 V only

230-1-50 all 50 Hz units

REMOTE INTERLOCKS AND ALARM

\..AA"-I FIELD-SUPPLIED

r ~~~R~2,URCE

I I

I ~ REMOTE ON-OFF

I R RELAY

I (PIN HN6IKK025)

L -H-----J

REMOTE SWITCH

CONTACTS *

(FI ELD SUPPL lED)

0J2

o o o o o o o o o o o

13 14 o

o

o

o

o

o

o

o

o

®

REMOTE ON-OFF RELAY CONTACTS

FIELD WIRING

* CONNECTION BETWEEN PINS 13 AND 14 SHOULD BE CLOSED FOR UNIT

TO RUN,OPEN FOR UNIT TO BE

ON STANDBY

S9 REMOTE ON/OFF WIRING

t

CONTROL POWER

Fig. 4 - Field Wiring Connections

6

,

On 400/3/50 Units

300B040,046,050 have one terminal block, with 4 conductors from the fused disconnect.

300B055,070 have one terminal block, with 3 conductors from the fused disconnect.

Control Power - A separate single-phase power source must be provided for the control circuit, through a fieldsupplied fused disconnect; the conductor is copper-only. This is the only means of shutting off all the control circuit power, so the disconnect must be located at the unit. NEC Article 440-14 states that the disconnect must be located within sight from and readily accessible from the unit.

The control power entrance into the unit is through a 7/8-in. (22-mm) conduit connecti.on locat~d in. ~he corner post (see Fig. I). Refer to Fig. 4 for field wmng details.

U nits with a power supply of 208,230,460 an? 57.5 volts/3 phase/60 Hz have 115/1/60 control circuit power.

U nits with a power supply of 380 volts/ 3 phase/60 Hz or 400 volts/ J phase/50 Hz have 230/1/60 or 230/1/50 control circuit power.

Control circuit current draw is 15 amps for all units, 300B040-070.

A CAUTION



Crankcase heaters, cooler heaters and board heater are wired into the control circuit ahead of control circuit switch so they are always operable as long as the control circuit power supply disconnect is on, even if any safety device is open or the control circuit ON-OFF switch is off. Compressor heaters must be on for 24 hours prior to start-up of any compressor.

Control Circuit Interlocks - An interlock circuit for external devices is provided between terminals QJ and W on TB2. Remove the orange wire between the terminals when installing the device. Contact rating of the external device should be for pilot duty.

Refer to separate Controls and Troubleshooting publication for details on external interlocks.

I nstall Accessories

ELECTRICAL

Several electrical accessories are available to provide the following optional features (for details, refer to the Controls and Troubleshooting book):

• Additional stages of cylinder unloaders

• Demand limiting

• Space temperature reset

• Outside air temperature reset

• Return water reset

• External alarm

• Remote ON-OFF control

• Seven-day time clock

• Oil pressure switche~ " .

• Ground current refngerant circuit protection

WIND BAFFLES - If operating temperatures below 32 F (0° C) are expected, install wind baffles.

d •... '·

\;"

IMPORT ANT: Before beginning Pre-Start-Up or Start-Up, review Start-Up Che~klist f?r ~Iotronic Chiller Systems at center of this pubh~atlOn The Checklist assures proper start-up of a Unit, and provides a record of unit condition, application requirements, system information, and operation at initial start-up.

PRE-START-UP

Do not attempt to start chiller, even momentarily, until the following checks have been completed:

System Check

1. Check all auxiliary components such as chilled water circulating pump, air-handling equipment, or other equipment to which the chiller supplied liquid. Consult the manufacturer's instructions. Contacts for chilled water pump starter must be properly interlocked in the control circuit (see control circuit label diagram on unit or in Wiring Book). Do not use the cooler pump for on-off chiller control.

2. Backseat (open) compressor suction and discharge shutoff valves.

3. Open liquid line valves.

4. Fill chilled liquid circuit with clean water (with recommended inhibitor added) or other noncorrosive fluid to be cooled. Bleed all air out of high points of system (see Chilled Water Piping). If outdoor temperatures below 32 F (0° C) are anticipated, sufficient ethylene glycol should be added to the chilled liquid circuit to prevent freezing under those ambient conditions.

5. Check tightness of all electrical connections.

6. Compressor oil should be visible in sight glass.

Acceptable oil level is from 1/8 to 3/8 of compressor sight glass.

7. Electrical power source must agree with unit nameplate rating.

8. Crankcase heaters must be firmly locked into compressors, and must be on (or 24 hours prior to start-up.

9. Check compressor suspension. The compressors must be floating freely on the springs.

10. Perform Quick Test.

Quick Test (see Fig. 5 and Table 6) - Both main power and control circuit power must be on.

The Quick Test program utilizes the 2-digit LED display (Fig. 5) on the set point board to show status of all input and output signals to the microprocessor control. Display action and Quick Test procedure are described as follows:

The Quick Test is a 42-step program that provides a means of checking all input and output signals of the microprocessor control prior to unit start-up. This check ensures that all control options, thermistors and control switches are in proper working order.

To initiate the Quick Test program, first turn the unit control switch to the ON position. When a" appears in the display, immediately press the display button ollce. An. will appear in the display and the alarm light will be energized; this indicates that the microprocessor in the control system is ready to run the Quick Test program.

IMPORT ANT: Do not allow the unit control circuit to remain energized with" showing in the display for more than 2 minutes. If the display button is not pressed within this time, the control will attempt to start the unit.

For each step of the 42-step program, the display button must be pressed twice. On the first press, the step number is displayed; the second press initiates the r~quired action and the code as shown III Table 6 IS displayed.

(continued on page 12)

7

DISPLAY

DISPLAY BUTTON

DISPLAY BOARD CONNECTOR

EXV CONNECTOR

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.100000000001 zro

POTENTIOMETER CONNECTOR

CONNECTOR

TRANSFORMER CONNECTOR

*EPROM H7204247-1-( __ l

WARNING: Do not remove label covering EPROM. Removal results in program erasure.

NOTES:

1 Refer to Controls and Troubleshooting publication for details

2 Processor Board is inverted from position shown when installed in unit.

Fig. 5 - Center of Flotronic™ Control System

8

t

,

ct

Table 6 - Quick Test •

SECTION A. - Configuration and Switch Check

QUICK NORMAL
TEST DISPLAY STEP DESCRIPTION CONTROL SWITCH
STEP NO.
- • Type Unit - Air-Cooled Chiller Configuration Header
- _to. No. of Compressors Configuration Header
- .' • No. of Unloaders Dip Switches 6 and 7
or. • - Switches 6 and 7 off
• - Switch 6 on; Switch 7 off
• - Switch 6 off; Switch 7 on
- .or. • Standard Chiller (Switch off) Dip Switch 8
• Brine Chiller* (Switch on)
• • or. • = EXV; • = TXV Configuration Header
- BlorlB • = 50-Hertz Power Configuration Header
.. = 60-Hertz Power
- .or. • = External Reset (Switch off) Dip Switch 1
• = Return Water Reset (Switch on)
- .or. • = No Reset (Switch off) Dip Switch 2
• = Reset Used (Switch on)
- .or. • = Pulldown Not Used (Switch off) Dip Switch 3
• = Pulldown Used (Switch on)
- .or. • = Demand Limit Not Used (Switch off) Dip Switch 5
• = Demand Limit Used (Switch on)
- .or_ • = Remote On/Off (Not used or Switch Closed) S9 Jumper:j:
• = Remote On/Off (Switch Open)
- • • = Loss-of-Charge Switch Closed Circuit 1 Loss-of-Charge
• = Loss-of-Charge Switch Open Switch
- • • = Loss-of-Charge Switch Closed Circuit 2 Loss-of-Charge
• = Loss-of-Charge Switch Open Switch
• .t • = Low Oil Pressure Switch Closed Circuit 1 Low Oil Pressure
• = Low Oil Pressure Switch Open Switch
- .t • = Low Oil Pressure Switch Closed Circuit 2 Low Oil Pressure
.. = Low Oil Pressure Switch Open Switch *Do not change select switch to brine on units that do not have modifications for brine.

Special modifications are required. Contact Carrier for details.

tWill always display. for 30GB040-060 unless oil pressure switch (OPS) is installed. :j:Units with EPROM HT204247-1-12 only. See Fig. 5.

9

Table 6 - Quick Test" (cont)

SECTION B. - Thermistor and Potentiometer Checkout

QUICK NORMAL THERMISTOR OR
TEST DISPLAY STEP DESCRIPTION POTENTIOMETER
STEP NO.
.. - _- Thermistor OK Cooler Leaving Water
_ - Thermistor Faulty Thermistor
• - • - Thermistor OK Cooler Entering Water
_ - Thermistor Faulty Thermistor
.. - _ - Thermistor OK Condenser Thermistor,
_ - Thermistor Faulty Circuit 1
• - _ - Thermistor OK Condenser Thermistor,
_ - Thermistor Faulty Circuit 2
.. -* _ - Thermistor OK Cooler Thermistor,
_ - Thermistor Faulty Circuit 1
.. -* _ - Thermistor OK Cooler Thermistor,
_ - Thermistor Faulty Circuit 2
.. -* • - Thermistor OK Compressor Thermistor,
_ - Thermistor Faulty Circuit 1
.. -* _ - Thermistor OK Compressor Thermistor,
_ - Thermistor Faulty Circuit 2
.. .or • • - Thermistor OK Accessory Reset
_ - Thermistor Faulty or Not Used Thermistor
.. - • - Potentiometer OK Leaving Water Set Point
_ - Potentiometer Faulty Potentiometer
.. - Not Applicable -
.. .or_ -- Potentiometer OK Accessory Reset Limit
-- Potentiometer Faulty or Not Used Potentiometer
.. .or • -- Potentiometer OK Accessory Demand Limit
-- Potentiometer Faulty or Not Used Potentiometer(s)
.. .or_ .- Potentiometer OK Accessory Reset Ratio
-- Potentiometer Faulty or Not Used Potentiometer
• .or_ -- Potentiometer OK Accessory Reset Set Point
-- Potentiometer Faulty or Not Used Potentiometer *Display is • for Flotronic™ units only.

Display is • for FlOP units (with TXV).

10

Table 6 - Quick Test .. (cont)

SECTION C. - Output Relay Check

QUICK NORMAL
TEST DISPLAY STEP DESCRIPTION RELAY NO.
STEP NO .
• - Energize First Stage of Condenser Fans K11
(See Table 7)
.. - Energize Second Stage of Condenser Fans K12
(See Table 7)
III - Energize Liquid Line Solenoid, Circuit 1 K9
(FlOP)
.. - Energize Liquid Line Solenoid, Circuit 2 K10
(FlOP)
III - These steps energize compressors K1 through K8
through then. according to chart below for 10 seconds.
• then_ Display shows status of compressor board
feedback contacts:
• - Compressor Board off
• - Compressor Board on STEP NO.

UNIT 30GB

RELAY

3

U - Unloader

*These steps also turn on a condenser fan

(3.5 = FC1; 3.9 = FC2). +Accessory unloader.

NOTE: When unloader is energized, "0" will be displayed.

U2t

U2t

Table 7 - Condenser Fan Sequence

FAN FAN CONTROLLED BY FAN
NO. CONTACTOR During Normal ARRANGEMENT
Quick Test Control (O-Fan; D-Compressor)
1 FC1 35 CR1 @ CD [D*
2 FC2 39 CR2 30GB040,046
3,4 FC3 31 Microprocessor, Stage 1 ® @ m
1 FC1 35 CR1
2 FC2 39 CR2 ® @ CD [D* 30G B045, 050,
3,4 FC3 3.1 Microprocessor, Stage 1 ®®®[]] 055,060
5,6 FC4 3.2. Microprocessor, Stage 2
1,2 FC1 35 CPCS1 ®@CD ~
1,2 FC2 3.9. CPCS3
3,4 FC3 31 Microprocessor, Stage 1 m 30GB070
5,6 FC4 32 Microprocessor, Stage 2 ®®® [D* CPCS - Compressor Protection Control System

CR - Control Relay

FC - Fan Contactor

'Compressor with unloader

II

NOTE: The step number is a numeral followed by a decimal point (a 2-digit number has a decimal point after each numeral). The action code number is one or 2 digits with no decimal point(s).

IMPORT ANT: Once the Quick Test is initiated, the display button must be pressed at least once every 10 minutes for the control to remain in the Quick Test mode. If the button is not pressed within this time, the control will attempt to start the unit.

To recheck any step in the Quick Test, the control must be recycled by turning the unit control switch off for a few seconds, then on again. Restart the Quick Test program as described above and proceed through the Quick Test steps. Press the display button twice for each step until the step to be rechecked is reached.

The Quick Test program is divided into 3 sections as described below and shown in Table 6. For more detailed information, refer to the Controls and Troubleshooting publication.

A. QUICK TEST STEPS 15; UNIT CONFIGURATION

The microprocessor in the unit control system is programmed by 2 switch assemblies located on the processor board (Fig. 5). The configuration header is factory set and cannot be changed in the field. The dip switch assembly contains 8 microswitches that must be set in accordance with various options and accessories selected by the customer. As shipped from the factory, all dip switches except those controlling the pull-down option (switch no. 3) and the single unloader switch (switch no.6) are in the OFF position. All dip switches should be checked and set to the proper position for options selected during the Quick Test.

Dip switch functions and display codes are shown in Fig. 5 and in Table 8. Refer to the Controls and Troubleshooting publication for details.

Table 8 - Dip Switch Functions

DIP SWITCH NO.

Type of Reset Reset

Pull Down Limit Not Used Demand Limit

1 Unloader

2 Unloaders Brine

SELECTED FUNCTION

1 2 3 4 5 6 7 8

B. QUICK TEST STEPS 16-30; THERMISTORS AND SET POINT POTENTIOMETERS

In these steps, the microprocessor checks the resistance values of all sensors and set point potentiometers to ensure that they are functional, connected properly and set within the proper range for the unit configuration.

Nominal resistance values for all sensors range from 363,000 to 2 I 9 ohms in accordance with Table 9. Normal display code for good sensors and potentiometer is

_. Display code. indicates a faulty potentiometer, thermistor or wiring. A _ display also indicates the potentiometer or thermistor is not being used.

Tables 6 and 10 show set point potentiometer function location, and Quick Test display codes.

C. OUTPUT RELAYS, STEPS 31-42

These Quick Test steps allow the microprocessor to check the output signals from the relay boards in the unit control system. In addition, the operation of all condenser fans and compressors is checked at each step.

IMPORTANT: Normal display code for steps _ through" is _. In steps" through. ' each compressor is started and allowed to run for approximately I 0 seconds. At start-up,. will appear, followed by a _ in a few seconds. At the end of the lO-second test, code _ returns to the display indicating that the test step has been successfully completed. The code. indicated that the compressor protection circuit (CPCS) was tested.

Fan and compressor operating sequence for Quick Test steps _ through. are shown in Tables 6 and 7.

If Quick Test steps do not operate as described, a defect exists in one or more of the following: relay being tested; the electronic control; unit wiring. Refer to the Controls and Troubleshooting publication for additional information.

START-UP AND OPERATION

NOTE: Refer to Start-U p Check List at center of publication, which can be easily removed if necessary.

Digital Display Action - The electronic control system uses a 2-digit LED display located on the display set point board (see Fig. 5) to show operational information and diagnostic codes.

When the control ON-OFF switch is turned on, the display shows _ for 2 minutes to indicate the control is in the initialization mode. The electronic expansion valve will be closed as part of the initialization sequence. This does not occur on FlOP units, where a conventional thermostatic expansion valve is used.

After the 2-minute period, the display turns off and the unit is allowed to start. If the button is pressed after

the. has been removed from the display, operational status codes or diagnostic information will be shown as long as the button is held in. The code numbers on the display will have the following significance:

CODE NUMBER

0-12 20-24 51-87

OPERATIONAL STATUS

Capacity stage Operational information Overload information

Refer to the unit label diagram or the Controls and Troubleshooting book

Under normal operation, only the stage number will be displayed. If an operational status code or an overload code is displayed, the display will rotate every 2 seconds and will display up to 3 numbers. Overload information will take priority over all other codes and the alarm light will be energized The codes will be stored by the microprocessor as long as the board is energized.

IMPORT ANT: The memory is cleared when power is removed

12

START-UP CHECKLIST FOR FLOTRONIC CHILLER SYSTEMS (Remove and use for job file.)

A. Preliminary Information
JOB NAME
LOCATION
INSTALLING CONTRACTOR
DISTRIBUTOR
START-UP PERFORMED BY
EQUIPMENT: Chiller:
COMPRESSORS:
CIRCUIT#1
1) M#
S#
MTR#
2) M#
S#
MTR#
3) M#
S#
MTR#
4) M#
S#
MTR# MODEL# SERIAL# __

COOLER:

MODEL# __

SERIAL# __

TYPE OF EXPANSION VALVES (check one):

CIRCUIT#2
5) M#
S#
MTR#
6) M#
S#
MTR#
7) M#
S#
MTR#
8) M#
S#
MTR# MANUFACTURED BY __

DATE __

EXV _

TXV __

AIR HANDLING EQUIPMENT:

MANUFACTURER _

MODEL#

--------------------

ADDITIONAL AIR HANDLING UNITS AND ACCESSORIES __

SERIAL #

-----------------------------

IF SO, WHERE

-------------------

B. Preliminary Equipment Check (YES or NO) IS THERE ANY SHIPPING DAMAGE?

---------

WI LL TH IS DAMAGE PREVENT UN IT START-UP? _

ASSURE COMPRESSOR BASE RAIL ISOLATORS HAVE ALL BEEN PROPERLY ADJUSTED __

CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? _

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (relerto Installation Instructions) _

ARE THE POWER WIRESTOTHE UNITSIZEDAND INSTALLED PROPERLY? (relerto Installation Instructions) _

HAS THE GROUN D WI RE BEEN CONNECTED? _

ARE ALL TERM INALS TIG HT? _

CL-1

B. Preliminary Equipment Check (cont)

DOES THIS CHILLER REQUIRE CARRIER CERTIFICATION? _

IF SO, HAS THE CHILLER BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CHILLED WATER PUMP STARTER? 'IF NOT, DO NOT CERTIFY UNTIL INTERLOCK HAS BEEN PROPERLY CONNECTED. (REFER TO WIRING DIAGRAM).

ARE THERE ANY REASONS WHY THIS JOB SHOULD NOT BE CERTIFIED? IF SO, EXPLAIN: _

CHECK AIR SYSTEMS (YES or NO)

ARE ALL AIR HANDLERS OPERATING? (refer to air handling equipment Installation and Start-Up Instructions) _

ARE ALL CHILLED WATER VALVES OPEN? _

IS THE WATER PIPING CONNECTED PROPERLY? _

HAS ALL AIR BEEN VENTED FROM THE COOLER LOOP? _

IS THE CHILLED WATER PUMP OPERATING? _

IS THE CWP ROTATION CORRECT?

CWP MOTOR AMPERAGE:

Rated _

Actual _

C. Unit Start-Up (insert check mark as each item is completed)

ASSURE THAT UNIT IS SUPPLIED WITH CORRECT CONTROL VOLTAGE POWER.

~ __ 115 VOLTS (60 HERTZ UNITS)

___ '230 VOLTS (50 HERTZ UNITS)

*(Overseas Units Only)

ASSURE CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF 24 HOURS PRIOR TO START-UP.

ASSURE COMPRESSOR OIL LEVEL IS CORRECT. _

ASSURE BOTH LIQUID LINE SERVICE VALVES ARE BACKSEATED. _

ASSURE ALL COMPRESSOR DISCHARGE SERVICE VALVES ARE BACKSEATED

ASSURE ALL COMPRESSOR SUCTION SERVICE VALVES ARE BACKSEATED. _

REMOVE COMPRESSOR SHIPPING ISOLATOR LOCKNUTS.

_____ (75 THROUGH 200 SIZE) (40 THROUGH 70 SIZE)

ADJUST SNUBBER BOLTS

OPEN GAGE PANEL SERVICE VALVES. _

LEAK CHECK THOROUGHLY: ALL COMPRESSORS, CONDENSER MANIFOLDS AND HEADERS, EXV'S, SOLENOID VALVES, FILTER DRIERS, FUSIBLE PLUGS, THERMISTORS, AND COOLER HEADS, WITH G.E. H-10-B ELECTRONIC

~EAKDETECTOR. _

LOCATE, REPAIR, AND REPORT ANY R-22 LEAKS. _

CHECK VOLTAGE IMBALANCE:

AB _

BC _

________ VOLTS

AC _

AB + AC + BC (dividedby3) = AVERAGE VOLTAGE = MAXIMUM DEVIATION FROM AVERAGE VOLTAGE

VOLTAGE IMBALANCE = (MAX. DEVIATION) x 100 = % VOLTAGE IMBALANCE

AVERAGE VOLTAGE -------------

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER! CALL LOCAL POWER COMPANY FOR ASSISTANCE

ASSURE THAT INCOMING POWER VOLTAGE TO CHILLER IS WITHIN RATED UNIT VOLTAGE RANGE. _

SYSTEM WATER VOLUME IN LOOP: TYPE SYSTEM:

AIR CONDITIONING - MINIMUM 3 GALLONS PER NOMINAL TON = GALLONS

PROCESS COOLING - MINIMUM 6 GALLONS PER NOMINAL TON = GALLONS

CL-2

C. Unit Start-Up (cont)

CHECK PRESSURE DROP ACROSS COOLER.

WATER ENTERING COOLER: _

P.S.I.G.

WATER LEAVING COOLER: P.S.I G.

(P.S.I.G DIFFERENCE) x 2.31 = FEET OF WATER PRESSURE DROP = _

PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (LOCATED IN PRODUCT DATA DIGEST LITERATURE) TO DETERMINE TOTAL G.P M

TOTAL G.P.M. = _

G.PM PERTON = _

UNIT'S RATED MIN. G.P M = _

UNIT'S RATED MIN. PRESS DROP = _

(Refer to product data literature)

JOB'S SPECIFIED G.P.M. (if available) _

'IF UNIT HAS LOW WATER FLOW, FIND SOURCE OF PROBLEM: CHECK WATER PIPING, IN-LINE WATER STRAINER, SHUT-OFF VALVES, CWP ROTATION, ETC

COOLER LOOP PROTECTION IF REQUIRED:

GALLONS OF BRINE ADDED.

------------------

PIPING INCLUDES ELECTRIC TAPE HEATERS. _

VISUALLY CHECK PROCESSOR BOARD FOR THE FOLLOWING:

ASSURE ALL DIP SWITCHES ARE PROPERLY SET. _

INSPECT ALL THERMISTORS AND EXV CABLES FOR POSSIBLE CROSSED WIRES. _

INSPECT ALL RIBBON CABLES AND PIN CONNECTORS FOR TIGHTNESS. _

INSPECT RELAY BOARD AND DISPLAY SETPOINT BOARD CONNECTIONS FOR TIGHTNESS. __

CHECK DIP SWITCH POSITIONS:

ON OFF

ON

OFF

5 6 7 8

2 3 4

TO START THE CHILLER: (insert check mark as each item is completed)

TURN THE START/STOP SWITCH TO "START". _

THE SETPOINT BOARD'S "LED" SHOULD DISPLAY NUMBER "20" .. _

PUSH THE DISPLAY BUTTON ONCE TO ENTER THE QUICK TEST MODE _

SETPOINT BOARD SHOULD DISPLAY NUMBER "88". _

FOLLOW THE CONTROLS AND TROUBLESHOOTING QUICK TEST INSTRUCTIONS. BE SURE TO CHECK FOR PROPER FAN ROTATION ON QUICK TEST STEPS 3.1 AND 3.2.

QUICK TEST NUMBER READOUTS - INDICATE RESULTS BELOW:
STEPS # 8 15 22 29 36
2 9 16 23 30 37
3 10 17 24 31 38
4 11 18 25 32 39
5 12 19 26 33 40
((t 6 13 20 27 34 41
7 14 21 28 35 42 CL-3

c. Unit Start-Up (cont)

MEASURE THE FOLLOWING: MEASURE WHILE MACHINE IS IN STABLE OPERATING CONDITION

CIRCUIT#1

CIRCUIT#2

OIL PRESSURE P S.I G

SUCTION PRESSURE P S.I G

SUCTION LINE TEMP (F) _

DISCHARGE PRESSURE P.S.I G

DISCHARGE LINE TEMP (F)

-------------------------

P.S.I.G. P.S I.G

P.S I G.

TXV UNITS ONLY: CHECK AND ADJUST SUPERHEAT.

USING A DC VOLT-METER AND VOLTAGE VS. TEMPERATURE CHART: MEASURE THE VOLTAGE AT THE J-1 THERMISTOR CONNECTIONS ON THE PROCESSOR BOARD WHILE THE UNIT IS OPERATING INDICATE THE CORRESPONDING VOLTAGE AND TEMPERATURE FOR EACH THERMISTOR:

T-1 = VOLTS DC = F
T-2 = VOLTS DC = F
T-3 = VOLTS DC = F
T-4 = VOLTS DC = F
T-5 = VOLTS DC = F - SUCTION PRESSURE
T-6 = VOLTS DC = F - SUCTION PRESSURE
T-7 = VOLTS DC = F
T-8 = VOLTS DC = F
NOTES: Tab 5c

For replacemenillems use Carrier Specified Paris

Table 9 - Sensor Temperature vs Resistance/Voltage Drop

ENGLISH

DEG F OHMS VOLTS DEG F OHMS VOLTS DEG F OHMS VOLTS DEG F OHMS VOLTS
-25.0 98,0096 4.684 38.0 13,825.5 3373 101.0 2,8349 1500 164.0 7653 0527
-24.0 94,7071 4673 39.0 13,449.2 3343 102.0 2,7732 1476 165.0 7495 0518
-23.0 91,5215 4662 40.0 13,084.2 3312 103.0 2,7131 1.453 166.0 7342 0.509
-22.0 88,4489 4651 41.0 12,730.1 3281 104.0 2,654.7 1430 167.0 7192 0501
-21.0 85,4855 4640 42.0 12,386.6 3250 105.0 2,5978 1.407 168.0 7046 0493
-20.0 82,6272 4628 43.0 12,053.3 3219 106.0 2,5423 1385 169.0 6904 0484
-19.0 79,8706 4616 44.0 11,7300 3187 107.0 2,488.3 1.362 170.0 6766 0476
-18.0 77,2120 4604 45.0 11,4161 3156 108.0 2,4358 1.341 171.0 6633 0468
-17.0 74,647.9 4591 46.0 11,111 5 3124 109.0 2,3845 1319 172.0 6503 0461
-16.0 72,1751 4578 47.0 10,8158 3093 110.0 2,3346 1298 173.0 6377 0453
-15.0 69,7903 4565 48.0 10,5287 3061 111.0 2,2859 1277 174.0 6255 0446
-14.0 67,490.4 4551 49.0 10,2500 3029 112.0 2,2385 1.256 175.0 6138 0438
-13.0 65,272.4 4537 50.0 9,9793 2997 113.0 2,1922 1.236 176.0 6023 0431
-12.0 63,1333 4523 51.0 9,7165 2965 114.0 2,1470 1.216 177.0 5913 0424
-11.0 61,0703 4509 52.0 9,461 3 2933 115.0 2,1030 1 196 178.0 5807 0417
-10.0 59,0806 4494 53.0 9,2134 2901 116.0 2,0600 1 176 179.0 5703 0410
-9.0 57,1617 4479 54.0 8,9726 2869 117.0 2,0180 1 157 180.0 5605 0403
-8.0 55,3109 4463 55.0 8,7386 2837 118.0 1,977 0 1 138 181.0 5509 0397
-7.0 53,5258 4448 56.0 8,5114 2805 119.0 1,9369 1120 182.0 5417 0390
-6.0 51,8040 4431 57.0 8,2906 2772 120.0 1,8978 1101 183.0 5329 0384
-5.0 50,1432 4415 58.0 8,0761 2740 121.0 1,8595 1083 184.0 5244 0378
-4.0 48,541 1 4398 59.0 7,8677 2708 122.0 1,8221 1065 185.0 5162 0371
-3.0 46,9956 4381 60.0 7,6651 2676 123.0 1,7855 1048 186.0 5084 0365
-2.0 45,5047 4363 61.0 7,4683 2644 124.0 1,7497 1030 187.0 5008 0.360
-1.0 44,0663 4345 62.0 7,2771 2612 125.0 1,7147 1013 188.0 4936 0354
0.0 42,6785 4327 63.0 7,0912 2581 126.0 1,6804 0997 189.0 4865 0348
1.0 41,3393 4308 64.0 6,9106 2549 127.0 1,6468 0980 190.0 4799 0342
2.0 40,047.1 4289 65.0 6,735.1 2517 128.0 1,6138 0964 191.0 4734 0337
3.0 38,8000 4.270 66.0 6,5644 2486 129.0 1,5816 0.948 192.0 467.2 0332
4.0 37,5964 4250 67.0 6,3986 2454 130.0 1,5500 0.932 193.0 4612 0326
5.0 36,4347 4230 68.0 6,2375 2423 131.0 1,519 a 0917 194.0 455.6 0321
6.0 35,3133 4.209 69.0 6,0808 2391 132.0 1,4886 0902 195.0 450:0 0316
7.0 34,230 7 4.188 70.0 5,9286 2360 133.0 1,4588 0887 196.0 4445 0311
8.0 33,1854 4167 71.0 5,7806 2329 134.0 1,4296 0872 197.0 4392 0306
9.0 32,1762 4145 72.0 5,6368 2299 135.0 1,4009 0.857 198.0 4344 0301
10.0 31,2015 4123 73.0 5,497 a 2268 136.0 1,3727 0843 199.0 4292 0297
11.0 30,260 1 4101 74.0 5,361 2 2237 137.0 1,3451 0829 200.0 4241 0292
12.0 29,350 9 4 078 75.0 5,2291 2207 138.0 1,318 a 0815 201.0 419.4 0288
13.0 28,4725 -4 055 76.0 5,1008 2177 139.0 1,2913 0802 202.0 4146 0283
14.0 27,6238 4 032 77.0 4,9760 2147 140.0 1,2652 0.788 203.0 4102 0279
15.0 26,8037 4008 78.0 4,8548 2117 141.0 1,2395 0775 204.0 4053 0274
16.0 26,011 2 3984 79.0 4,7369 2088 142.0 1,2143 0762 205.0 4008 0270
17.0 25,2451 3959 80.0 4,6224 2058 143.0 1,1895 0750 206.0 396.2 0266
18.0 24,5046 3934 81.0 4,511 1 2029 144.0 1,1652 0.737 207.0 3912 0262
19.0 23,7887 3909 82.0 4,4029 2000 145.0 1,141 3 0.725 208.0 3864 0258
20.0 23,0964 3883 83.0 4,2977 1972 146.0 1,1178 0713 209.0 3816 0254
21.0 22,4269 3858 84.0 4,1955 1943 147.0 1,0948 0701 210.0 3767 0250
22.0 21,7793 3831 85.0 4,0961 1915 148.0 1,0722 0689 211.0 3716 0247
23.0 21,1528 3805 86.0 3,9996 1887 149.0 1,0499 0678 212.0 3661 0243
24.0 20,5467 3778 87.0 3,9057 1859 150.0 1,0281 0666 213.0 3607 0239
25.0 19,960.2 3751 88.0 3,8144 1832 151.0 1,0068 0655 214.0 3556 0236
26.0 19,3925 3723 89.0 3,7258 1805 152.0 9858 0644 215.0 3498 0232
27.0 18,8430 3696 90.0 3,6395 1778 153.0 9652 0634 216.0 3437 0229
28.0 18,3110 3668 91.0 3,5557 1751 154.0 9450 0623 217.0 3376 0225
29.0 17,7958 3639 92.0 3,4742 1725 155.0 9253 0613 218.0 3317 0222
30.0 17,2970 3.611 93.0 3,3950 1699 156.0 9059 0602 219.0 3250 0219
31.0 16,8138 3582 94.0 3,3180 1673 157.0 8870 o 5!l2 220.0 3184 0215
32.0 16,3457 3.553 95.0 3,2431 1.647 158.0 8683 0582 221.0 311 4 0212
33.0 15,8922 3523 96.0 3,1703 1622 159.0 8502 0573 222.0 3044 0209
34.0 15,4527 3494 97.0 3,0994 1597 160.0 8324 0563 223.0 2969 0206
35.0 15,0267 3464 98.0 3,0305 1572 161.0 8151 0554 224.0 2894 0203
36.0 14,6139 3,434 99.0 2,9635 1548 162.0 7981 0545 225.0 2821 0200
37.0 14,2136 3404 100.0 2,8984 1523 163.0 7815 0536
38.0 13,8255 3373 101.0 2,8349 1500 164.0 7653 0527 It

13

81 METRIC

Table 9 - Sensor Temperature vs Resistance/Voltage Drop (cont)

DEG C OHMS VOLTS DEG C OHMS VOLTS DEGC OHMS VOLTS DEGC OHMS VOLTS DEGC OHMS VOLTS
-32.0 1000490 4690 -4.0 200759 3756 24.0 52032 2201 52.0 16940 1003 80.0 602.4 0431
-31.5 970064 4680 -3.5 195608 3732 24.5 50881 2174 52.5 16635 0908 80.5 5924 0.425
-31.0 940608 4671 -3.0 190606 3707 25.0 49760 2147 53.0 16335 0974 81.0 5828 0.418
-30.5 91 2093 4661 -2.5 185748 3682 25.5 48668 2120 53.5 16041 0959 81.5 5734 0412
-30.0 88449.0 4651 -2.0 181029 3656 26.0 47602 2094 54.0 15752 0945 82.0 564.4 0406
-29.5 85777 0 4641 -1.5 17 644 5 3631 26.5 46564 2067 54.5 15469 0931 82.5 5557 0400
-29.0 831907 4630 -1.0 171991 3.605 27.0 45552 2041 55.0 15190 0917 83.0 5472 0394
-28.5 806871 4620 -0.5 167663 3579 27.5 44566 2015 55.5 14916 0903 83.5 5391 0388
-28.0 782639 4609 0.0 163457 3553 28.0 43604 1989 56.0 14647 0890 84.0 5312 0383
-27.5 759183 4597 0.5 159369 3526 28.5 42667 1963 56.5 14383 0876 84.5 5236 0377
-27.0 736480 4586 1.0 155395 3500 29.0 41754 1938 57.0 14123 0863 85.0 5162 0371
-26.5 714506 4574 1.5 151531 3473 29.5 40863 1912 57.5 13868 0850 85.5 5092 0366
-26.0 693237 4562 2.0 147775 3446 30.0 39996 1887 58.0 13616 0837 86.0 5023 0.361
-25.5 672650 4550 2.5 144122 3419 30.5 39150 1.862 58.5 13369 0825 86.5 4957 0355
-25.0 652724 4537 3.0 140569 3392 31.0 38325 1837 59.0 13126 0812 87.0 4894 0350
-24.5 633437 4525 3.5 137114 3364 31.5 37521 1813 59.5 12887 0800 87.5 4832 0345
-24.0 61 4769 4512 4.0 133753 3337 32.0 36737 1789 60.0 12652 0788 88.0 4774 0340
-23.5 596700 4499 4.5 130483 3309 32.5 35973 1764 60.5 12421 0776 88.5 4716 0335
-23.0 579209 4485 5.0 127301 3281 33.0 35229 1741 61.0 12193 0765 89.0 4661 0331
-22.5 562279 4471 5.5 124205 3253 33.5 34502 1717 61.5 11969 0753 89.5 4608 0326
-22.0 545891 4457 6.0 121192 3225 34.0 33794 1693 62.0 1 1748 0742 90.0 4556 0321
-21.5 530027 4443 6.5 118260 3197 34.5 33104 1670 62.5 1153.2 0731 90.5 4506 0317
-21.0 51 4670 4428 7.0 115405 3169 35.0 32431 1647 63.0 1 131 8 0720 91.0 4457 0312
-20.5 499804 4413 7.5 112627 3140 35.5 3177 5 1624 63.5 11109 0709 91.5 4409 0308
-20.0 48541 1 4398 8.0 109921 3112 36.0 31134 1602 64.0 10902 0698 92.0 4363 0303
-19.5 471477 4383 8.5 107288 3083 36.5 3051.0 1579 64.5 10699 0688 92.5 4318 0299
-19.0 457986 4367 9.0 104723 3054 37.0 2990.1 1557 65.0 10500 0678 93.0 4274 0295
-18.5 444924 4351 9.5 102226 3026 37.5 29307 1536 65.5 10303 0667 93.5 4230 0291
-18.0 432276 4334 10.0 99793 2997 38.0 2872 8 1 514 66.0 10110 0657 94.0 4188 0287
-17.5 420029 4318 10.5 97425 2968 38.5 28162 1492 66.5 9921 0648 94.5 4145 0283
-17.0 408169 4301 11.0 95117 2939 39.0 2761 1 1471 67.0 9734 0638 95.0 4103 0279
-15.5 396683 4283 11.5 92870 2911 39.5 27072 1450 67.5 9551 0628 95.5 4060 0275
-16.0 385559 4266 12.0 90680 2882 40.0 26547 1430 68.0 9371 0619 96.0 4018 0271
-15.5 374784 4248 12.5 88547 2853 40.5 26034 1409 68.5 9194 0609 96.5 3976 0267
-15.0 364347 4230 13.0 86469 2824 41.0 25533 1389 69.0 9021 0600 97.0 3933 0264
-14.5 354237 4211 13.5 84445 2795 41.5 25044 1369 69.5 8851 0591 97.5 3890 0260
,14.0 344442 4193 14.0 82472 2766 42.0 24566 1349 70.0 8684 0582 98.0 3847 0257
-13.5 334952 4174 14.5 80550 2737 42.5 24100 1330 70.5 8520 0574 98.5 3803 0253
-13.0 325756 4154 15.0 78677 2708 43.0 23644 1 311 71.0 8360 0565 99.0 3758 0250
-12.5 316846 4135 15.5 76851 2680 43.5 23199 1292 71.5 8202 0557 99.5 371 1 0246
-12.0 30821 0 4115 16.0 75072 2651 44.0 22763 1273 72.0 8048 0548 100.0 3665 0243
-11.5 299840 4094 16.5 73339 2622 44.5 22338 1254 72.5 7898 0540 100.5 3616 0240
-11.0 291727 4074 17.0 7164.9 2593 45.0 21922 1236 73.0 7750 0532 101.0 3567 0236
-10.5 283863 4053 17.5 70003 2565 45.5 2151.5 1 218 73.5 7606 0524 101.5 3515 0233
-10.0 276238 4032 18.0 68398 2536 46.0 21117 1200 74.0 7465 0516 102.0 3463 0230
-9.5 268844 4010 18.5 66834 2508 46.5 20728 1182 74.5 7326 0508 102.5 341 1 0227
-9.0 261675 3989 19.0 65309 2479 47.0 20347 1165 75.0 7192 0501 103.0 3353 0224
-8.5 254722 3967 19.5 63823 2451 47.5 19974 1148 75.5 7061 0493 103.5 3297 0221
-8.0 247978 3944 20.0 62375 2423 48.0 19609 1131 76.0 6933 0486 104.0 3238 0218
-7.5 241436 3922 20.5 60963 2395 48.5 19251 1 114 76.5 6808 0479 104.5 3179 0215
-7.0 235090 3899 21.0 59587 2367 49.0 18901 1098 17.0 6686 0.472 105.0 3116 0212
-6.5 228932 3876 21.5 58246 2.339 49.5 18557 1081 17.5 6568 0465 105.5 3053 0209
-6.0 222956 3852 22.0 56939 2311 50.0 1822.1 1065 78.0 6452 0458 106.0 2986 0206
-5.5 217157 3829 22.5 55664 2283 50.5 17891 1049 78.5 6340 0451 106.5 2921 0204
-5.0 211528 3805 23.0 54422 2256 51.0 17568 1034 79.0 6232 0444 107.0 2852 0201
-4.5 206064 3781 23.5 53212 2228 51.5 17251 1019 79.5 6126 0437
;-4.0 200759 3756 24.0 52032 2201 52.0 16940 1003 80.0 6024 0431 Table 10 - Potentiometer Locations

POTENTIOMETER

Set Point Board (Standard) Accessory Board (Option) Field-Supplied Option Accessory Board (Option) Accessory Board (Option)

LOCATION

Leaving Water Set Point Reset Limit Set Point Load Shed Input

Reset Ratio Set Point Reset Temperature

Actual Start-Up Actual start-up should be done onlv under supervision 0/ a qualified refrigeration mechanic.

I. Be sure all service valves are open.

2. Set leaving water temperature. No cooling range adjustment is necessary.

3. If accessory board or demand limit accessory are used, set potentiometers. Refer to the Controls and Troubleshooting book for details.

4. Turn ON-OFF switch to ON and wait 2 minutes for • to be removed from display.

5. Allow unit to operate and confirm that everything is functioning properly. Check to see that the leaving water temperature agrees with the dial setting on the set point board. If the temperature does not agree with the setting, the variation can be compensated by shifting the control point slightly If temperature reset is used, the actual water temperature may not agree with the leaving water set point.

Operating Limitations TEMPERATURES (See Table II)

Table 11 ~ Temperature Limits F (e)

DOMESTIC EXPORT
UNITS UNITS
Maximum Ambient Temp 115 ( 46) 125 ( 52)
Minimum Ambient Temp 0 (-18) 0 (-18)
Maximum Cooler EWT 95 ( 35) 112 ( 44)
Maximum Cooler LWT 70 ( 21) 70 ( 21)
Minimum Cooler LWT 40 ( 4) 40 ( 4) EWT - Entering Water Temp

LWT - t.eavinq Water temp

14

Table 12 - Minimum Cooler Flow Rate

NOMINAL COOLER WATER MINIMUM PRESSURE MINIMUM
UNIT FLOW RATE* PRESSURE DROP FLOW (1) DROP VOLUME (2)
30GB Gpm Lis It of water Lis Gpm Lis It of water kPa Gallons Liters
040 881 556 108 3.61 56 35 44 13.2 110 414
045 109.6 692 9.5 318 67 4.2 38 114 136 513
055 127.3 8.04 126 422 67 42 38 11 4 157 594
060 142.9 902 129 432 67 4.2 38 114 179 674
070 1666 1052 140 468 76 48 31 9.3 206 780 'Nominal flow rate is flow rate required for standard air conditioning units, 54 F (12.2 C) EWT, 44 F (66 C) LWT

NOTES

1 Minimum flow based on 1.5 fps (046 m/s) velocity in cooler without special cooler baffling.

2 Minimum Loop Volumes

Gallons = V x ARI Cap. (tons)

Liters = N x ARI Cap. (kW)

For operation with leaving water temperature above approximately 60 F (16 C), the expansion valves will limit the suction pressure to 90 psig (620 kPa) to avoid overloading the compressor (Flotronic and FlOP).

If operation below 32 F (O°C) ambient is expected, wind baffles are necessary.

If the unit is to be used in an area with high solar radiation, the mounted position should be such that the control box is not exposed to direct radiation.

For chillers specially modified for brine applications, the unit can operate down to 15 F (-9 C) brine temperature. For this application, only the Flotronic chiller is available, only on special order. Contact your Carrier distributor.

MINIMUM VOLUMES AND FLOW RATES - COOLER WATER LOOP - The cooler loop volume must be at least 3 gallons per nominal machine ton (3.2 liters per kW). Greater loop volumes tend to improve control stability and control accuracy. Table 12 shows the minimum cooler gpm (LI s).

VOLTAGE

Main Power Supply - The minimum and maximum acceptable supply voltages are listed in Tables 4 and 5.

Unbalanced 3-Phase Supply Voltage - Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the % voltage imbalance:

% Voltage Imbalance

max voltage deviation from average voltage = 100 x ---__:::.__------,------=-----=-average voltage

Example: Supply voltage is 240-3-60

ABC

~

AB = 243 volts BC = 236 volts AC = 238 volts

A verage Voltage =

243 + 236 + 238 3

717

= -3- = 239 volts

APPLICATION

325 65 65

V

N

Normal Air Conditioning Process Type Cooling

Low Ambient Unit Operation

3 6 6

Determine maximum deviation from average voltage: (AB) 243 - 239 = 4 volts

(BC) 239 - 236 = 3 volts

(AC) 239 - 238 = I volt

Maximum deviation is 4 volts. Determine % voltage imbalance.

4

% Voltage Imbalance = 100 x 239 = 1.7%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

Control Circuit Power - The electronic control includes logic to detect low control circuit voltage. The acceptable voltage range is shown in Table 13.

Table 13 - Control Circuit Voltage Range

CONTROL CIRCUIT POWER

104 127

207 254

198 254

VOLTS

Min Max

115-1-60 230-1-60 230-1-50

Operation Sequence - During the unit off cycle, the crankcase heaters are energized. If the ambient temperature is below 36 F (2 C), the cooler heaters and a microprocessor board heater are also energized.

When the control ON-OFF switch is turned to ON, the control first goes through a 2-minute initialization period, during which the display will continuously show

_. Ninety (90) seconds after the _leaves the display, the control begins to bring on compressors The rate at which the compressors are started depends on the leaving chilled water temperature and the rate of change of the leaving water temperature.

On standard units (one unloader), refrigerant circuit no. 1 is always first to start. With the addition of an accessory unloader, an automatic lead-lag feature in the control system determines by random selection either circuit 1 or 2 to start first.

At the first call for cooling, the microprocessor starts the first compressor, de-energizes the crankcase heater and starts one condenser fan.

15

FLOTRONIC UNITS - The electronic expansion valve (EXV) remains closed for 10 seconds to purge the cooler and suction line of any liquid refrigerant that may have migrated to these areas during the off period. After the 10 seconds, the expansion valve starts to open. As more cooling is required, the control brings on additional stages of capacity. The loading sequence for the compressors is shown in Table 14.

FlOP UNITS - The liquid line solenoid valve is not energized for the first 10 seconds of compressor operation. This is called the pre-pumpout cycle.

The microprocessor determines how rapidly capacity stages are added or subtracted, based on the deviation from the leaving chilled water temperature set point and the rate of change of the leaving water temperature. If the water temperature is very warm and the pull-down option is being used, the microprocessor limits the rate of temperature drop of the leaving water to 10 F (0.56 C) per minute to avoid high peak kW charges. If the capacity is being limited by pulldown, the control display shows

a • when the display button is pressed. FLOTRONIC UNITS - When the capacity is satisfied and a refrigerant circuit is to be shut down, the microprocessor closes the EXV. The compressor continues to run for 10 seconds to purge the cooler and suction line of liquid refrigerant, then stops.

FlOP UNITS - When a circuit is shut down, the liquid line solenoid is de-energized 10 seconds prior to the compressor stopping. This is called the pumpout cycle. The rest of the operation sequence is the same as the Flotronic units.

If the load shed option is being used, the control limits the maximum capacity to the load shed input value. Refer to the Controls and Troubleshooting publication for details. If capacity is limited by a load shed signal, the

display shows a .when the display button is pressed. FLOTRONIC AND FlOP UNITS - If temperature reset is being used, the microprocessor adjusts the lea v-

ing water temperature to obtain greater part-load efficiency. Refer to the Controls and Troubleshooting book for details. If the leaving water temperature is being

reset, the display shows a. when the display button is pressed.

FLOTRONIC UNITS - The microprocessor also controls the electronic expansion valve (EXV) to maintain a superheat of 20 F (11 C) entering the compressor cylinders. This is equivalent to 3 F to 5 F (2 C to 3 C) superheat leaving the cooler.

The microprocessor control also cycles condenser fans on and off to maintain an adequate pressure differential across the expansion valves. The fans are controlled by the position of the EXV. When the expansion valve is fully open, fan stages are removed; when the valve is approximately half open, fan stages are added. This method allows the unit to run at very low condensing temperatures at part load. Thus the chiller has very high part-load EER's. The fan sequence is shown in Table 7.

FlOP UNITS - Thermostat expansion valves, one for each refrigerant circuit are factory set to maintain 8 F - 10 F (4.4 C - 5.6 C) superheat of vapor leaving cooler to control flow of liquid refrigerant into the cooler. Superheat can be reset but should be done only if absolutely necessary.

The logic to cycle microprocessor-controlled fans is based on saturated condensing temperature only. This temperature is sensed by thermistors T3 and T4 (Fig. 9). The microprocessor will turn on an additional stage of fans when either of the coil thermistors (T3 or T 4) is greater than 113 F (45 C) and will turn off a fan stage when T3 and T4 are both below 73 F (23 C). Between each change in fan stage, the control will wait one minute to allow the head pressure to stabilize unless either T3 or T4 is greater than 125 F (52 C), in which case all microprocessor-controlled fans will come on immediately.

Condenser fan sequence is shown in Table 7.

Table 14 - Capacity Control Steps (Standard Units)

% OPERATING
UNIT CONTROL DISPLACEMENT No. of Comoressor No.
30GB STEPS (Approx) No. of
Compr Cyl Circuit 1 Circuit 2
1 250 1 2 1* -
040 2 500 1 4 1 -
3 750 2 6 l' 2
4 100.0 2 8 1 2
1 200 1 2 l' -
045, 2 400 1 4 1 -
046 3 800 2 8 1* 2
4 1000 2 10 1 2
050, 1 333 1 4 l' -
055, 2 500 1 6 1 -
060 3 83.3 2 10 1* 2
4 100.0 2 12 1 2
1 250 1 4 1* -
2 375 1 6 1 -
60 Hz 3 62.5 2 10 l' 3
070 4 750 2 12 1 3
5 875 3 14 1 *,2 3
6 100.0 3 16 1,2 3
1 22.2 1 4 l' -
2 333 1 6 1 -
50 Hz 3 55.6 2 10 1 * 3
070 4 667 2 12 1 3
5 889 3 16 1',2 3
6 100.0 3 18 1,2 3 'Compressor unloaded

16

DISCHARGE GAS THERMOSTAT

COMPRESSOR JUNCTION BOX

COMPRESSOR MOUNTING

MOUNTING PLATE

BASE CHANNEL

(30GB050 SHOWN) 30GB040,045,046,050,055,060

COMPRESSOR MOUNTING SPRING

COMPRESSOR NO 2

COMPRESSOR NO 3

30GB070

Fig. 6 - General View of Compressor End



17

SERVICE

ELECTRIC SHOCK HAZARD.

Turn off all power to unit before servicing. The ON-OFF switch on the control panel does not shut off control power; use the field disconnect.

Diagnostics and Troubleshooting - Refer to the Controls and Troubleshooting book.

Refrigerant Circuit

LEAK TESTING - All 30GB units are shipped with complete operating charge of refrigerant R-22 (see Tables 2 and 3) and should be under sufficient pressure to conduct a leak test. If there is no system pressure, admit refrigerant until a pressure is observed and then proceed to test for leaks. After leaks are repaired, the system must be dehydrated.

DEHYDRATION - Refer to the Carrier Standard Service Techniques Manual, Chapter I, Refrigerants, Sections 6 and 7 for details. Do not use the compressor to evacuate the system.

REFRIGERANT CHARGE (Refer to Tables 2 and 3)Immediately ahead of the filter drier in each circuit is a factory-installed liquid line service valve. On each valve is a 1/ 4-in. flare connection for charging liquid refrigerant.

Chargin~ with Unit Off and Evacuated - Close liquid line service valve before chargmg. Weigh in the charge shown on the unit nameplate (also in Tables 2 and 3). Open liquid line service valve; start unit and allow it to run several minutes fully loaded. Check for a clear sight glass. Be sure the clear condition is liquid and not vapor.

Charging with Unit Running - If charge is to be added whlle unit IS operating, It will be necessary to have all condenser fans and compressors on. It may be necessary to block the condenser coils at low ambient temperatures to raise the condensing pressure to approximately 280 psig (1931 kPa) in order to turn all the condenser fans on. Do not totally block a coil to do this. Randomly block all coils in uniform pattern. Charge each circuit until the sight glass shows clear liquid, then weigh in the amount over a clear sight glass as listed.

IMPORT ANT: When adjusting refrigerant charge, circulate water through the cooler continuously to prevent freezing. Do not overcharge and never charge liquid into the low-pressure side of the system.

Electronic Components

CONTROL COMPONENTS - The unit uses an advanced electronic control system that normally will not require service. For details on the controls refer to the Controls and Troubleshooting book.

Compressors - If the lead compressor on either refrigerant circuit on a Flotronic'" chiller becomes inoperative for any reason, the circuit is locked off and cannot be operated due to features built into the electronic control system. Do not attempt to bypass this compressor to force other compressors in the circuit to run.

OIL CHARGE (Refer to Tables 2 and 3) - All units are factory charged with oil. Observe oil level only during operation. Oil level in the compressor may vary from 1/8 to 3/8 of the sight glass.

When additional oil or a complete charge is required, use only Carrier-approved compressor oil.

Approved oils are:

Zerol 150 (Synthetic) Suniso 3GS

Capella WF-32

Do not reuse drained oil and do not use an)' oil that has

been exposed to atmosphere. .

Access for Servicing

COMPRESSOR SECTION - Hinged panels provide access to the compressor section. In this section are the compressors, filter driers (replaceable core), liquid line shutoff/ charging valves, moisture-liquid indicators and the expansion valves (on unit sizes 045,050,055 and 060). The expansion valves on 040,046 and 070 sizes are located at the opposite end of the unit (see Fig. 3). On 070 units only, the liquid line shutoff/ charging valves, filter driers, and moisture-liquid indicators are also at the opposite end.

Compressor Removal - Each compressor is mounted on a flanged plate which is mounted to the bottom of the compressor compartment with 4 bolts (Fig. 6). Disconnect the electric and refrigerant lines and all capillaries from the compressor, leaving the compressor mounted on the plate. Lift compressor and plate out of the unit. For servicing, leave compressor on plate unless a replacement is to be installed. In this case, mount the new compressor on the plate outside the unit and then reinstall (see Compressor Mounting). Secure the plate with the 4 bolts that were removed and reconnect the lines and capillaries.

CONDENSER FANS - Each fan is supported by a formed-wire mount bolted to the fan deck and covered with a wire guard. The exposed end of the fan motor shaft is protected from the weather by a rubber boot. If a fan motor must be removed for service or replacement, be sure the rubber boot is reinstalled and be sure the fan guard is in place before starting the unit. Figure 7 shows the proper position of the mounted fan. Fan motors have permanently lubricated bearings.

[(046,050)

RUBBER BOOT OVER HUB

f

RAIN SHIELD

50 Hz

RUBBER BOOT OVER HUB

::J

043" (040,045,055) (060 FANS 1,3,5)

t

225"(070)

::;r (060 FANS 2,4,6)

-l. TO HUB FACE

t

~

Fig. 7 - Condenser Fan Adjustment

18

UNIT CONTROL BOX - Above the compressor section, and covered by the same outer panels, is the unit control box. Two removable covers on the control box are attached with screws. Without removing these covers, the following items are accessible: compressor and fan circuit breakers, control circuit ON-OFF switch, convenience outlet, display set point board and alarm light, controller set point adjustment.

COOLER SECTION - Removable panels are provided at the back of the unit for access to the cooler section, located below the condenser fans. The front end of the cooler is accessible through the compressor section.

Cooler Freeze-Up Protection

COOLER HEATERS

Cooler Freeze-Up Protection - The cooler is wrapped with heater cables as shown in Fig. 8, which are wired through an ambient temperature switch set at 36 F (2 C). The entire cooler is covered with I layer of 31 4-in. (l9-mm) closed-cell insulation, applied over the heater cables. The heaters plus the insulation protects the cooler against low ambient temperature to 0° F (-18 C).

IMPORT ANT: If the unit is installed in an area where ambient temperatures fall below 32 F (0° C), it is recommended tha t ethylene glycol or other suita ble solution be used in the chilled-liquid circuit.

APPROXIMATELY 4"TO 5"(I02-127~mm) EACH HALF:

BETWEEN THE HEATER TAPE ONE COIL!040-070)

WINDINGS (TYP)

~ INSULATION

AT LEAST ONE TURN BETWEEN NOZZLE (TYP) SECURE CABLES TO

AND TUBE SHEET (BOTH ENDS) COOLER SHELL WITH TAPE

Fig. 8 - Cooler Heater Cables

CI

~ -
7- DU2
WHT-~
It
~,
-- '------
PL22-1
-<f-VIO ..... VIV VIO-*-VIO--VI07>-
115 VOLT

V~A
CHC (J15V CONT PWR) Fig. 9 - Wiring Schematic - Cooler Heaters

Servicing the Cooler - When the cooler heads and partition plates are removed, the tube sheets are exposed showing the ends of the tubes as seen in Fig. 10. Four tubes in the bundle are secured inside the cooler at

Fig. 10 - Tube Sheet

the baffles and cannot be removed. These are identified on the tube sheets by a drill mark horizontally adjacent to each of the 4 tubes (Fig. 10). If leakage occurs in any of these 4 tubes, plug the tube as described under Tube Plugging.

TUBE PLUGGING - A leaky tube(s) can be plugged until retubing can be done. The number of plugged tubes determines how soon the cooler must be retubed. If several tubes require plugging, check with your local Carrier representative to find out how the number and location will affect unit capacity.

Figure II shows an Elliott tube plug and a crosssectional view of a plug in place. Table 15 lists the components for plugging.

Use extreme care when installing plugs to prevent damaging the tube sheet sections between the holes.

Clean parts with Locquic "N" and apply a few drops of Loctite #75 to obtain a tight seal without using too much force to set the pin.

Usually plugs can be removed by heating the projecting end of the pin to approximately 100 F (540 C) and chilling quickly with water. Apply the heating flame to the side of the pin to prevent overheating the tube sheet.

RETUBING (See Table 15) - When retubing is to be done, obtain the service of qualified personnel, experienced in boiler maintenance and repair. Most standard procedures can be followed, except that for the tubes in the 30GB coolers, a 5% crush is recommended in setting torque (5/8-in. [15.87-mm] diameter tubes are used in the 30GB cooler).

Example:

a. Tube sheet hole diameter 0.630 in. (16.00 mm)

b. Tube 00 0.625 in. (15.87 mm)

c. Clearance (a minus b) 0.005 in. (0.13 mrn)

d. Tube 10 before rolling

(use Elliott tube gage) 0.549 in. (13.9 mm)

e. 5% of twice the wall thickness

(5% of b minus d) 0.004 in. (0.10 mm)

f. Tube ID after rolling

(c + d + e) 0.558 in. (14.2 mm)

NOTE: The tubes next to the gasket webs must be flush with the tube sheet (both ends).

19

TUBE SHEET

Ct::J(W

PIN RING

Fig. 11 - Elliott Tube Plug

Table 15 - Tubes and Plugs

UNIT 30GB 040,046 I 045,050, 1 070
055,060
TUBE DATA SPECIFICATIONS
Part No. 10HA50 1043 1 1053 1 1063
Length In. (mm) 745 (1892) I 855 (2172) 11095 (2781)
00 in. (mm) 0625 (159)
Wall Thickness, in. (mm)
Plain End 0038 (097 )
Finned Section 0025 (064')
COMPONENTS FOR PART NO.
PLUGGING
For Tubes
Brass Pin 853103-500t
Brass Ring 853002-559t
For Holes Without Tubes
Brass Pin 853103t
Brass Ring 853002-631 t
Loctlte No 75t
Locquic "N"t 'Check with thickness gage (23 gal

+Order directly from Elliott Company, Lagonda Operation, Springfield, Ohio.

tCa.n be obtained locally

COOLER HEAD INST ALLA nON

Gasket Preparation - When reassembling, use new gaskets. Compressed asbestos - neoprene gaskets (Carrier Material Specification ZAOO-24) are to be momentarily dipped in compressor break-in oil prior to assembly. Gaskets are not to be soaked in oil as gasket deterioration results. Dipped gaskets are to be used within 30 minutes to prevent deterioration.

Bolt Torques - The following torques are to be applied during the bolt tightening sequence:

5/8-in. diameter flange bolts 150- I 70 Ib-ft

(203-230 N-m) 1/2-in. diameter center stud nuts and

1/2-in. diameter flange bolts 70-90 Ib-ft

(95-122 N-m)

Bolt Tif;htening - The following is a recommended bolt tightening sequence:

~ - Tighten moderately (without torquing) all the flange bolts in the sequence shown in Fig. 12.

Step 2 - Tighten moderately (without torquing) the hex nuts on the center studs (no specified sequence).

TOP

Fig. 12 - Tightening Sequence, Cooler Head Bolts

Step 3 - Repeat Step I, tightening the bolts to the specIfied torque.

Step 4 - Repeat Step 2, tightening the nuts to the specified torque.

Step 5 - Not less than one hour later, retighten the center stud nuts to the specified torque.

Refrigerant Feed Components - Each circuit has all the necessary refrigerant controls.

ELECTRONIC EXPANSION VALVE (EXV) - The Flotronic™ chiller is equipped with the new Carrierdesigned electronic expansion valve (EXV). A cutaway drawing of the valve is shown in Fig. 13.



--- OUT

3 - LEAD SCREW 2 -PISTON

I - ORIFICE ASSEMBLY

Fig. 13 - Electronic Expansion Valve

The high-pressure liquid refrigerant enters the valve through the bottom. A series of calibrated slots have been machined in the side of the orifice assembly. As the refrigerant passes through the orifice, the pressure drops and the refrigerant changes to a 2-phase condition (liquid and vapor). To control the refrigerant flow for different operating conditions, the piston moves up and down over the orifice and modulates the orifice size. The piston is moved by a linear stepper motor. The stepper motor moves in increments and is controlled directly by the processor board. As the stepper motor rotates, the motion is transferred into linear movement by the lead screw. Through the stepper motor and lead screw, 760 discrete steps of motion are obtained. The large number of steps and the long stroke results in very accurate control of the refrigerant flow.

Control of the valve is by the microprocessor. Two thermistor temperature sensors are used to determine superheat. One thermistor is located in the cooler and the other is located in the passage between the compressor motor and the cylinders. The difference between the 2 temperatures controls the superheat. On a normal TXV system, the superheat leaving the evaporator is normally IO F (5.6 C) and the motor then adds approximately 15 F (8 C), resulting in approximately 30 F (16.7 C) superheat entering the cylinders. The EXV controls the superheat entering the cylinders to approximately 20 F (1 I C). Thus the superheat leaving the cooler is approximately 3 F to 5 F (2 C to 3 C).

20

'1

'.'

~/

Because the EXV's are controlled by the processor board, it is possible to track the valve position. By this means, head pressure is controlled and the unit is protected against loss of charge and a faulty valve. During initial start-up, the EXV is fully closed.

After the initialization period, the valve position is tracked by the processor by constantly observing the amount of valve movement.

The EXV is also used to limit the cooler suction temperature to 55 F (13 C). This makes it possible for the chiller to start at high cooler water temperatures without overloading the compressor. This is commonly referred to as MOP (maximum operating pressure).

Servicing the EXV - For procedures on troubleshooting, refer to the Controls and Troubleshooting book. If the valve is to be replaced, wrap the valve with a wet cloth to prevent excessive heat from damaging internal components. The superheat control built into the valve is not adjustable.

THERMOSTATIC EXPANSION VALVE (TXV) - The FlOP chiller is equipped with the conventional thermostatic expansion valve, one per circuit. This control system necessitates the use of a liquid line solenoid valve. The TXV is factory set to maintain 8 F to 10 F (4.4 C to 5.6 C) superheat of vapor leaving the cooler by controlling flow of refrigerant into the cooler. Superheat can be reset but should be done only if absolutelv necessary.

When the TXV is used, thermistors T5, T6, T7, T8 are eliminated (see Fig. 14).

MOISTURE-LIQUID INDICATOR - Clear flow of liquid refrigerant indicates sufficient charge in the system. Bubbles indicate undercharged system or presence of noncondensables. Moisture in the system measured in parts per million (ppm), changes color of indicator:

Green - moisture is below 45 ppm; chartreuse (caution) - 45 to 130 ppm; vellow (wet) above 130 ppm. Change filter drier cores at first sign of moisture in the system

IMPORTANT: Unit must be in operation at least 12 hours before moisture indicator can give an accurate reading. With unit running, indicating element must be in contact with liquid refrigerant to give true reading.

FILTER DRIER - Whenever the moisture-liquid indicator shows presence of moisture, replace filter drier core(s) per table below. Refer to Carrier Standard Service Techniques Manual, Chapter I, Refrigerants, for details on servicing filter driers.

30GB CORES/DRIER
Ckt 1 Ckt 2
040-060 1 1
070 2 1 LIQUID LINE SOLENOID VALVE - On FlOP units (with TXV) a liquid line solenoid valve is used to prevent liquid refrigerant migration to the low side of the system.

LIQUID LINE SERVICE VALVE - This valve is located immediately ahead of the filter drier, provided with a 1/ 4-in. flare connection for field charging. In combination with the compressor discharge service valve, each circuit can be pumped down into the high side.

Thermistors - The electronic control uses 9 thermistors to sense temperatures. These sensors are for:

I. Cooler leaving water temperature.

2. Cooler entering water temperature.

3. Saturated condensing temperature, circuit I.

4. Saturated condensing temperature, circuit 2. *5. Cooler saturation temperature, circuit I.

*6. Cooler saturation temperature, circuit 2.

*7. Compressor return gas temperature, circuit I. *8. Compressor return gas temperature, circuit 2.

9. Accessory reset-space or outside air sensor. * U sed only on Flotronic™ units

The general locations are shown in Fig. 14.

All thermistors are identical in the temperature vs resistance and voltage drop characteristics. Resistance and voltage drop at various temperatures are listed in Table 9. Refer to Controls and Troubleshooting book and service bulletins for proper use of data.

COOLER LEAVING WATER SENSOR - This thermistor is located in the leaving water nozzle. The probe is immersed directly in the water. Connection is made through a I/4-in. coupling (Fig. 15). Actual location is shown in Fig. 14.

COOLER ENTERING WATER SENSOR - This thermistor is located in the cooler shell in the first baffle space, in close proximity to the tube bundle. The 1/ 4-in. coupling is used (Fig. 15). Actual location is shown in Fig. 14.

SATURATED CONDENSING TEMPERATURE SENSORS - These thermistors are each clamped to the outside of a return bend on the condenser coil. Exact locations for all units are shown in Fig. 14.

COOLER SATURATION TEMPERATURE SENSORS (Only on Flotronic™ units) - These thermistors are located next to the refrigerant inlet in the cooler head. The 1/ 4-in. coupling is used (Fig. IS). Typical location is shown in Fig. 14.

COMPRESSOR RETURN GAS TEMPERATURE SENSORS (Only on Flotronic™ units) - These thermistors are located in the lead compressor in each circuit in a suction passage between the motor and the cylinders, above the oil pump The I /4-in. coupling is used (Fig. 15). Location is shown in Fig. 14.

RESET SENSOR - This is an accessory thermistor, mounted remotely from the unit. Refer to the Controls and Troubleshooting book for further information.

SENSOR REPLACEMENT (Compressor and Cooler)

A CAUTION

The sensors are installed directly in the refrigerant or water circuit. Relieve all refrigerant pressure or drain water before removing.

Proceed as follows (refer to Fig. 15).

I. Remove and discard original sensor and coupling.

IMPORTANT Do not disassemble new coupling. Install as received.

2. Apply pipe sealant to 1/ 4-in. NPT threads on replacement coupling and install in place of original. Do not use packing nut to tighten coupling; this would damage the ferrules

3. Insert new sensor in coupling body to its full depth Hand tighten packing nut to position ferrules, then finish tightening 1-1/4 turns with a suitable tool. The ferrules are now attached to the sensor, which can be withdrawn from the coupling for unit servicing.

21

SENSOR LOCATION ON RETURN BEND

o 0<::::::'

+ +-t t /+ + +

RH UPPER COIL

16th TUBE FROM BOTTOM OF UPPER

COIL 130GB0701

SENSOR LOCATION ON RETURN BEND

22nd TUBE FROM BOTTOM ON 055,060

LH COIL

130GB055,060 I

+ RH COIL

LH COIL

SENSOR LOCATION ON RETURN BEND

31 st TUBE ON 045 } 32 nd TUBE ON 050 FROM BOTTOM OF COIL

130GB045, 0501

RH COIL

SENSOR LOCATION ON RETURN BEND

LH COIL

130GB040, 0461

RH COIL

'~

T5 a T6*

ENTER REFRIGERANT 30GB040, 046,070 ONLY

@ SENSOR LOCATION ON RETURN BEND



23rd TUBE FROM BOTTOM OF COIL

22ndTUBE FROM BOTTOM OF COIL

Ie-- 3-0-GB-0-60~1

o

Compressor End - Headers Removed CONDENSER COILS

COMPRESSOR SENSOR

(T7 8rT8)*

COMPRESSOR END

I

SUCTION

T2 ENTERING WATER

,

ENTER REFRIGERANT 30GB045,050, 055,060

~ T5 a T6*

THERMISTOR CODE

DESCRIPTION

T1 Leaving Cooler Water

T2 Entering Cooler Water

T3 Saturated Condensing Temp. (Ckt 1)

T4 Saturated Condensing Temp (Ckt 2)

T5* Saturated Suction Temp (Ckt 1)

TS* Saturated Suction Temp (Ckt 2)

T7* Superheated Gas Entering Cylinder (Ckt 1)

TS* Superheated Gas Entering Cylinder (Ckt 2)

*Flotronic™ chillers only.

Fig. 14 - Sensor Locations; 30GB040-070

22

•'

,



I

FERRULES INSIDE

COUPLING ASSEMBLY

Fig. 15 - Thermistor (Compressor and Cooler)

COUPLING BODY

Safety Devices - The chillers contain many safety devices and protection logic built into the electronic control, The following is a brief summary of the major safeties. For complete details refer to the Controls and Troubleshooting book.

COMPRESSOR PROTECTION

Circuit Breaker - One manual reset calibrated trip magnetic circuit breaker for each compressor protects against overcurrent. Do not bypass or increase size of a breaker to correct problems. Determine the cause for the trouble and correct before resetting the breaker. Circuit breaker must trip amps (MT A) are listed in Tables 4 and 5.

Compressor Protection Board (CPCS) - This is standard on 30G B070 units and accessory on 30GB040 through 060 units

On 30GB040-060 units; a control relay is used in place of the CPCS board, which performs the same functions as the CPCS board except it does not provide ground current refrigerant circuit protection.

The CPCS board is used to control and protect the compressors and crankcase heaters, providing the following features:

• Compressor contactor control

• Crankcase heater control

• Ground current protection

• Status communication to processor board

• High-pressure protection

• Discharge gas temperature protection

One large relay is located on the CPCS board that controls the crankcase heater and compressor contactor; also, the relay provides a set of 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 feedback contacts, the control locks the compressor off.

The board contains logic that can detect if the currentto-ground of any winding exceeds 2.5 amps; if so, the compressor shuts down.

A high-pressure switch is mounted on each compressor, the switch setting is shown in Table 16. The switch is wired in series with the CPCS board or control relay. If the switch opens, the CPCS relay, or control relay, opens and the processor detects it through feedback contacts; the compressor locks off.

Table 16 - Pressure Switch Settings, psig (kPa)

SWITCH CUTOUT CUT-IN
High Pressure 298 ± 20 (2055 ± 138)
Domestic 395 ± 10 (2724 ± 69)
Export 426 ± 7 (2937 ± 48) 320 ± 20 (2206 ± 138)
Loss-ot-Charge 5 (345) 21 (1448) A discharge gas thermostat (DGT) mounted in the center head of the compressor detects excessive discharge gas temperatures. The DGT is set to trip at 295 ± 5 F (146 ± 3 C) and to reset at minimum 235 F (113 C). The switch is wired in series with the CPCS board and when it opens, the compressor stops.

LOW OIL PRESSURE PROTECTION (Standard on 30GB070; accessory for 30GB040-060) - The lead compressor in each circuit is equipped with a switch to detect low oil pressure. The switch is connected directly to the processor board. The switch is set to open at approximately 5 psig (35 kPa) and to close at 9 psig (62 kPa) maximum. If the switch opens when the compressor is running, the processor board stops all compressors in the circuit. During start-up, the switch is bypassed for 60 seconds.

CRANKCASE HEATERS - Each compressor has a 200-watt crankcase heater to prevent absorption ofliquid refrigerant by oil in the crankcase when the compressor is not running. The heater power source is the auxiliary control power, independent of the main unit power. This assures compressor protection even when the main unit power disconnect switch is off.

IMPORT ANT: Never open any switch or disconnect that de-energizes the crankcase heaters unless the unit is being serviced or is to be shut down for a prolonged period. After a prolonged shutdown or a service job, energize the crankcase heaters for 24 hours before starting the unit.

COOLER PROTECTION

Freeze Protection - Refer to Cooler Heaters, under Cooler Freeze-Up Protection.

23

Low Water Temperature - The microprocessor is programmed to shut the chiller down if leaving water temperature drops below 35 F (1.7 C). When the water temperature rises 6 F (3.3 C) above the leaving water set point, the safety resets and chiller restarts.

No-Flow Protection - The microprocessor contains internal logic that protects the cooler against loss of cooler flow. The entering and leaving water temperature sensors in the cooler detect a no-flow condition. The leaving sensor is located in the leaving water nozzle and the entering sensor is located in the first cooler baffle space in close proximity to the cooler tubes, as shown in Fig. 14. When there is no cooler flow and the compressors start, the leaving water temperature does not change. However, the entering water temperature drops rapidly as refrigerant enters the cooler through the expansion valve. The entering sensor detects this temperature drop and when the entering temperature is 5 F (2.8 C) below the leaving temperature the unit stops and is locked off.

Loss-of-Charge - A pressure switch connected to the high side of each refrigerant circuit protects against total loss-of-charge. The switch settings are listed in Table 16. If the switch is open, the unit cannot start; if it opens during operation, the unit locks out and cannot restart until the switch is closed.

Relief Devices - Fusible plugs are located in each circuit to protect against damage from excessive pressures.

HIGH-SIDE PROTECTION - One device is located between the condenser and the filter drier; a second is on the filter drier. These are both designed to relieve on a temperature rise to approximately 210 F (99 C).

LOW -SIDE PROTECTION - A device is located on the suction line, designed to relieve on a temperature rise to approximately 170 F (77 C).

Other Safeties - There are several other safeties that are provided by the microprocessor control. For details on these, refer to Controls and Troubleshooting book.

Tab 5c

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

Book 2 PC 111 Catalog No 533-001 Printed in USA Form 30GB-35SIM Pg 24 2-89 Replaces: 30GB-31SIM

For replacemenl Items use Carrier Specilled Paris.