Carrier 040-420 Installation And Service Manual
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Carrier 040-420 Installation And Service Manual

Carrier 040-420 Installation And Service Manual

Carrier air conditioner user manual
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SAFETY CONSIDERATIONS . . . + . . . . , e +. . , . . , . 1
GENERAL . . . . . . , . . . . , . , . . . , . , . . . . , . , . . . . . . . . 2
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-4
Processor Module . . . . . . . . . . . . . . . . . . . . . . . . ...2
Low-Voltage Relay Module . , . . . . . . , . , . , , . . . . . 2
Electronic Expansion Valve Module . . . . . . . . . . . 2
Options Module . . . . . . . . . . . . . . . . *. . . . . . . . . . . . 2
(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . . 2
Control Switch . + . . . , . . . . . . . . . . . . . . . . . . . . . . . . 2
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
Module (CPCS) . . , . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION DATA . . . . . . . . . . . . . , . . . . , . + . . . , 5-47
Capacity Control . . . . , , . . . . . . . . . . . . . . . . . . + . . . . 5
Head Pressure Control . . 1 . . . . . + . . . . . . . . . . . . . 26
(Also Called HSIO or LID)
ACCESSING FUNCTIONS AND :tiBFtiN?TI'dNS
SUMMARY DISPLAY
SET POINT FUNCTION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .
Checking Display Codes . . . . . . . . . . . . . . . . . . . . .
Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . .
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . .
Lag Compressor Stoppage . . . . . . . . . . . . . . . . . .
SAFETY
CONSIDERATIONS
Installing, starting up, and servicing this equipment can
be hazardous due to system pressures, electrical compo-
nents, and equipment location (roof, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start-up, and service this equipment.
When working on this equipment, observe precautions in
the literature, and on tags, stickers, and labels attached to
the equipment, and any other safety precautions that apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment,
and in handling all electrical components.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 563-015
Book 2
P C 9 0 3
T a b 5c
CONTENTS
P a g e
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . ...48
l
Alarm Codes . . . . . . , . . . . . . . , . . . . . . . . . . , . . . . . 49
Compressor Alarm Circuit . . . . . e +. . . . . . . . . . . . 50
Electronic Expansion Valve . . . . . . . . . . . . . . . . , . 56
l
l
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...60
l
. . . , . . . . . . . . 4
Pressure Transducers . . . , . . . , . . . . . . + . . . + . . . . 60
l
l
Control Modules . . . . . . . . . . . . . . . . . . . . . . . , . . . . 64
l
. RED LED
l
28
l
l
. 4IN/40UT MODULE (SIO)
Installation . . . . . . . , . . . s . . . , . . . . s . . . . . . . . .'.'. . 68
l
l
48-67
FIELD WIRING . . . . . . . . . . . . , . . . . . . . . . . . . . . . 71-73
48
REPLACING
48
48
48
48
Electrical shock can cause personal injury and death.
Shut off all power to this equipment during installation
and service. There may be more than one disconnect
switch. Tag all disconnect locations to alert others not
This unit uses a microprocessor-based electronic con-
trol system. Do not use jumpers or other tools
out components, or to bypass or otherwise depart from
recommended procedures. Any short-to-ground of the
control board or accompanying wiring may destroy the
electronic modules or electrical components.
Printed in U S A.
Form 30GN-2T
EXV OPERATION
CHECKOUT PROCEDURE
THERMISTOR REPLACEMENT (Tl, T2, T7, T8)
TROUBLESHOOTING
PROCESSOR MODULE (PSIO), 4IN/40UT
MODULE (SIO), LOW-VOLTAGE RELAY
MODULE (DSIO), AND EXV DRIVER MODULE
(DSIO)
040-110, 130 (60 Hz) UNITS
130 (50 Hz), 150-210, 225, 250, and 280 UNITS
(and associated modular units)
DEFECTIVE
PROCESSOR
MODULE (PSIO) . . . . + s . . . . . . . + . . . . . . * . + . 73,74
1 - 9 4
Page
68-7 1
to
short
Replaces: 30GB,GT-1
T ,

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Summary of Contents for Carrier 040-420

  • Page 1: Table Of Contents

    Any short-to-ground of the control board or accompanying wiring may destroy the electronic modules or electrical components. Printed in U S A. Form 30GN-2T 040-420 v----w Page 68-7 1 DEFECTIVE PROCESSOR...

  • Page 2: General

    This is a 3-position manual switch that allows the chiller to be put under the control of its own Flotronic II controls, manually stopped, or put under the control of a Carrier Corn- fort Network (CCN), Switch allows unit operation as shown in Table 2.
  • Page 3 \- -.-...- KEYPAD;DISPLAY M O D U L E (HSIO/LID) LEGEND - c Zarrier Comfort Network -1 “erminal Block Fig. 1 - 30GN Control Panel (040-110, 240B, 270B Unit Shown) ELECTRONIC EXPANSION VALVES DRIVER MODULE (DSIO EXV) L O W - V O L T A G E R E L A Y M O D U L E TB-7 (DsroiLv)

  • Page 4: Electronic Expansion Valve (Exv)

    In the LOCAL/ENABLE position, the chiller is under lo- cal control and responds to the scheduling configuration and set point data input at its own local interface device (key- pad and display module). In the CCN position, the chiller is under remote control and responds only to CCN network commands.

  • Page 5: Operation Data

    OPERATION DATA Capacity Control - The control system cycles compressor to give capacity control steps as shown in Tables 4A-4D. The unit controls leaving chilled water tem- perature. Entering water temperature is used by the micro- processor in determining the optimum time to add or sub- tract steps of capacity, but is not a control set point.
  • Page 6 Table 4A - Capacity Control Steps, 040-070 (cant) UNIT 3 0 G N 050 (50 Hz) 060G Hz) 050 (50 Hz) “g pgy 050 (50 Hz) 060A\~**Hz) 050 (50 Hz) 06g$,y 060 (50 Hz) 070fc Hz) 060 (50 Hz) 07Odpto**Hz) 060 (50 Hz) oypg~) *Unloaded compressor.
  • Page 7 Table 4A - Capacity Control Steps, 040-070 (cant) UNIT 30GN 1 _ . . (50 Hz) “‘“G Hz) oy&ya 070 (50 Al t**,Bl** *Unloaded compressor. tCompressor unloader, standard. accessory. **Compressor unloader, ttTwo unloaders, both unloaded. LOADING SEQUENCE A Displacement Compressors tApprod 1 0 0 A-FBI...
  • Page 8 Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units UNIT 3 0 G N 080 (60 Hz) Aly*,Blv 08Aqy;,y 080 ( S O H z ) Aif”*,6if** *Unloaded compressor. +Compressor unloader, standard **Compressor unloader, accessory ++Two unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing.
  • Page 9 Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) UNIT CONTROL STEPS 30GN 090 (60 Aly*,Blt 090 (60 Alt**,BlY* *Unloaded compressor. tCompressor unloader, standard. **Compressor unloader, accessory TtTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing. iQUENCE A LOADING ! Displacement...
  • Page 10 Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) CONTROL UNIT 3 0 G N STEPS 090 (50 Hz) Alt,Bly 090 (50 Hz) Al t**,Bl t** 100, 2408, 100,24OB, 270B (60 Hz) Alt**,Blt 100,24OB, 270B (60 Hz) Alt,Blt^* *Unloaded compressor +Compressor unloader, standard.
  • Page 11 Table 40 - Capacity Control Steps, 080-I IO and Associated Modular Units (cant) UNIT 3 0 G N 100, 2406, 270B (60 Hz) Alr*,Blr 100, 240B, 2708 (50 Hz) A1tW-t 100, 240B, 2708 (50 Hz) Aft**,Blt 100, 2408, 270B (50 Hz) 8’...
  • Page 12 Table 48 - Capacity Control Steps, 080-110 and Associated Modular Units (cant) UNIT 30GN 110 (60 Hz) Al t**,Bl Y 110 (50 Hz) Alt,Blt *Unloaded compressor. TCompressor unloader, standard **Compressor unloader, accessory. TtTwo unloaders, both unloaded. NOTE: These capacity control steps vary due to LOADING SEQUENCE A Displacement...
  • Page 13 Table 4B - Capacity Control Steps, 080-110 and Associated Modular Units (cant) CONTROL UNIT 3 0 G N STEPS 110 (50 Hz) Alt**,Blt 110 (50 Hz) Alt,Blv 110 (50 Hz) Alt**,Blt** *Unloaded compressor. TCompressor unloader, standard. **Compressor unloader, accessory TTTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing LOADING SEQUENCE A...
  • Page 14 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units UNIT 30GN 130, 240A, 130, 240A, 130, 240A, 130, 240A, 130,24OA, *Unloaded compressor tCompressor unloader, standard. **Compressor unloader, accessory ttTwo unloaders, both unloaded NOTE: These capacity control steps may vary due to lag compressor sequencing+ LOADING EQUENCE A Displacement...
  • Page 15 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT CONTROL 3 0 G N STEPS Displacement 130, 24OA, 130,24OA, 130, 240A, *Unloaded compressor. tCompressor unloader, standard. **Compressor unloader, accessory ttTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing. LOADING SEQUENCE A Compressors hwrox)
  • Page 16 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT 3 0 G N 150 (60 Hz) Aly*,Blt** 15Aq y4 *Unloaded compressor. tCompressor unloader, standard **Compressor unloader, accessory. ttTwo unloaders, both unloaded NOTE: These capacity control steps may vary due to lag compressor sequencing LOADING EQUENCE A Displacement...
  • Page 17 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT SIZE 150 (50 Hz) Alt,Bly* 150 (50 Hz) Alr*,Blt*” 170, 270A, 300B, 330;; fTt Hz) 170, 270A, 3008, *Unloaded compressor. tCompressor unloader, standard. **Compressor unloader, accessory ttTwo unloaders, both unloaded.
  • Page 18 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT SIZE 170, 270A,300B, 170,27OA, 300B, 170,27OA, 300B, 33oA/,$cH350 *Unloaded compressor. tcompressor unloader, standard. **Compressor unloader, accessory. ttTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing LOADING SEQUENCE A Displacement Compressors...
  • Page 19 Table 4C - Capacity Control Steps, 130210 and Associated Modular Units (cant) U N I T CONTROL SIZE STEPS 170, 270A, 300B, 33OA/z, t”fB,:“O Hz) 170, 270A, 3008, 33OA/z, t”609+{,50 Hz) 170,27OA, 3008, 330~A~~~f\; ff Hz) *Unloaded compressor. j-Compressor unloader, standard **Compressor unloader, accessory ttTwo unloaders, both unloaded.
  • Page 20 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT CKEL SIZE 190,36OA/B, 39oEpt 190,36OA/B, 39;: jfj’;,“” 190, 360A/B, 39;; (BGp*w 190,36OA, 39OE31(6CC 190,36OA, 39;; j:;,W *Unloaded compressor. tCompressor unloader, standard. **Compressor unloader, accessory. TtTwo unloaders, both unloaded NOTE: These capacity control steps may vary due to lag compressor sequencing Compressors Al j2,B-i...
  • Page 21 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT CONTROL SIZE S T E P S Displacement 190,36OA, 39:: (8514w 190,36OA, =J”8”1 y 210,39QA, (86p Hz) 420%: 210, 390A, 42y3g 210, 390A, 42of,Bs(f~~ Hz) *Unloaded compressor. j-Compressor unloader, standard.
  • Page 22 Table 4C - Capacity Control Steps, 130-210 and Associated Modular Units (cant) UNIT SIZE 210, 390A, 420AIB (60 Hz) Al**,Bl** 210, 390A, 420/U; f-5; Hz) 210, 390A, 42Ofy;; 210, 390A, 42Of,~gw 210,39OA, 42\yE gyp) *Unloaded compressor tCompressor unloader, standard **Compressor unloader, accessory ttTwo unloaders, both unloaded.
  • Page 23 Table 4D - Capacity Control Steps, 225, 250,280 UNIT 30GT Displacement (Awox) 225 (60 Hz) 225 (50 Hz) *Unloaded compressor. TCompressor unloader, standard. **Compressor unloader, accessory TtTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing LOAC \IG SEQUENCE A Compressors...
  • Page 24 Table 4D - Capacity Control Steps, 225, 250,280 (cant) UNIT 30GT 250 (60 *Unloaded compressor. JCompressor un!oader, standard **Compressor unloader, accessory ttTwo unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing. SEQUENCE A LOAC Compressors Al% * Al ,Bl*...
  • Page 25 Table 4D - Capacity Control Steps, 225, 250, 280 (cant) UNIT CONTROL S T E P S 3 0 G T 250 (50 Hz) 280 (60 Hz) 250 f& Hz), Al** 250 $;; Hz), Al**,Bl** *Unloaded compressor. -/-Compressor unloader, standard. ““Compressor unloader, accessory ttTwo unloaders, both unloaded NOTE: These capacity control steps may vary due to lag compressor sequencing...

  • Page 26: Head Pressure Control

    Head Pressure Control - The microprocessor con- trols the condenser fans in order to maintain the lowest con- densing temperature possible, thus the highest unit efficiency. Instead of using the conventional head pressure control meth- ods, the fans are controlled by the position of the EXV and suction superheat.

  • Page 27: Pumpout

    FAN ARRANGEMENT 30GT225 30GT250 (60 Hz) 30GT250 (50 Hz) AND 30GT280 / ‘ : i *Control box. tPower box. Pumpout - When the lead compressor in each circuit is started or stopped, that circuit goes through a pumpout cycle to purge the cooler and refrigerant suction lines of refrigerant.

  • Page 28: Keypad And Display Module

    Keypad and Display Module (Also Called HSIO or LID) - The only function of this module is to allow the operator to communicate with the processor. It is used to enter configurations and set points and to read data, per- form tests, and set schedules.
  • Page 29 Table Status su6FUNFT’oN STAT Automatic Display Alarm D i s p l a y ;g;faQeratiw) plWe$Y Set Points (Current Operating) Temperatures Pressures Analog Inputs outputs Table 8 - Accessing Functions and Subfunctions OPERATION To access a function, press subfunction no and function name key.
  • Page 30 KEYPAD ENTRY 2 ALARMS 3 MODES 4 STAGE 5 SET POINT 6 TEMPERATURE LEGEND - Carrier Comfort Network E X V - Electronic Expansion Valve M O P - Maximum Operating Pressure Table 9 - Keypad Directory STATUS DISPLAY Refer to Automatic Display Operation on page 28...

  • Page 31: Status Function

    Table 9 - Keypad Directory (cant) SUBFUNCTION KEYPADENTRY 6 TEMPERATURE (cant) cl 4 cl 4 cl 4 7 PRESSURE 8 ANALOG 9 1NPUTS STATUS (cant) DISPLAY Circuit B Saturated Condenser Temperature SCTB X Circuit B Saturated Suction Temperature S S T B X Compressor Bl Suction Temperature C T B X SHB X...
  • Page 32 SUBFUNCTION 10 OUTPUTS To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position To operate a test, scroll to desired test Then, press m to start test. Press m to stop test. KEYPAD ENTRY SUBFUNCTION 1 OUTPUTS Table 9 - Keypad Directory (cant) STATUS (cant) DISPLAY OUTPUTS...

  • Page 33: Test Function

    KEYPAD ENTRY 1 OVERRIDE For example, to extend current occupied mode for 3 hrs, press: 2 CLOCK SELECT LEGEND - Carrier Comfort Network - Electronic Expansion Valve ~~” - Maximum Operating Pressure M O P Table 9 - Keypad Directory (cant)
  • Page 34 To toggle between inputs (Yes/No) Press: Fi Fi 4 PERIOD 2 5 PERIOD 3 . . . 9 PERIOD 7 10 PERIOD 8 11 HOLIDAYS New = Unassigned Holiday Date For example: To enter July 4th holiday press: 07 04 01 operation, refer to Schedule Function section on page 45.
  • Page 35 The next 3 subfunctions provide the ability to modify configurations Refer to separate Installation, Start-Up, and Service Instructions supplied with unit for further information To change a configuration, enter the new configuration and press F.-’ SUBFUNCTiON 3 FACTORY CONFIGURATION 4 FIELD CONFIGURATION 5 SERVICE CONFIGURATION...
  • Page 36 KEYPAD ENTRY SUBFUNCTION r;lm 1 RUN TIME c l b 1 lHlST1 2 STARTS c l + c l + c l + 3 ALARM HISTORY I 3 I lH4 To read a set point, go to proper subfunction and read desired set point To LOCAL/ENABLE-STOP-CCN switch must be in LOCAL or STOP position, SUBFUNCTION KEYPAD ENTRY...
  • Page 37 STATUS FUNCTION - This function shows the rotating display, current status of alarm (diagnostic) codes, capacity stages, operating modes, chilled water set point, all meas- ured system temperatures and pressures, superheat values, pressure switch positions, analog inputs, and switch inputs. These subfunctions are defined on pages 37 and 38.
  • Page 38 Example 2 - Reading Current Operating Modes KEYPAD DISPLAY COMMENTS ENTRY RESPONSE I Keypad has not been used for at TUE 15:45 least 10 minutes Rotating summary LOCAL ON C O O L 1 display appears on screen 0 A L A R M S There are 2 modes currently in effect p-lH 2 MODES...

  • Page 39: History Function

    Example 3 - Using Test Function KEYPAD DISPLAY COMMENTS ENTRY RESPONSE C O M P Factory/field test of compressors subfunction of test function Circuit A, Compressor 1A test CPA 1 OFF CPA 1 ON Pressing ENTR when the compressor should be running the display shows CPA1 on CPA 1 OFF If the test is allowed to time out (10 sec-...

  • Page 40: Service Function

    I. Maximum Reset Amount (CRST2) - allowable range 0” to 20” F (0” to 11” C). This is maximum amount leav- ing chilled water point is to be increased. 2. Maximum Reset Reference (CREF2) - allowable range 0” to 20” F (0” to 11” C). This is the cooler temperature drop at which reset reaches its maximum value.
  • Page 41 Temperature Reset Based on External Temperature - If de- sired, temperature reset can be based on an external tem- perature, such as space or outdoor-air temperature. This re- quires a thermistor (TlO, Part No. 30GB660002) located in the space or outdoor air and wired to terminals as follows (also see Field Wiring section on page 71): 4 in/4 Module - 57-15 and J7-16.

  • Page 42: Service Function

    --e-------1- __-----a ---mm- LIMIT _ _ - - - - . _------ (ALARM C O D E 3 1 2 __---- - - - (MODE ___---c--- - - - - - _ - - - - - - - - ‘-+p-------- (MODE ----...

  • Page 43: Set Point Function

    Loadshed L S T Y P 0 NOTE: Select 3 for Carrier comfort Network (CCN) load limiting Select 4 for CCN demand limiting. R E S E T R E F E R E N C E S I G N A L...

  • Page 44: Set Point Function

    M A X D E M A N D Reading and Changing Time Displav - Time is entered and displayed in 24-hour time. The day of the week is en- tered as a number. 1 = Mon, 2 = Tue, 7 = Sun, etc. m Kev is used as the colon when entering time.
  • Page 45 0 = No Interlock 1 = With Interlock Cooler Pump Control Select 0 = Not Controlled 1 = ON/OFF Controlled L E G E N D - Carrier Comfort Network - Electronic Expansion Valve *And associated modular units SERVICE FACTORY CONFF$ikTlON...

  • Page 46: Schedule Function

    M O N N O MON YES T U E N O TUE YES W E D Y E S W E D N O CCN - Carrier Comfort Network Example 9 continued next page. schedule override in effect 3 hours override in effect...
  • Page 47 Example 9 - Using the Schedule Function (cant) KEENYTPRAYD D I S P L A Y PROGRAMMING PERIOD 3: Define P E R I O D 3 period 3 Start of occupied occ 00 a0 l i m e Tyo$e;;rne will start occ 7 00 Start of unoccupied time (end of period 3).

  • Page 48: Troubleshooting

    TROUBLESHOOTING The FlotronicTY II control has many features to aid the technicians in troubleshooting a Flotronic II Chiller. By us- ing keypad and display module and status function, actual operating conditions of the chiller are displayed while unit is running. Test function allows proper operation of com- pressors, compressor unloaders, fans, EXVs and other com- ponents to be checked while chiller is stopped.

  • Page 49: Alarm Codes

    Alarm Codes - Following is a detailed description of each alarm code error and possible cause. Manual reset of an alarm is accomplished by moving LOCAWENABLE- STOP-CCN Switch to STOP position, then back to LO- CAL or CCN position. See Table 14 for listing of each alarm code.

  • Page 50: Compressor Alarm Circuit

    Possible causes of failure: High-Pressure Switch Open - High-pressure switch for each compressor is wired in series with 24-v power that energizes compressor control relay. opens during operation, compressor stops. This is detected by microprocessor through the feedback terminals. DSIO-LV or DSIO-EXV Module Failure - If a DSIO-LV 3 d.
  • Page 51 Code 30 Reset input failure (4 to 20 mA) Code 31 Demand limit input failure (4 to 20 mA) These codes apply only if unit is configured for these functions. If 4-20 mA signal is less than 4 or more than 20 mA, reset or demand limit function is disabled and unit functions normally.
  • Page 52 Possible causes of fault are low refrigerant charge, plugged filter drier, or a faulty EXV or thermistor. Code 48 Low suction superheat, Circuit A Low suction superheat, Circuit B Code 49 If EXV is at minimum position, suction superheat is less than 10”...
  • Page 53 LEGEND - Contactor - Communications Bus - Compressor Protection Control Module Discharge Gas Thermostat (Optional) - Relay Module (Low Voltage) DSIO - l-tigh-Pressure Switch - Low Voltage - Plug - Power - Terminal Block - Transformer - Unloader Fig. 1OB - 24-V Safety Circuit Wiring (080-110 and Associated Modular Units) 24VAC CONTROL 5CtlEliATIC TNANZ...
  • Page 54 LEGEND Ground Fault Module Communications Compressor Contactor Relay EM” Relay Module (Low Voltage) High-Pressure Switch Low Voltage Plug Snubber Terminal Block Transformer TRAN Unloader Fig. IOC - 24-V Safety Circuit Wiring (130-210 and Associated Modular Units)
  • Page 55 LEGEND Contactor Ground Fault Module C G F - C o m m o n Control Relay Z” Discharge Gas Thermostat (Optional) D G T - Relay Module (Low Voltage) DSIO E X V - Electronic Expansion Valve High-Pressure Switch H P S - Low Volta Normally losed...

  • Page 56: Electronic Expansion Valve

    Electronic Expansion Valve EXV OPERATION - These valves control the flow of liq- uid refrigerant into the cooler. They are operated by pro- cessor to maintain a specified superheat at lead compressor entering gas thermistor (located between compressor motor and cylinders). There is one EXV per circuit. See Fig. 11. High-pressure liquid refrigerant enters valve through bot- tom.
  • Page 57 Because the EXVs are controlled by the processor mod- ule, it is possible to track valve position. During initial start-up, EXV is fully closed. After start-up, valve po- sition is tracked by processor by constantly observing amount of valve movement. _I.: ,/:.
  • Page 58 MUFFLERS C O M P R E S S O R S LEGEND D P T - Discharge Pressure Transducer - Oil Pressure Transducer - Suction Pressure Transducer :ppTT - Thermistor Number Fig. 13 - Thermistor and Pressure Transducer Locations CIRCUIT B CIRCUIT A FILTER...
  • Page 59 A I R VENT D R A I N L E A V I N G W A T E R / B R I N E C O N N E C T I O N (Circuits A and B, Lead Compressor Only) COUPLING A C C E S S O R Y poi-i,...

  • Page 60: Thermistors

    Thermistors - All thermistors are identical in their tem- perature vs. resistance performance. Resistance at various temperatures are listed in Tables 15 and 16. LOCATION - General location of thermistor sensors are shown in Fig. 13. Cooler Leaving Water Thermistor (Tl) - Tl is located in leaving water nozzle.
  • Page 61 Table 15 - Thermistor Temperature (OF) vs Resistance/Voltage Drop; Flotronic’” VOLTAGE TEMP:;fTURE D R O P ( V ) -2i.b 4 8 2 1 -24.0 4818 4814 -23.0 4806 -22.0 -21.0 4.800 -20.0 4793 4786 4779 - 1 8 . 0 4772 - 1 7 .
  • Page 62 Table 16 - Thermistor Temperature (“C) vs Resistance/Voltage Drop; Flotronic’” II TEMPERATURE VOLTAGE RESISTANCE DROP (V) - 4 0 4.896 - 3 9 - 3 8 4 . 8 7 4 - 3 7 - 3 6 4 . 8 6 6 - 3 5 4 8 5 7 - 3 4...
  • Page 63 THERMISTOR* REFRIGERANT ENTERING TEMPERATURE CYLINDERS SUCTION EQUALIZER PRESSURE LINE TRANSDUCER* TRANSDUCER* Fig. 17 - Lead Compressor Transducer and Thermistor Locations DISCHARGE PRESSURE TRANSDUCER* PRESSURE SIGHT GLASS (EACH COMPRESSOR) *Lead compressor only...

  • Page 64: Control Modules

    Control Modules Turn controller power off before servicing controls. This ensures safety and prevents damage to controller. PROCESSOR MODULE (PSIO). 4 IN/4 OUT MODULE (SIO), LOW-VOLTAGE TiELAY’MODULE (DSIO), AND EXV DRIVER MODULE (DSIO) - The PSIO, DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware.

  • Page 65: Processor Module (Psio)

    PSI0 DSIO DSIO HSIO ( L I D ) ( 4 I;W;UT pRocEMssOp (RELAY) (EXV DRIVER) Fig. 19 - Sensor Bus Wiring (Communications) PROCESSOR MODULE (PSIO) (Fig. 20) Inputs - Each input channel has 3 terminals; only 2 of the used.
  • Page 66 4 IN/4 OUT MODULE (SIO) (Fig. 22) - 4 In/4 Out mod- ule allows the following features to be utilized: 1. Temperature Reset by outdoor air or space temperature. A remote thermistor (Part No, 30GB660002) is also re- quired. NOTE: This accessory is required for return water temperature reset.
  • Page 67 SYMPTOMS CAUSE COMPRESSOR DOES Power line open NOT RUN Control fuse open High Pressure Switch (HPS) tripped Tripped power breaker Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective Seized compressor COMPRESSOR CYCLES OFF Loss of charge ON LOW PRESSURE Bad transducer Low refrigerant charge...

  • Page 68: Accessory Unloader Installation

    115 v or 230 v coil must be used for 130 (50 Hz), 150-210, 225, 250, 280, and associated modular units. Coil voltage depends on control circuit voltage, Consult current Carrier price pages for appropriate part numbers. NOTE: The accessory package will include all necessary...
  • Page 69 -- 13 6 y r--‘---------‘-‘-“--“‘-“-----------~ -9RA 1’ - VI0 L--a--- RED- L E G E N D - Contactor ERCS - Compressor Protection Control System - Control Relay Rel a Module - Low oltage Fig. 23 - Accessory Unloader Control Wiring ~13014 115v 0R 230y;f;~RO~ FROM 115V OR IDS00...

  • Page 70: And Associated Modular Units

    130 (50 Hz), 150-210, 225, 250, AND 280 UNITS (and associated modular units) 1. Install control wiring. The minimum wire size for in- stallation is 16 AWC (American Wire Gage). Refer to Fig. 24 and 25 for proper wiring. Open the control box door.

  • Page 71: Field Wiring

    GdYEL & Lfh]f - - - - - - - - - cALARncooE31~ Fam&& S W I T C H ‘-%F----- tRoDEn ~~ - (AIJM CODE 21,301 r - - - - - - - - o(oocm qg&#g’ I-)o M-wT~r- - - - - - - - ----------a balToysTER - - - - - - - - - - - - - - - A - - - lmyTEF4...

  • Page 72: And Associated Modular Units

    EXTERNAL 3OGN040-210 AND ASSOCIATED MODULAR UNITS ---- 30GT225,250,280 FLOTRONIC II UNITS TB - Terminal Block NOTE: The 30GT225,250,280 Flotronic’” II units require the acces- sory options module package for this feature Fig. 27 - Demand Limit - 4-20 mA Signal (Externally Powered) --j370 30GN040-210...

  • Page 73: Module (Psio)

    __-- T5-3 rior corner post. The proper software and unit configuration -t-l data is factory installed by Carrier in the replacement mod- ule. Therefore, when ordering a replacement processor mod- ule (PSIO), specify complete replacement part number, full --v-w unit model number, and serial number. If these numbers...
  • Page 74 8. Reinstall all 6 wire connectors and the green ground wire. 9. Carefully check all wiring connections before restoring power. 10. Verify the LOCAL/ENABLE-STOP-CCN switch is in STOP position 11. Restore control power. Verify the red and green lights on top of PSI0 and front of each DSIO module re- spond as described in Control Modules section on page 64.
  • Page 76 Copyright 1994 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 P C 9 0 3 Catalog No 563-015 T a b 5c Printed in U S A...

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