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Carrier Air Conditioner Operation And Service Manual

Air-cooled reciprocating liquid chillers with comfortlink controls 50/60 hz
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Controls Start-Up, Operation,
Service, and Troubleshooting

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service mechanics should in-
stall, 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 han-
dling all electrical components.
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
This unit uses a microprocessor-based electronic control
system. Do not use jumpers or other tools to short out com-
ponents, or to bypass or otherwise depart from recom-
mended procedures. Any short-to-ground of the control
board or accompanying wiring may destroy the electronic
modules or electrical components.
To prevent potential damage to heat exchanger tubes
always run fluid through heat exchangers when adding or
removing refrigerant charge. Use appropriate brine solu-
tions in cooler fluid loops to prevent the freezing of heat
exchangers when the equipment is exposed to temperatures
below 32 F (0° C).
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented outdoors in accor-
dance with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigeration and Air Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen-
trations of vapor is harmful and may cause heart irregulari-
ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 903
Book 2
Tab
5c
Catalog No. 563-025
Printed in U.S.A.
Air-Cooled Reciprocating Liquid Chillers
with ComfortLink™ Controls
DO NOT attempt to unbraze factory joints when servicing
this equipment. Compressor oil is flammable and there is
no way to detect how much oil may be in any of the refrig-
erant lines. Cut lines with a tubing cutter as required when
performing service. Use a pan to catch any oil that may
come out of the lines and as a gage for how much oil to add
to system. DO NOT re-use compressor oil.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . . . 3-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Expansion Valve (EXV) Board . . . . . . . . . . . . . . . . . . . . 3
Compressor Expansion Board (CXB). . . . . . . . . . . . . 3
Scrolling Marquee Display . . . . . . . . . . . . . . . . . . . . . . . 3
Energy Management Module (EMM) . . . . . . . . . . . . . . 3
Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . 3
Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . 3
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Module Communication. . . . . . . . . . . . . . . . . . 4
Carrier Comfort Network Interface . . . . . . . . . . . . . . . 4
OPERATING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-47
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• T1 - COOLER LEAVING FLUID SENSOR
• T2 - COOLER ENTERING FLUID SENSOR
Thermostatic Expansion Valves (TXV). . . . . . . . . . . 15
(CPCS) or Control Relay (CR) . . . . . . . . . . . . . . . . . 15
(CGF) and Control Relay (CR) . . . . . . . . . . . . . . . . . 15
Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 16
Energy Management Module . . . . . . . . . . . . . . . . . . . . 16
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
• ADDING ADDITIONAL UNLOADERS
• MINUTES LEFT FOR START
Form 30GTN-3T
30GTN,GTR040-420
30GUN,GUR040-420
50/60 Hz
CONTENTS
Pg 1
3-00
Replaces: 30GTN-2T
Page

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  Summary of Contents for Carrier Air Conditioner

  • Page 1: Table Of Contents

    Control Module Communication....4 Carrier Comfort Network Interface ....4 OPERATING DATA.
  • Page 2: General

    CONTENTS (cont) • LEAD/LAG DETERMINATION • CAPACITY SEQUENCE DETERMINATION • CAPACITY CONTROL OVERRIDES Head Pressure Control ......27 •...
  • Page 3: Major System Components

    Information is transmitted between modules via a 3-wire com- UNIT 30GTN,R munication bus or LEN (Local Equipment Network). The — — CCN (Carrier Comfort Network) bus is also supported. Con- — nections to both LEN and CCN buses are made at TB3. See — Fig. 5.
  • Page 4: Control Module Communication

    YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication. Carrier Comfort Network (CCN) Interface — The 30GTN,R chiller units can be connected to the CCN if desired.
  • Page 5: Status Switches

    CR-A1 CR-A1 CR-A1 LEGEND FOR FIG. 1-4 — Compressor Contactor — Circuit Breaker — Carrier Comfort Network — Compressor Ground Fault — Cooler Heater Thermostat — Circuit — Cooler Heater Relay — Compressor Protection and Control System — Chilled Water Flow Switch —...
  • Page 7 DATA COMMUNICATION PORT Fig. 2 — 24 V Control Schematic, Unit Sizes 040-070...
  • Page 8 DATA COMMUNICATION PORT Fig. 3 — 24 V Control Schematic, Unit Sizes 080-110, 230B-315B Fig. 3 — 24 V Control Schematic, Unit Sizes 080-110, 230B-315B...
  • Page 9 DATA COMMUNICATION PORT Fig. 4 — 24 V Control Schematic, Unit Sizes 130-210, 230A-315A, 330A/B-420A/B...
  • Page 10 LEN (LOCAL EQUIPMENT NETWORK) CEPL130346-01 STATUS Fig. 6 — Enable/Off/Remote Contact Switch, Emergency On/Off Switch, YELLOW LED - CCN (CARRIER COMFORT NETWORK) Fig. 5 — Main Base Board RESET BUTTON (SIZES 130-210 AND ASSOCIATED MODULES ONLY) and Reset Button Locations...
  • Page 11: Operating Data

    OPERATING DATA Sensors — The electronic control uses 4 to 10 thermistors to sense temperatures for controlling chiller operation. See Table 2. These sensors are outlined below. See Fig. 7-10 for thermistor locations. Thermistors T1-T9 are 5 kΩ at 77 F (25 C).
  • Page 12 040-070 080-110 AND ASSOCIATED MODULAR UNITS* 130-210 AND ASSOCIATED MODULAR UNITS* *When thermistor is viewed from perspective where the compressor is on the left and the cooler is on the right. Fig. 8 — Thermistor T3 and T4 Locations...
  • Page 13 LEGEND EXV — Electronic Expansion Valve Fig. 9 — Compressor Thermistor Locations (T7 and T8) Fig. 10 — Typical Thermistor Location (30GTN,R and 30GUN,R 210, 315A, 390A, 420A/B Shown)
  • Page 14: T10 - Remote Space Temperature Sensor

    The space temperature sensor includes a terminal block (SEN) and a RJ11 female con- nector. The RJ11 connector is used to tap into the Carrier Com- fort Network (CCN) at the sensor. To connect the space temperature sensor (Fig. 11): 1.
  • Page 15: Thermostatic Expansion Valves (Txv)

    Thermostatic Expansion Valves (TXV) — 30GTN,R and 30GUN,R 040-110 units are available from the factory with conventional TXVs with liquid line solenoids. The liquid line solenoid valves are not intended to be a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system.
  • Page 16: Electronic Expansion Valve (Exv)

    Electronic Expansion Valve Fig. 15) — Standard units are equipped with a bottom seal EXV. This device eliminates the use of the liquid line solenoid pumpdown at unit shutdown. An O-ring has been added to bot- tom of orifice assembly to complete a seal in the valve on shut- down.
  • Page 17 CEBD430351-0396-01C STATUS RED LED - STATUS The capacity control algorithm runs every 30 seconds. The algorithm attempts to maintain the leaving chilled water tem- perature at the control point. Each time it runs, the control reads the entering and leaving fluid temperatures. The control deter- mines the rate at which conditions are changing and calculates 2 variables based on these conditions.
  • Page 18 Table 5A — Part Load Data Percent Displacement, Standard Units UNIT CONTROL 30GTN,R STEPS 30GUN,R 040 (60 Hz) 040 (50 Hz) 045 (60 Hz) 045 (50 Hz) 050 (60 Hz) 050 (50 Hz) 060 (60 Hz) 060 (50 Hz) 070 (60 Hz) 070 (50 Hz) 080, 230B (60 Hz) 080, 230B (50 Hz)
  • Page 19 Table 5A — Part Load Data Percent Displacement, Standard Units (cont) UNIT CONTROL 30GTN,R STEPS 30GUN,R 100, 255B 270B (50 Hz) 110, 290B, 315B (60 Hz) 110, 290B, 315B (50 Hz) 130 (60 Hz) 130 (50 Hz) 150, 230A, 245A, 255A (60 Hz) *Unloaded compressor.
  • Page 20 Table 5A — Part Load Data Percent Displacement, Standard Units (cont) UNITT CONTROL 30GTN,R STEPS 30GUN,R 150, 230A, 245A, 255A (50 Hz) 170, 270A, 330A/B (60 Hz) 170, 270A, 330A/B, 360B (50 Hz) 190, 290A, 360A/B, 390B (60 Hz) 190, 290A, 360A, 390B (50 Hz) 210, 315A, 390A, 420A/B (60 Hz)
  • Page 21 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders UNIT CONTROL 30GTN,R STEPS 30GUN,R 040 (60 Hz) 040 (50 Hz) 045 (60 Hz) 045 (50 Hz) 050 (60 Hz) 050 (50 Hz) 060 (60 Hz) 060 (50 Hz) 070 (60 Hz) 070 (50 Hz) 080, 230B (60 Hz)
  • Page 22 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT CONTROL 30GTN,R STEPS 30GUN,R 090, 245B (50 Hz) 100, 255B, 270B (60 Hz) 100, 255B, 270B (50 Hz) 110, 290B, 315B (60 Hz) 110, 290B, 315B (50 Hz) *Unloaded compressor.
  • Page 23 Table 5B — Part Load Data Percent Displacement, with Accessory Unloaders (cont) UNIT CONTROL 30GTN,R STEPS 30GUN,R 130 (60 Hz) 130 (50 Hz) 150, 230A, 245A, 255A (60 Hz) 150, 230A, 245A, 255A (50 Hz) *Unloaded compressor. Two unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing.
  • Page 24 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT CONTROL 30GTN,R STEPS 30GUN,R 170, 270A, 330A/B (60 Hz) 170, 270A, 330A/B, 360B (50 Hz) 190, 290A, 360A/B, 390B (60 Hz) *Unloaded compressor. †Two unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing.
  • Page 25 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT CONTROL 30GTN,R STEPS 30GUN,R 190, 290A, 360A, 390B (50 Hz) 210, 315A, 390A, 420A/B (60 Hz) 210, 315A, 390A, 420A/B (50 Hz) *Unloaded compressor. †Two unloaders, both unloaded. NOTE: These capacity control steps may vary due to lag compressor sequencing.
  • Page 26: Minutes Off Time

    ADDING ADDITIONAL UNLOADERS — See Table 6 below for required hardware. Follow accessory instructions for installation. Connect un- loader coil leads to PINK wires in compressor A1/B1 junction box. Configuration items CA.UN and CB.UN in the OPT1 sub-mode of the configuration mode must be changed to match the new number of unloaders.
  • Page 27: Head Pressure Control

    LEGEND STANDARD DEADBAND LWT — Leaving Water Temperature Low Cooler Suction Temperature — To avoid freezing the cooler, the control will compare the circuit Cooler Suction tem- perature (T5/T6) with a predetermined freeze point. If the cool- er fluid selected is Water, the freeze point is 34 F (1.1 C). If the cooler fluid selected is Brine, the freeze point is 8°...
  • Page 28 FAN ARRANGEMENT 30GTN,R040-050 30GUN,R040-050 30GTN,R060-090, 230B, 245B 30GUN,R060-090, 230B, 245B 30GTN,R100,110, 255B-315B 30GUN,R100,110, 255B-315B 30GTN,R130 (60 Hz), 30GUN,R130 (60 Hz) POWER 30GTN,R130 (50 Hz), 150-210, 230A-315A, 330A/B-420A/B† 30GUN,R130 (50 Hz), 150-210, 230A-315A, 330A/B-420A/B† POWER *Control box. †Fan numbers 11 and 12 do not apply to 30GTN,R and 30GUN,R 130-170 and associated modular units (see Table 1). FAN RELAY —...
  • Page 29: Marquee Display Usage

    Marquee Display Usage (See Fig. 19 and Tables 7-25) — The Marquee display module provides the user interface to the ComfortLink™ control system. The dis- play has up and down arrow keys, an ESCAPE ENTER key. These keys are used to navigate through the dif- ferent levels of the display structure.
  • Page 30 RETURN FLUID *Depending on piping sizes, use either: — HH79NZ014 sensor and 10HB50106801 well (3-in. sensor/well) — HH79NZ029 sensor and 10HB50106802 well (4-in. sensor/well) SERVICE TEMPERATURES STATUS TEST Auto Manual Unit Display Mode Temperatures (VIEW) On/Off (UNIT) (TEST) Machine Ckt A/B Ckt A Hours/Starts Outputs...
  • Page 31 Table 8 — Run Status Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM ENTRY VIEW ENTER SETP CTPT STAT MODE STGE ALRM TIME MNTH DATE YEAR HRS.U ENTER STR.U HOUR HRS.A ENTER HRS.B HR.A1 HR.A2 HR.A3 HR.A4 HR.B1 HR.B2 HR.B3 HR.B4 STRT ST.A1 ENTER...
  • Page 32 Table 9 — Service Test Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM ENTRY TEST TEST ENTER OUTS LLS.A ENTER EXV.A LLS.B EXV.B FAN1 FAN2 FAN3 FAN4 CLR.P CND.P RMT.A COMP CC.A1 ENTER CC.A2 CC.A3 CC.A4 UL.A1 UL.A2 HGBP CC.B1 CC.B2 CC.B3 CC.B4 UL.B1...
  • Page 33 Table 10 — Temperature Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM ENTRY UNIT CEWT ENTER CLWT CNDE CNDL DLWT CIR.A SCT.A ENTER SST.A SGT.A SUP.A CIR.B SCT.B ENTER SST.B SGT.B SUP.B Table 11 — Pressure Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM PRC.A...
  • Page 34 Table 13 — Reading and Changing Chilled Fluid Set Point SUB-MODE KEYPAD ENTRY ITEM COOL CSP.1 ENTER ENTER ENTER ENTER CSP.1 ENTER Table 14 — Inputs Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM ENTRY GEN.I STST ENTER FLOW CND.F DLS1 DLS2 ICED DUAL...
  • Page 35 Table 16 — Configuration Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM ENTRY DISP TEST ENTER METR LANG LEGEND — Carrier Comfort Network — Energy Management Module — Electronic Expansion Valve — Leaving Chilled Water ITEM RANGE OFF-ON OFF-ON OFF-ON OFF-ON OFF-ON...
  • Page 36 OPT2 CTRL 0 - 3 ENTER CCNA 1 - 239 CCNB 0 - 239 LEGEND — Carrier Comfort Network — Energy Management Module — Electronic Expansion Valve — Leaving Chilled Water NAVIGATOR ITEM EXPANSION DISPLAY RANGE AIR COOLED UNIT TYPE...
  • Page 37: Loading Sequence

    Table 16 — Configuration Mode and Sub-Mode Directory (cont) KEYPAD MARQUEE SUB-MODE ITEM ENTRY DISPLAY RANGE OPT2 BAUD 1 - 5 (cont) LOAD 1 - 2 LLCS 1 - 3 2 - 60 ∆ F LCWT (–16 - 16 ∆ C) DELY 0 - 15 ICE.M...
  • Page 38 Table 16 — Configuration Mode and Sub-Mode Directory (cont) KEYPAD MARQUEE SUB-MODE ITEM ENTRY DISPLAY RANGE SLCT CLSP ENTER HTSP RL.S ENBL-DSBL 0.2 - 2.0° F CRMP (0.1 - 1.1° C) 0.2 - 2.0° F HRMP (0.1 - 1.1° C) HCSW COOL-HEAT Z.GN...
  • Page 39 Table 18A — Example of Configuring Dual Chiller Control SUB-MODE KEYPAD ENTRY ITEM RSET CRST ENTER LLDY ENTER ENTER ENTER LLDY ESCAPE LLBD LLBL ENTER ENTER ENTER LLBL ESCAPE SLVA ENTER ENTER ENTER ESCAPE SLVA MSSL Table 18B — Example of Configuring Dual Chiller Control SUB-MODE KEYPAD ENTRY ITEM...
  • Page 40 Table 19 — Example of Compressor Lead/Lag Configuration KEYPAD SUB-MODE ITEM ENTRY OPT2 CTRL ENTER CCNA CCNB BAUD LOAD LLCS ENTER ENTER ENTER LLCS ESCAPE NOTE: Options 1 and/or 3 not valid for sizes 040-070 without Circuit B accessory unloader installed. Table 20 —...
  • Page 41 Table 21 — Setting an Occupied Time Schedule SUB-MODE KEYPAD ENTRY ITEM SCHD MON.O ENTER ENTER ENTER ENTER ENTER MON.O ESCAPE Table 22 — Operating Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY MODE ENTER LEGEND — Flotronic™ System Manager — Saturated Condensing Temperature WSM —...
  • Page 42 MODE NO. ITEM EXPANSION FSM CONTROLLING CHILLER WSM CONTROLLING CHILLER MASTER/SLAVE CONTROL LOW SOURCE PROTECTION RAMP LOAD LIMITED TIMED OVERRIDE IN EFFECT LOW COOLER SUCTION TEMP A LOW COOLER SUCTION TEMP B SLOW CHANGE OVERRIDE MINIMUM OFF TIME ACTIVE LOW SUCTION SUPERHEAT A LOW SUCTION SUPERHEAT B DUAL SET POINT TEMPERATURE RESET...
  • Page 43: Temperature Reset

    Table 24 — Alarms Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY CRNT ENTER RCRN ENTER HIST ENTER RHIS ENTER Table 25 — Example of Reading and Clearing Alarms KEYPAD SUB-MODE ITEM ENTRY AXXX or TXXX CRNT ENTER CRNT ESCAPE RCRN ENTER ENTER Temperature Reset —...
  • Page 44 KEYPAD MODE SUB-MODE ENTRY DISP ENTER UNIT OPT1 OPT2 RSET CONFIGURATION The following are examples of outdoor air and space tem- perature resets: LEGEND LWT — Leaving Water (Fluid) Temperature Table 26 — Configuring Temperature Reset KEYPAD ITEM DISPLAY ENTRY EXPANSION TEST ON/OFF...
  • Page 45: Cooling Set Point (4 To 20 Ma)

    Cooling Set Point (4 to 20 mA) — and generated, externally powered 4 to 20 mA signal can be used to provide the leaving fluid temperature set point. Connect the signal to TB6-3,5 (+,–). See Table 27 for instructions to (38) (27) (15)
  • Page 46: Demand Limit

    Demand Limit — Demand Limit is a feature that allows the unit capacity to be limited during periods of peak energy usage. There are 3 types of demand limiting that can be config- ured. The first type is through 2-stage switch control, which will reduce the maximum capacity to 2 user-configurable per- centages.
  • Page 47: Troubleshooting

    100% CAPACITY AT 4 mA TROUBLESHOOTING Compressor Protection Control (CPCS) Board — The compressor protection board con- trols the compressor and compressor crankcase heater. The ground current protection is provided by the compres- sor board. The large relay located on the board is used to provide a feedback signal to the Main Base Board.
  • Page 48: Step 5 - Check Operation Of The Exv

    2. Make sure that thermistor leads are connected to the proper pin terminals at the J5 connector on EXV board and that thermistor probes are located in proper position in the refrigerant circuit. When these checks have been completed, the actual opera- tion of the EXV can be checked by using the procedures out- lined in Step 5 —...
  • Page 49: Alarm And Alert Codes

    ALARM/ ALARM ALERT DESCRIPTION CODE ALERT T051 Alert Circuit A, Compressor 1 Failure T052 Alert Circuit A, Compressor 2 Failure T053 Alert Circuit A, Compressor 3 Failure T054 Alert Circuit A, Compressor 4 Failure T055 Alert Circuit B, Compressor 1 Failure T056 Alert...
  • Page 50 Pressure T119 Alert Circuit B Low Oil Pressure LEGEND — Carrier Comfort Network CPCS — Compressor Protection Control System — Compressor Expansion Board EMM — Energy Management Module — Entering Fluid Temperature — Electronic Expansion Valve — Flotronic™ System Manager LCW —...
  • Page 51 ALARM/ ALARM ALERT DESCRIPTION CODE ALERT A150 Alarm Emergency Stop A151 Alarm Illegal Configuration A152 Alarm Unit Down Due to Failure T153 Alert Real Time Clock Hardware Failure A154 Alarm Serial EEPROM Hardware Failure T155 Alert Serial EEPROM Storage Failure Alarm Critical Serial A156...
  • Page 52 WSM T951 Alert Loss of Communica- tion with FSM LEGEND — Carrier Comfort Network CPCS — Compressor Protection Control System — Compressor Expansion Board EMM — Energy Management Module — Electronic Expansion Valve — Flotronic™ System Manager LCW — Leaving Chilled Water —...
  • Page 53: Service

    Acceptable oil level for each compressor is from -in. of sight glass (see Fig. 35). When additional oil or a complete charge is required, use only Carrier-approved compressor oil. 30GTN,R approved oils are as follows: Petroleum Specialties, Inc. — Cryol 150 (factory oil charge) Texaco, Inc.
  • Page 54: Replacing Cooler

    70 to 90 ft-lb (94 to 122 N-m). NOTE: The suction flange has a 4-bolt pattern. See Carrier specified parts for replacement part number, if necessary. 4. Using adhesive, reinstall the cooler insulation on the re- frigerant connection end of the cooler.
  • Page 55 Thermistor T2 is used in the freeze protection algorithm for the controller. If sev- eral tubes require plugging, check with your local Carrier rep- resentative to find out how number and location can affect unit capacity.
  • Page 56: Condenser Coils

    3. Apply torque in one-third steps until required torque is reached. Load all bolts to each one-third step before pro- ceeding to next one-third step. 4. No less than one hour later, retighten all bolts to required torque values. 5. After refrigerant is restored to system, check for refriger- ant leaks with soap solution or Halide device.
  • Page 57: Condenser Fans

    Enviro-Shield™ Coil Cleaner Application Equipment • 2 Gallon Garden Sprayer • Water Rinse with Low Velocity Spray Nozzle Enviro-Shield Coil Cleaner Application Instructions • Although Enviro-Shield Coil cleaner is harmless to humans, animals, and marine life, proper eye protection such as safety glasses is recommended during mixing and application.
  • Page 58: Refrigerant Feed Components

    FILTER DRIER — Whenever shows presence of moisture, replace filter drier(s). There is one filter drier on each circuit. Refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, for details on ser- vicing filter driers.
  • Page 59: Thermistors

    Thermistors — Electronic control uses 4 to 10 ther- mistors to sense temperatures used to control the operation of chiller. Thermistors T1-T9 vary in their temperature vs resistance and voltage drop performance. Thermistor T10 is a 10 kΩ in- put channel and has a different set of temperature vs resistance and voltage drop performance.
  • Page 60 Table 32A — 5K Thermistor Temperature (F) vs Resistance/Voltage VOLTAGE DROP A FOR THERMISTORS T1, T2, T7-T9 VOLTAGE VOLTAGE TEMP RESISTANCE DROP A DROP B (Ohms) –25 3.699 4.538 98,010 –24 3.689 4.523 94,707 –23 3.679 4.508 91,522 –22 3.668 4.493 88,449 –21...
  • Page 61 Table 32B — 5K Thermistor Temperature (C) vs Resistance/Voltage (cont) VOLTAGE DROP A FOR THERMISTORS T1, T2, T7-T9 VOLTAGE VOLTAGE TEMP RESISTANCE DROP A DROP B (Ohms) –32 3.705 4.547 100,260 –31 3.687 4.520 94,165 –30 3.668 4.493 88,480 –29 3.649 4.464 83,170...
  • Page 62 Table 33A — 10K Thermistor Temperatures (°F) vs Resistance/Voltage Drop TEMP VOLTAGE RESISTANCE DROP (V) (Ohms) –25 4.758 196,453 –24 4.750 189,692 –23 4.741 183,300 –22 4.733 177,000 –21 4.724 171,079 –20 4.715 165,238 –19 4.705 159,717 –18 4.696 154,344 –17 4.686 149,194...
  • Page 63 Table 33B — 10K Thermistor Temperatures (°C) vs Resistance/Voltage Drop TEMP VOLTAGE RESISTANCE DROP (V) (Ohms) –32 4.762 200,510 –31 4.748 188,340 –30 4.733 177,000 –29 4.716 166,342 –28 4.700 156,404 –27 4.682 147,134 –26 4.663 138,482 –25 4.644 130,402 –24 4.624 122,807...
  • Page 64: Safety Devices

    Safety Devices — Chillers contain many safety devices and protection logic built into electronic control. Following is a brief summary of major safeties. COMPRESSOR PROTECTION Circuit Breaker — One manual-reset, calibrated-trip magnetic circuit breaker for each compressor protects against overcur- rent.
  • Page 65: Relief Devices

    Adjust the oil level as re- quired. No oil should be removed unless the crankcase heater has been energized for at least 24 hours. See Oil Charge section on page 53 for Carrier-approved oils. 7. Electrical power source must agree with unit nameplate. device located 8.
  • Page 66: Start-Up And Operation

    Low-Ambient Operation — If operating temperatures below 0° F (–18 C) are expected, refer to separate installation instruc- tions for low-ambient operation using accessory Motor- master® III control. Contact your Carrier representative for details. NOTE: Wind baffles and brackets must be field-fabricated for all units using accessory Motormaster III controls to ensure proper cooling cycle operation at low-ambient temperatures.
  • Page 67: Flow Rate Requirements

    Consult application data section in the Product Data litera- ture and job design requirements to determine flow rate re- quirements for a particular installation. Table 36 — Nominal and Minimum Cooler Fluid Flow Rates NOMINAL UNIT SIZE FLOW RATE* 30GTN,R AND 30GUN,R 5.43 6.37...
  • Page 68: Control Wiring

    CWFS CWPI HGBPS — Hot Gas Bypass Switch SPT ACCESSORY MBB, PLUG J8 OAT ACCESSORY OR DUAL CHILLER LWT. (MASTER CHILLER) Fig. 36 — Accessory Sensor Control Wiring MAIN BASE BOARD PLUG J10A Fig. 38 — Hot Gas Bypass Control Wiring (115 V, 230 V) LEGEND FOR FIG.
  • Page 69 PLUG J10B Fig. 39 — Chilled Water Pump Control Wiring and Remote Alarm 115 V Relay Wiring EMM, PLUG J6 12 11 10 12 11 10 TB6 3 4.20 MA 4.20 MA SIGNAL SIGNAL GENERATOR GENERATOR COOLING TEMPERATURE SETPOINT RESET Fig.
  • Page 70 CXB ACCESSORY BOARD Fig. 41 — Compressor Expansion Board (CXB) Accessory Wiring CXB ACCESSORY UL-A2 UL-B2 115V/ 230V...
  • Page 71: Appendix A - Ccn Tables

    DESCRIPTION Unit Type Unit Size Circuit A1% Capacity Number Circ A Compressor Compressor A1 Cylinders Number Circ B Compressor Compressor B1 Cylinders EXV Module Installed EXV Superheat Setpoint EXV MOP EXV Superheat Offset EXV Circ. A Min Position EXV Circ. B Min Position Refrigerant Low Pressure Setpoint Fan Staging Select...
  • Page 72 DESCRIPTION Control Method Loading Sequence Select Lead/Lag Circuit Select Cooling Setpoint Select Heating Setpoint Select Ramp Load Select Heat Cool Select High LCW Alert Limit Minutes off time Deadband Multiplier Ice Mode Enable DESCRIPTION Service Password Password Enable Metric Display Language Selection DESCRIPTION Schedule Number...
  • Page 73 APPENDIX A — CCN TABLES (cont) RESETCON (Temperature Reset and Demand Limit) DESCRIPTION COOLING RESET Cooling Reset Type No Cool Reset Temp Full Cool Reset Temp Degrees Cool Reset HEATING RESET Heating Reset Type No Heat Reset Temp Full Heat Reset Temp Degrees Heat Reset DEMAND LIMIT Demand Limit Select...
  • Page 74 APPENDIX A — CCN TABLES (cont) DESCRIPTION Control Mode Occupied CCN Chiller Alarm State Active Demand Limit Override Modes in Effect Percent Total Capacity Requested Stage Active Setpoint Control Point Entering Fluid Temp Leaving Fluid Temp Emergency Stop Minutes Left for Start Heat Cool Select CIRCA_AN (Circuit A Analog Parameters) DESCRIPTION...
  • Page 75 APPENDIX A — CCN TABLES (cont) CIRCB_AN (Circuit B Analog Parameters) DESCRIPTION Circuit B Analog Values Percent Total Capacity Percent Available Cap Discharge Pressure Suction Pressure Saturated Condensing Tmp Saturated Suction Temp Compressor Suction Temp Suction Superheat Temp EXV % Open CIRCBDIO (Circuit B Discrete Parameters) DESCRIPTION CIRC.
  • Page 76 APPENDIX A — CCN TABLES (cont) DESCRIPTION FANS Fan 1 Relay Fan 2 Relay Fan 3 Relay Fan 4 Relay UNIT ANALOG VALUES Cooler Entering Fluid Cooler Leaving Fluid Condensing Entering Fluid Condenser Leaving Fluid Lead/Lag Leaving Fluid TEMPERATURE RESET 4-20 mA Reset Signal Outside Air Temperature Space Temperature...
  • Page 77 DESCRIPTION Machine Operating Hours Machine Starts Circuit A Run Hours Compressor A1 Hours Compressor A2 Hours Compressor A3 Hours Compressor A4 Hours Circuit B Run Hours Compressor B1 Hours Compressor B2 Hours Compressor B3 Hours Compressor B4 Hours Circuit A Starts Compressor A1 Starts Compressor A2 Starts Compressor A3 Starts...
  • Page 78 APPENDIX A — CCN TABLES (cont) DESCRIPTION FSM controlling chiller WSM controlling chiller Master/Slave control Low source protection Ramp Load Limited Timed Override in effect Low Cooler Suction TempA Low Cooler Suction TempB Slow Change Override Minimum OFF Time Low Suction Superheat A Low Suction Superheat B Dual Setpoint Temperature Reset...
  • Page 79: Appendix A — Ccn Tables

    APPENDIX A — CCN TABLES (cont) CSM/FSM EQUIPMENT TABLE (Type 621H, Block 2) LINE Chiller Status 0 = Chiller is off 1 = Valid run state in CCN mode 2 = Recycle active 3 = Chiller is in Local Mode 4 = Power Fail Restart in Progress 5 = Shutdown due to fault 6 = Communication Failure...
  • Page 80: Curves

    APPENDIX B — FLUID DROP PRESSURE CURVES Cooler Fluid Pressure Drop Curves — 30GUN,GUR040-110 LEGEND — 040 — 045,050 NOTE: Ft of water = 2.31 x change in psig. ENGLISH AND SI...
  • Page 81 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GUN,GUR130-210 ENGLISH COOLER PRESSURE DROP KEY 1 — 30GUN,GUR130,150 2 — 30GUN,GUR170,190 3 — 30GUN,GUR210 NOTE: Ft of water = 2.31 x change in psig.
  • Page 82 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GUN,GUR230A-255A, 270A/B-420A/B COOLER PRESSURE DROP KEY 1 Module B — 30GUN,GUR270 2 Module A — 30GUN,GUR230-255 3 Module A — 30GUN,GUR270,330 Module B — 30GUN,GUR330,360 (50 Hz) 4 Module A —...
  • Page 83 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GUN,GUR230B-315B ENGLISH AND SI COOLER PRESSURE DROP KEY 1 Module B — 30GUN,GUR230,245 2 Module B — 30GUN,GUR255,290,315 NOTE: Ft of water = 2.31 x change in psig.
  • Page 84 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GTN,GTR040-110 LEGEND — 040 — 045,050 NOTE: Ft of water = 2.31 x change in psig. ENGLISH AND SI...
  • Page 85 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GTN,GTR130-210 ENGLISH COOLER PRESSURE DROP KEY 1 — 30GTN,GTR130,150 2 — 30GTN,GTR170,190 3 — 30GTN,GTR210 NOTE: Ft of water = 2.31 x change in psig.
  • Page 86 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GTN,GTR230A-420A, 270B, 330B-420B COOLER PRESSURE DROP KEY 1 Module B — 30GTN,GTR270 2 Module A — 30GTN,GTR230-255 3 Module A — 30GTN,GTR270,330 Module B — 30GTN,GTR330,360 (50 Hz) 4 Module A —...
  • Page 87 APPENDIX B — FLUID DROP PRESSURE CURVES (cont) Cooler Fluid Pressure Drop Curves — 30GTN,GTR230B, 245B, 255B, 290B, 315B ENGLISH AND SI COOLER PRESSURE DROP KEY 1 Module B — 30GTN,GTR230,245 2 Module B — 30GTN,GTR255,290,315 NOTE: Ft of water = 2.31 x change in psig.
  • Page 88 Course descriptions and schedules are in our catalog. [ ] Packaged Service Training Copyright 2000 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No.
  • Page 89 START-UP CHECKLIST FOR COMFORTLINK™ CHILLER SYSTEMS A. Preliminary Information JOB NAME _______________________________________________________________________________ LOCATION _______________________________________________________________________________ INSTALLING CONTRACTOR _________________________________________________________________ DISTRIBUTOR ____________________________________________________________________________ START-UP PERFORMED BY _________________________________________________________________ EQUIPMENT: Chiller: MODEL NO. COMPRESSORS: CIRCUIT A 1) MODEL NO. SERIAL NO. MTR NO. 2) MODEL NO. SERIAL NO.
  • Page 90 B. Preliminary Equipment Check IS THERE ANY SHIPPING DAMAGE? _________________________________________________________________________________________ WILL THIS DAMAGE PREVENT UNIT START-UP? HAVE COMPRESSOR BASE RAIL ISOLATORS ALL BEEN PROPERLY ADJUSTED? CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions) ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)
  • Page 91 C. Unit Start-Up (cont) CHECK VOLTAGE IMBALANCE: AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = VOLTAGE IMBALANCE = AVERAGE VOLTAGE IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER! CALL LOCAL POWER COMPANY FOR ASSISTANCE.
  • Page 92 C. Unit Start-Up (cont) ITEM DESCRIPTION TYPE Unit Type TONS Unit Size CAP.A Circuit A1% Capacity CMP.A Number Circ A Compressor Compressor A1 Cylinders CYL.A CMP.B Number Circ B Compressor CYL.B Compressor B1 Cylinders EXV Module Installed SH.SP EXV Superheat Setpoint SH.OF EXV Superheat Offset REFG...
  • Page 93 C. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘OPT1’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT2’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW: ITEM DESCRIPTION CTRL Control Method CCNA CCN Address CCNB CCN Bus Number BAUD CCN Baud Rate LOAD Loading Sequence Select LLCS...
  • Page 94 C. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘RSET’. PRESS DOWN ARROW KEY TO DISPLAY ‘SLCT’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW: ITEM DESCRIPTION CLSP Cooling Setpoint Select HTSP Heating Setpoint Select Ramp Load Select RL.S CRMP Cooling Ramp Loading HRMP Heating Ramp Loading HCSW...
  • Page 95 C. Unit Start-Up (cont) USE ESCAPE/ARROW KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER TO DISPLAY ‘DISP’. PRESS ENTER AGAIN TO DISPLAY ‘TEST’ FOLLOWED BY ‘OFF’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ DISPLAY FLASHES. ‘PASS’ AND ‘WORD’ WILL FLASH IF PASSWORD NEEDS TO BE ENTERED.
  • Page 96: All Units

    SATURATED SUCT TEMP (T5/T6) SUCTION GAS TEMP (T7/T8) COOLER ENT FLUID (T2) COOLER LVG FLUID (T1) Copyright 2000 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book PC 903 Catalog No.