=> 30GB040-200 (50/60 Hz) Low-Ambient Operation/Motormaster® Control Installation Instructions INTRODUCTION AIL 30GB Flotronic chillers (either with Carrier elee- tronic expansion valve or with factory-option thermal expansion valve) will operate at ambient temperatures down to 32 F (0°C) without modification. ‘The modifications described in this book are required {0 operate these chillers at ambient temperatures below ve Table 2, APPLICATION NOTES Antifreeze approved for chiller use must be added to the cooler water loop to protect it to temperatures 1S F (8C) below the lowest expected outdoor temperature. To minimize compressor cycling, provide sufficient volume in the chilled water loop, even if it meansaddinga properly baffled storage tank to the system. At least 6 gallons per ton (6.5 liters per kW) of refrigeration is recommended minimum provided there is @ moderate system load PTs ‘Operation at low ambient is not recommended if the minimum load on chiller is below its minimum step of capacity. See Table 1 Table 1 — Minimum Capacity Step NIT TaINIMUM CAPACITY 3008 (eH FULL LOAD) 040 2 ons 20 os 20 050 33 055, 060 33 070 (60 H2) 25 07050 H2) 22 os 22 080 22 090 7 100 ” 10 18 125 7 150 1" ws 4 200 3 With field-instaled accessory unionder NOTE: Unioaders should not pe added to 30GB040-070, BoGei7S or S0GH200 units to reduce minimum capacity step’ Unloading below minimum capacity step could cause ol raturn problems ang reduce unt raliabilty 30GB Product Data for additional information, Winter Start — All 30GB Flotronie chillers have winter start features included in their microprocessor control logic. No additional provisions are necessary. genta ony tne, specications or cexgrs Table 2 — Changes Required for Low-Ambic ‘Operation nt '30G6000-200 FLOTRONIC CHILLER. Oureoda With Elecronte [With Thermal ‘Expansion xpansion eames |e vatve (ORV) vvaive (Option) Down ae No changes: No changes: ‘a2F (O"C) Down to 1 Al 4.2.3, OF (790) OF (-17-8¢) Down to, All 1,2,3, A 1,2,8 SF (880) NOTE: Unit operation below -20 (-28 8 G) not recommended Required changes: ‘Step 1 — Add feld-fabricated wind battles Step 2 — Nodity lead tans (s00 Fig. 3 and Table 3) Change 2 lead fan motors (per Table’) ‘da’? capacitors (per Table.) ‘Change 2 load fan blades (80GB075-200 unit) Step — Ada Motormaster® control(s) ‘Add Special transtormer for 575-volt units REQUIRED CHANGES. Step 1 — Wind Baffles must be field fabricated for 30GB units to operate at low-ambient temperatures, Construct 2 baffles, one for each side, to cover coil areas: 30GB040.070 — Figure 1 shows one-piece baffle that can be field fabricated for these units. Make baffles out of L8-gage (I.4-mm) minimum galvanized sheet metal or similar weather-resistant material, | “TOP IEW '(857) MIN CROSS BREAK eainal i 1 e0; | \ exes \ aaee are hi ae [-—.5——] E eresear ae [eee tease [te Smteon FHT ea ey Tee ae aE ea] GSS [oe Fig. 1 — Wind Baffles — 30GB040-070 marnetice snd wihout incurring oohgetone Pet 267 ‘Replaces: 208-2251 Forn30GB.29S1TYPICAL WIND BAFFLE INSTALLATION eracéeT "pane, . (Sree redo 2150) panel EACH Si0€) EACH Sie) OVERLAP PANEL BRACKET © o use f-20 te) FASTENERS FOR MOUNTING BRACKETS AND PANELS DIMENSIONS — in. (mm) UNIT] NO. OF PANELS | NO. OF BRACKETS | __, B c 2068 REQUIRED REQUIRED. 075,080 Z 3 Tae (eaz)_| OSM (BOTS) _| 10S (276) ‘090-100 4 70 = ay (1873)_| 74% (1899) 710,125 CKtT 2 a Tae ee | TosK (2573) [709 (2769) 310,125 cKt2 2 6 = 97-1758) | 73. (1854) 150-200 2 76 Tam (va4a)_[ 705% (2079) | 109-2709), (0.30 (7.0) HOLES 43eA@_ 8" (203)= 32" (812) 14 + 5 4 toes | 1 * : |i Lu : 4 3¥'09-+| Laczieendl & ae) — PANELS 43" (092) 4y0183 03078) ee re ; SyoLes 02018) HH tev ercs 2 Fe ey ws) ae t a * oe fo] 458, @ 8! (203) 7 212) a (3) TIAL BRACKETS Lo Fig. 2 — Wind Baffles — 30GB075-200 WELD TwPICALLY Stacks 2OOO@|s} [OOOH] [OOOO] | |k}QOO ggg fen LEGEND: || MOTORMASTER LOCATION ,2,7-LEAD FAN LOCATIONS Puaw view - Fig. 8 — Lead Fan and Motormaster® Locations > Table 3 — Lead Fan Modifications Tart onrTwaeecaTe] _oWaeR REPLACEWENT Soda [NTSEMREET"| ectineD | ota —[ caper [Fan Base eon | meas} | rene a Se mmo | —2 | serena | noose [nn 0 a [ cszveseo | Hosanieo_| NF 20 “0 =| weawesse | nn a wae 50_| ——t00 [reaver | — nn NE tsenre-| 0 eSeYEsoT [wosbasoa | — ne sso0_| "#75 rewvser | nosoeema?_{ Nn 8 oE ‘pearrenss | resssenss-| Wi S07 [aH HOSETED | Hsoapite | CAPTUAGRS it eSavEte-| nesosaaey-{ Cant aa 20 | iesrreser | wesoaanae-[ canteens a8 ep reazreaie | renoneno-| oreo INR — Replacement part not required. Use existing capacitors or fan blades (Fan ¥ and Fan 2) *20GB0%0 and 3068100 require 2 Motorm ter controls, but only one set of fan replacement parts (or Fan No 1, PM). Two relays must be added To contol circut (see Fig 32) 30GBO75-200 — Figure 2 shows a built-up baffle installa~ tion using field-fabricated brackets and panels for the larger size units (30GB090,100 shown). Make the number and sizes of brackets and panels as shown in the table on Fig. 2. Use 20-gage (I-mm) minimum galvanized sheet metal, or similar weather-resistant material for the panels and 16-gage (1.6-mm) minimum galvanized sheet metal for the brackets, Use field-supplied fasteners to attach baffles to unit, Fasteners should be 1/4 in, (63 mm) or larger diameter. Drill holes to suit. Use extreme care when drilling and screwing in fasteners to avoid damage to refrigerant coils and electrical components Check application, Table 2, for Steps 2 and 3 (049-0800 remuacon on EP TSS am) Sven me prro-soot wn) KT ag wsr20m = Tro we nce Fig. 4 — Motormaster Fan Adjustment (60 H2) (ot 050 (0401 oa Ff t03ea 2 080m) pose Table 4 — Motormaster Application ea) C & F eree Tar s068 WOTORMASTER AND 7 Mawestere | Noronmasren | MnemMee acy own nice “poz seo | Gactoonco, | — anzsos.e0 onan” | Satrsoos- Beas pan 0 S30" 51 ee SALTBOOD 0-180 i Serene oo8 Fig. 6 — Motormaster Fan Adjustment (60 H2) May require addition of a neutral terminal bosea (Carrier Part No HVHUASTS), Cheek Motormaster Power Wiring Diagram ‘Requires special vanslormer (Carrier Part No HTOTAH4) or ‘each Motormaster contral Step 2 — Modify Lead Fans — Change lead fan motors, add capacitors, and change lead fan blades as shown in Table 3. The lead fan motors are those shown numbered (I and 2 or 7) in Fig. 3. Each fan motor is supported by a formed-wire mount bolted to the fan deck and covered with a wire guard, Exposed end of the motor shaft is protected from the weather by a rubber boot or by Permagum sealant. If 2 fan motor is replaced, be sure rubber boot or sealant is reinstalled and fan guard isin place before leaving unit, Figures 4 and 5 show proper position of fan blade in orificeMOUNT ON BULKHEAD 'BEKIND CONTROL. BOX al he MOTORMASTER #2 3068090,100 ONLY woToRMaSTER 41 Fig. 6 — Typical Motormaster® Control Loc 30GB040-070 nTRoLs| COG! OCOOk PLAN VIEW 2068040-070 woTorwasteR #2 3060075, cal OO0®@ OOO ‘AN VIEW 8068075.080 ‘CONTROLS: O0OCO CONTROLS OOOO Ne PLAN VIEW 3068030,100 (FM! ONLY? JOOO, JO 1OOOh 10 PCAN VIEW 3068110-200 “IN CENTER SECTION ON 306B110-200; (MOTORMASTER /#2 OPPOSITE) SEE PLAN VIEW. Fig. 7 — Typical Motormaster Control Location '30GB075-200 Step 3 — Install Motormaster Control(s) (2) selected for proper application voltage per Table 4 at locations shown in Fig. 6 (30GB040-070) or Fig. 7 (0GBO75-200), Motormaster control mounts on parti- tion nearest to fan to be controlled. Refer to Installation Instructions furnished with Motormaster control for detailed mounting instructions. PETG Use extreme care when drilling and screwing in fasteners to avoid damaging components and wiring, ON 575-VOLT UNITS, a special transformer (Part No. HT01AH854, $75-v Pri/230-v Sec) is required for each Motormaster control, The transformers must mount inside the control box. CAPACITORS ADDED TO 30GB075-200. UNITS ‘must also mount in the control box. See Table 5, Diagram Index. Figures 8 through 13 show proper Motormaster sensor locations on condenser coils, Right hand and left hand areas viewed from header end of coils. On most units the proper return bend can be located by noting its relationship to existing thermistor sensor, T3 or TA, Figures 14 through 31 show correct power wiring for the Motormaster-controlled fan motors. Route common lead to Motormaster control, then to motor. Use 14-gage wire with 4/64 thick weatherproof insulation, 75 C type, ‘of locally approved equivalent. + The 30GBO45 and 30GB0S5,060 460-volt units require additional field modification of fan power wiring shown in Fig. 17, The 30GB090 and 30GB100 units require addition of 2 conitol relays to the control circuit, as shown in Fig. 32Table 5 — Diagram Index SENSOR MOTORWASTER SENSOR WOTORMASTER unr NAMEPLATE yur NAMEPLATE LocaTION wining LBGaTiON WIRING 3068 | “FIG. NO. VOLTAGE FIG.NO. 3068 | “FIG. NO. VOLTAGE FIG. NO. OSTA 77 FORTE 460 2 oo 8 300.400 13 07s 8 ‘80 a si i a8 35 20720 80 7 =| a 400 2a — a 7 * °208/230,460 26 S78 16. 990" 1B "380,400 a 046 70 200" 15 100" S75. 28 050 7 700 1 FOR7230 160 2 TOBTIOAT 7 vw] os ‘0 2 os, | yy S80 ie 5 3 60 Ba % tas 208/230.460 29 7 He) 3 13 380,400 30, POHT2IO ROT 30 M3 3 m6 by 070 2 00,400 x 200 38 be ee ——— “Requires control eieult modification shown in Fig 22 7 oa is] a # ks Hy is Hil RE Ty] Hees -T3 SENSOR a! ES —~ Gish TUBE UP) FSI Hat eae 55s fat St URE uay a] ES orormessren sy eS versuasrer ee MOTORMASTER- =) |=} MOTORMASTER ‘SENSOR 2 eee Seen iss) Be | sie isin TUBE uP ete ue | Fesz | Gers tome uy - oe 1 senso [FI S13 sensor iar | 24 esa cca) yi fee i Bet Ba ig ese 33 Hy ESS 35} ea ce UH Neanee ee ND 30GB040 30GB045 Fig. 8 — Motormaster Sens ‘Condenser C Locations on Fig. 9 — Motormaster Sensor ‘Condenser Coils Locations onFa fl a Hy is Ay FS wa z wy MoToRWasTER 2 FS | wee sorormasren — EES} it se un (22nd TUBE UP) s ot Tey eo —|é est +4 censon— 4 13 sensor TEESE Ger ql 2 (ism 709 UPL Ay Es iB et Ay eS FSI ES 2 TR HeaogR a 30GB046 Fig. 10 — Motormaster® Sensor Locations on Condenser Coils oS : | 13 SENSOR 0:3 — 14 sensor | f +2 Beatie [Tre ull P}—woronnasten Lae secant woromusrea Tt + T ti le vy soi MS GAaEue t+ 20 HEADER END 30GB055060 *rRom gortom oF UPPER COIL 74 sensor ~ (Sone TORE OFT worormasrer — Senson 2 (ism TUBE UP) eager 30GB050 _-13 SENSOR (Bera TUBE UPL —noroemaster SENson Uigth TUE UP) Fig. 11 — Motormaster Sensor Locations on ‘Condenser Coils 3 seNson (ayn TURE uy Sensor! : itom'Tose ve |S sy oS: Sota Ta seNsoR anu UP) Mororuasrer iiaty Tuse ver) Fig. 12 — Motormaster Sensor Locations on ‘Condenser Coils UF UPPERCOL RHTUPPER COL HEADER END 30GB070q [| --esmcase f= — vere, | i SS , vrewncn MOU PLAN VIEW 3068075,080 Te BE erpoge 7 ead woToRMASTER La cou fF 4 eae WworonwasteR 7 : bo A IN — = se = eu ad a (5, ae, PLAN VIEW 3068090,100 0g0 MOTORMASTER CIR 1 SeeTION Z 3 views COMPRESSOR SIDE OF UNIT PLAN VIEW 3068110,125 seein wororutsreR cin2— fi veqrion gj iT Ls = — COMPRESSOR SIDE OF UNIT VIEW K LAW VIEW 3068150,75,200 | cenren Fig. 13 — Motormaster Sensor Locations on Condenser Coils LEGEND (or Fig. 14-32) © — Contactor FM — Fan Motor Gap. = Capaci R= Relay Gcs — Compressor Protection and t “Thermistor fo Bem sytem Hodtte Te. Termipal Boars — Fan Contactor ‘Transformer FCB = Fen Circuit Breaker LeeMOTORMASTER® POWER WIRING eee eee ee ores eres eee eee e A e eux Ds b— 0K Le ser reo— awe emt eux wat vee Rewove FoR asov ree capo +@) ve on me an - | | es nOTORNASTER Senson2 EL {Boor veL | 4 -@) aay Vetta eee avs Fe cana ew Be BLU 7 anne or Fig. 14 — 30GB040; 208/230, 460 V Feo Fe cam meaera. BL oo He '380,A00¥ ONLY a Fee rue . fe NGTORWASTER Senso 2 YEL Bs ow -veL —H aay VEL ek paver ris 380,406 ovr Roe ve ve Fea capa aw Bon Peay eee vio —e— war: rua yeL—e—oLK Fig. 15 — 30GB040; 380, 400 V and 30GB046; 400 VMOTORMASTER POWER WIRING sav l 230 eK neo —4 |p — reve at TO ™ veL r neo" tf oO Bang-aurd 4 wrronnatre YEL {i Fee @ MOTORMASTER os a 2. Gp © ~@ aS ut ver |} susan. vet] cane wit» ware “Field-supplied wire > Fig. 16 — 30GB040,045,055,060; 575 V rote! [MoT AR prc @ -@——_] OC __ ey, jew mu ve @ Ye ak Pom —e anu rus car FOR 460-V ae — 7 vet ean BLU Boost 1) on eu Heke een MS. \ oer ;—| ‘EL e a soko ont—2—eux » Fig. 17 — 3068048,085,060; 208/230, 460 9ro Ta! ree Fo LK) — LK MOTORMASTER® POWER WIRING MOTORN ASTER fr sens OF | 1 lax way Reo. * car NeOTAAL vel he ru ak war ve Fee care +® ew {____ wir Fue ve. reo MOTORMASTER Censor 2 Fes VEL {pow @- EL {14 K€) ey EE eee ae Fern 2 enn rus vio—e— war vee ve cana Koen vio wir rua yee atk yeu Fes Lu Gs eow@-aLu 4 HQ) ae ont BL kJ Fat —e— arn rus orto war vee cars Peek —o— ern ey —e—wit rus one 0LK Fig. 18 — 30GB045,055,060; 380 V and 30GB050; 400 V WGTORWASTER F———————————— sensor 1 fet @- +@)- REO car 842i rw Fel aw reo Fee car ro Feat OA-e wir rue D4 He ew fee ‘et [NEUTRAL woToRMASTER f= senso 2 *Field-supplied wire. NOTE A neutr Fig. 19 — 30GB055,060; 400 V 10 ‘wire must be Installed to the unit and a neutral terminal board added, Part No. HY TUASIS.ro reas f vonnf To Foal ro *Fleld-supplied wire. MOTORMASTER POWER WIRING MOTORMASTER fr. sensor 1 4) = on i (—voo. rue va ® Ga PNK Foe Coe naaaaaaeeeaemes a! ——wo run OA ee PNK WworoRWASTER F————————————— sensor 2 Fig. 20 — 30GB070; 208/230, 460 V MOTORWASTER SENSOR 1 4 +). an ory. ———_®4 ~— vo rue Fel Pa Fee careeaa es | <—vo ru BH 3 . Pv 4 ree i — nororasreR sensor 2 ‘cded, Part No. HYTIUASTS. Fig. 21 — 30GB071 NOTE: On 380-volt and 400-volt units aneutral wirerustbeinstalledo the unitand aneutralterminal board. rue 70 Fe9 er am + ony —o-aux al wOTORWASTER ve. Sensors ewove For wororwasren | sux OTORWASTER 4 ru }_____@4 i ox LY" aK fee srar'3]| Sézsov,, cara 8tK ie OI-@ Ty vio ‘Rw Fig. 22 — 30GBO70; 575 V nro ronif won 0 Feat 18 MOTORMASTER® POWER WIRING WOTORMASTER sensor 1 fo O4-@ ap 1 fw a ow fea ae la ¢— w rue OA @- ve. a OTORNASTER sensor 2 [waTorwasrer} sensor | fet 0 He) ry - 23" fw re ew Fee Cie |g ¢$—w ewe NEUTRAL sensor 2 *Field-supplied wire 0 Foe MOTORNASTER NOTE: On 989-volt and 400-vot unite aneutral wire must beinstlled othe unit and aneutralterminal board ‘added, Part No. HY TUARTS. Fig. 24 — 30GB075; 380 V and 30GB080; 400 V ay ——— wir ve fi ‘soy aK BH +8 ret S78 | [ete al Ppa rt NOTORMASTER ‘WoTORMASTER [jaa ‘Trans SENSORS Fig. 25 — 30GBO75; 575 VMOTORMASTER POWER WIRING wo 18 cans to Fest {2} ory (— ory Fer ibe ' FM 1 core oH WOTORMASTER I fer Lc 4) H— ne To rce! a O54 H+ ro woToRastea 2 }—< sensor 2 rorcet 6-supplea wire NOTE: Seo Fig. 22 for contol ecut moitiction requires Fig. 26 — 30GB090, 100; 208/230, 460 V vio cant (——— rv —— co oensons a cee Oe WOTORMASTER 1 ror Lr >——@4 Ha—$ enn: ro @—| Fea 4 He) Fea MOTORWASTER 2 _[-— He oye ee Z QH-@ yeu ru Buu BLU (OR) Fea CaF O-H-e y sextnen) f rwr BH-B- VEL (ORD Fee (0 8 125) ne Fig. 29 — 30GB110,126,150,1 175,200; 208/230, 460 V NoTORWASTER sensor re To Fest: 4+ €) a BLK: [118i fw | Fel as raster} sensor (10 8 125) fea robe MAHe a 2.8 artorn mur ——! ia BLU(ORN) NEUTRAL *Field-supplied wire. NOTE: On 380-and 400-volt units a neutral wire must be installed to the unit, and a neutral terminal board added, Part No HVITUASTS Fig. 30 —- 30GB110; 380 V; 30GB126,150,175,200; 380, 400 VMOTORMASTER POWER WIRING ro Few uy) wr | cael O41+-e. be ve om Fei sev 3] Sxze0v aux O4H® {jane MOTORMASTER Sensors wOTORWASTER rans i rue —_- Lteeoyeux V4 ux rons f Fea s73r | Seay cares PE OAr@ f torn vEL enn a NOTE: Wiring designation in parenthesis applies to 110 and 126 size units only. ig. 31 — 30GB110,125,150,175,200; 575 V on ror om i \ oe (=) aa Ke roe! (res SEENOTE Rt Fes \ cow 9 cress: He To ¢3 {a)res *Field-suppliog wire NOTE: Carrier part numbers for Rt and R are 196 volt — HN6IKKOMt: 230 volt — HNBIKXO10 Fig. 32 — 30GB090,100 Control Wiring Modifications for Motormaster ApplicationTonclorurerrereret ine nro cecortmn er change st any tne epeaicauons or designs without Reice ana Without ieurhng OIGMONS. Book] PCIT Catalogo. 689-024 PrntedinUSA—Fomm30GB.29s1—Pyt8 «287 Replaces: S0GB-22S1