Carrier FLOTRONIC II 30GN040-420 Operating And Troubleshooting Manual
Carrier FLOTRONIC II 30GN040-420 Operating And Troubleshooting Manual

Carrier FLOTRONIC II 30GN040-420 Operating And Troubleshooting Manual

Flotronic ii control system reciprocating liquid chillers 50/60 hz with microprocessor controls and electronic expansion valves
Table of Contents

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with Microprocessor Controls and Electronic Expansion Valves
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-5
Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low-Voltage Relay Module . . . . . . . . . . . . . . . . . . . 4
Electronic Expansion Valve Module . . . . . . . . . . . 4
Options Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . . 4
Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic Expansion Valve (EXV) . . . . . . . . . . . . 4
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Module (CPCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 24
Pumpout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
• EXV UNITS
• TXV UNITS
(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . 24
• KEYPAD OPERATING INSTRUCTIONS
• HISTORY FUNCTION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 47-64
Checking Display Codes . . . . . . . . . . . . . . . . . . . . 47
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. 563-079
Tab
5c
Flotronic™ II Reciprocating Liquid Chillers
Controls, Operation, and
Troubleshooting
Page
Printed in U.S.A.
CONTENTS
Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . 48
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . 48
Lag Compressor Stoppage . . . . . . . . . . . . . . . . . . 48
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Compressor Alarm/Alert Circuit . . . . . . . . . . . . . 50
Electronic Expansion Valve (EXV) . . . . . . . . . . . 55
• CHECKOUT PROCEDURE
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• LOCATION
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . 60
• TROUBLESHOOTING
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• PROCESSOR MODULE (PSIO), 4IN/4OUT
MODULE (SIO), LOW-VOLTAGE RELAY
MODULE (DSIO-LV), AND EXV DRIVER
• 4IN/4OUT MODULE (SIO)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• 130 (50 Hz), 150-210 UNITS
(And Associated Modular Units)
FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,70
MODULE (PSIO) . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Form 30GN-3T
30GN040-420
50/60 Hz
Pg 1
7-95
Replaces: 30G-1T
Page

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Summary of Contents for Carrier FLOTRONIC II 30GN040-420

  • Page 1: Table Of Contents

    Controls, Operation, and with Microprocessor Controls and Electronic Expansion Valves SAFETY CONSIDERATIONS ....2 GENERAL ........2 MAJOR SYSTEM COMPONENTS .
  • Page 2: Safety Considerations

    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.
  • Page 3 LEGEND CCN — Carrier Comfort Network — Terminal Block Fig. 1 — 30GN Control Panel (040-110 Unit Shown) COMM 3 POINT NUMBER FIRST CHANNEL STATUS STATUS COMM COMM COMM 1 COMM 3 F US E 1 STAT EXPN FU S E 2...
  • Page 4: Low-Voltage Relay Module

    This is a 3-position manual switch that allows the chiller to be put under the control of its own Flotronic II controls, manu- ally stopped, or put under the control of a Carrier Comfort Network (CCN). Switch allows unit operation as shown in Table 2.
  • Page 5: Sensors

    The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler by monitoring the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless absolutely necessary.
  • Page 6 UNIT CONTROL 30GN STEPS 040 (60 Hz) A1†,B1 040 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1 040 (50 Hz) 045 (60 Hz) A1†,B1** 040 (50 Hz) 045 (60 Hz) A1†,B1** 045 (50 Hz) 050 (60 Hz) A1†,B1 045 (50 Hz) 050 (60 Hz) A1†,B1**...
  • Page 7 Table 4A — Capacity Control Steps, 040-070 (cont) UNIT CONTROL 30GN STEPS 045 (50 Hz) 050 (60 Hz) A1†**,B1** 050 (50 Hz) 060 (60 Hz) A1†,B1 050 (50 Hz) 060 (60 Hz) A1†,B1** 050 (50 Hz) 060 (60 Hz) A1†**,B1 050 (50 Hz) 060 (60 Hz) A1†**,B1**...
  • Page 8 Table 4A — Capacity Control Steps, 040-070 (cont) UNIT CONTROL 30GN STEPS 060 (50 Hz) 070 (60 Hz) A1†**,B1 070 (50 Hz) A1†,B1 070 (50 Hz) A1†,B1** 070 (50 Hz) A1†**,B1 070 (50 Hz) A1†**,B1** 070 (50 Hz) A1†,B1 070 (50 Hz) A1†**,B1 *Unloaded compressor.
  • Page 9 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units UNIT CONTROL 30GN STEPS 080, 230B (60 Hz) A1†,B1† 080, 230B (60 Hz) A1†**, B1† 080, 230B (60 Hz) A1†,B1†** 080, 230B (60 Hz) A1†**,B1†** 080, 230B (50 Hz) A1†,B1†...
  • Page 10 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 090, 245B (60 Hz) A1†,B1† 090, 245B (60 Hz) A1†**,B1† 090, 245B (60 Hz) A1†,B1†** 090, 245B (60 Hz) A1†**,B1†** 090, 245B (50 Hz) A1†,B1†...
  • Page 11 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 090, 245B (50 Hz) A1†,B1†** 090, 245B (50 Hz) A1†**,B1†** 100, 255B, 270B (60 Hz) A1†,B1† 100, 255B, 270B (60 Hz) A1†**,B1† 100, 255B, 270B (60 Hz) A1†,B1†** *Unloaded compressor.
  • Page 12 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 100, 255B, 270B (60 Hz) A1†**,B1†** 100, 255B, 270B (50 Hz) A1†,B1† 100, 255B, 270B (50 Hz) A1†**,B1† 100, 255B, 270B (50 Hz) A1†,B1†** 100, 255B, 270B (50 Hz) A1†**,B1†**...
  • Page 13 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 110, 290B, 315B (60 Hz) A1†,B1† 110, 290B, 315B (60 Hz) A1†**,B1† 110, 290B, 315B (60 Hz) A1†,B1†** 110, 290B, 315B (60 Hz) A1†**,B1†** 110, 290B, 315B (50 Hz) A1†,B1†...
  • Page 14 Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 110, 290B, 315B (50 Hz) A1†**,B1† 110, 290B, 315B (50 Hz) A1†,B1†** 110, 290B, 315B (50 Hz) A1†**,B1†** *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded.
  • Page 15 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units UNIT CONTROL 30GN STEPS 130 (60 Hz) A1†,B1† 130 (60 Hz) A1†**,B1† 130 (60 Hz) A1†,B1†** 130 (60 Hz) A1†**,B1†** 130 (50 Hz) A1†,B1† *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory.
  • Page 16 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 130 (50 Hz) A1†**,B1† 130 (50 Hz) A1†,B1†** 130 (50 Hz) A1†**,B1†** 150, 230A, 245A, 255A (60 Hz) A1†,B1† *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory.
  • Page 17 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL 30GN STEPS 150, 230A, 245A, 255A (60 Hz) A1†**,B1† 150, 230A, 245A, 255A (60 Hz) A1†,B1†** 150, 230A, 245A, 255A (60 Hz) A1†**,B1†** 150, 230A, 245A, 255A (50 Hz) A1†,B1†...
  • Page 18 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 150, 230A, 245A, 255A (50 Hz) A1†,B1†** 150, 230A, 245A, 255A (50 Hz) A1†**,B1†** 170, 270A, 330A/B (60 Hz) A1†,B1† 170, 270A, 330A/B (60 Hz) A1†**,B1†...
  • Page 19 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 170, 270A, 330A/B (60 Hz) A1†,B1†** 170, 270A, 330A/B (60 Hz) A1†**,B1†** 170, 270A, 330A/B,360B (50 Hz) A1†,B1† *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory. ††Two unloaders, both unloaded.
  • Page 20 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1† 170, 270A, 330A/B, 360B (50 Hz) A1†,B1†** 170, 270A, 330A/B, 360B (50 Hz) A1†**,B1†** *Unloaded compressor. †Compressor unloader, standard. **Compressor unloader, accessory.
  • Page 21 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 190, 290A, 360A/B, 390B (60 Hz) A1,B1 190, 290A, 360A/B, 390B (60 Hz) A1**,B1 190, 290A, 360A/B, 390B (60 Hz) A1,B1** 190, 290A, 360A/B, 390B (60 Hz) A1**,B1** 190, 290A, 360A,...
  • Page 22 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 190, 290A, 360A, 390B (50 Hz) A1,B1** 190, 290A, 360A, 390B (50 Hz) A1**,B1** 210, 315A, 390A, 420A/B (60 Hz) A1,B1 210, 315A, 390A, 420A/B (60 Hz) A1**,B1 210, 315A, 390A,...
  • Page 23 Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT CONTROL SIZE STEPS 210, 315A, 390A, 420A/B (60 Hz) A1**,B1** 210, 315A, 390A, 420A/B (50 Hz) A1,B1 210, 315A, 390A, 420A/B (50 Hz) A1**,B1 210, 315A, 390A, 420A/B (50 Hz) A1,B1** 210, 315A, 390A,...
  • Page 24: Head Pressure Control

    Head Pressure Control EXV UNITS (All 30GN units except 040 and 045 with op- tional brine) — The microprocessor controls the condenser fans in order to maintain the lowest condensing temperature possible, thus the highest unit efficiency. Instead of using the conventional head pressure control methods, the fans are con- trolled by the position of the EXV and suction superheat.
  • Page 25: Automatic Display Operation/Default

    FAN ARRANGEMENT 30GN 040-050 060,070 080,090 (and associated modular units*) 100,110 (and associated modular units*) 130-170 (and associated modular units*) 190,210 (and associated modular units*) *See Table 1. †Control box. AUTOMATIC DISPLAY OPERATION/DEFAULT DIS- PLAY — This display automatically rotates as follows: DOW —...
  • Page 26: Display

    Table 6 — Keypad and Display Module Usage FUNCTION KEYS STATUS — For displaying diagnostic codes and current operating information about the machine. HISTORY — For displaying run time, cycles and previous alarms. SERVICE — For entering specific unit configura- tion information.
  • Page 27: Accessing Functions And Subfunctions

    Table 8 — Accessing Functions and Subfunctions OPERATION To access a function, press subfunction no. and function name key. Display shows sub- function group. To move to other elements, scroll up or down using arrow keys. NOTE: These displays do not show if control is not configured for reset.
  • Page 28: Status Function

    SUBFUNCTION KEYPAD ENTRY 4 STAGE 5 SET POINT 6 TEMPERATURE LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure Table 9 — Keypad Directory (cont) STATUS (cont) DISPLAY STAGE Capacity Staging Information COOL X...
  • Page 29: Display

    SUBFUNCTION KEYPAD ENTRY 7 PRESSURE 8 ANALOG 9 INPUTS 10 OUTPUTS LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure Table 9 — Keypad Directory (cont) STATUS (cont) DISPLAY PRESSURE MM DD YY...
  • Page 30: Display

    SUBFUNCTION KEYPAD ENTRY 10 OUTPUTS (cont) To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position. To operate a test, scroll to desired test. Then, press to start test. Press to stop test. SUBFUNCTION KEYPAD ENTRY 1 OUTPUTS To toggle between inputs (Yes/No) Press: During compressor test, compressors start and run for 10 seconds.
  • Page 31: Test Function

    2 CLOCK SELECT 3 PERIOD 1 Yes = Schedule Opera- tional for that day LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured.
  • Page 32: Display

    SUBFUNCTION 3 PERIOD 1 (cont) To toggle between inputs (Yes/No) Press: 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 44.
  • Page 33: Display

    CONFIGURATION To toggle between inputs (Yes/No) Press: 5 SERVICE CONFIGURATION LEGEND CCN — Carrier Comfort Network — Electronic Expansion Valve MOP — Maximum Operating Pressure *Will read ALARM or ALERT as appropriate. †Must be configured. Table 9 — Keypad Directory (cont)
  • Page 34: Display

    SUBFUNCTION KEYPAD ENTRY 1 RUN TIME 2 STARTS 3 ALARM/ALERT HISTORY†† LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure Table 9 — Keypad Directory (cont) HISTORY DISPLAY RUN TIME Run Time Information...
  • Page 35: Set Point Function

    2 RESET SET POINTS 3 DEMAND SET POINTS 4 DATE AND TIME 5 LEAVING CHILLER FLUID ALERT LIMIT LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve MOP — Maximum Operating Pressure Table 9 — Keypad Directory (cont) SET POINT DISPLAY...
  • Page 36: Display

    STATUS FUNCTION — This function shows the rotating display, current status of alarm and alert (diagnostic) codes, capacity stages, operating modes, chilled water set point, all measured system temperatures and pressures, superheat val- ues, pressure switch positions, analog inputs, and switch in- puts.
  • Page 37: Display

    X minute off-to-on delay is in effect. MODE 18 Low suction superheat protection is in effect. CCN — Carrier Comfort Network (Set Point) — This subfunction displays leaving fluid temperature and leaving chilled fluid set point. If unit is programmed for dual set point, the chilled fluid set point currently in effect (either occupied or unoccupied) is displayed.
  • Page 38: Display

    Keypad entry allows the operator to make the following checks by using • LID display check. Proper display is 8.8.8.8.8.8.8.8. • Operation of alarm relay. • Operation of condenser fans. • Operation of chilled fluid pump. • Operation of liquid line solenoids. •...
  • Page 39: Service Function

    Example 4 — Reading and Changing Chilled Fluid Set Point KEYPAD DISPLAY ENTRY RESPONSE SET POINT System set points CSP1 44.0 Present occupied chilled fluid set point is 44.0 F CSP1 42.0 Press the Display shows new occupied chilled fluid set point is 42.0 F Present unoccupied chilled fluid CSP2 44.0 set point is 44.0 F...
  • Page 40: Display

    Example 5B — 4 to 20 mA and Internally or Externally Powered Reset In this example, the unit set point is reset from full load at 4 mA to a maximum reset value of 10 F (5.5 C) at 20 mA. Internally powered 4 to 20 mA option is used in this example.
  • Page 41: Display

    Fig. 6 — Cooling External Temperature Reset Fig. 7 — 4 IN/4 OUT Options Module Wiring for Reset, Demand Limit, and Dual Set Point COMM — Communications Bus — Power — Switch NOTE: For specific connection points, see Fig. 25 - 29. LEGEND...
  • Page 42: Display

    Fig. 8 — 4-20 mA Cooling Temperature Reset Example 6 — Changing Reset Type To change type of reset, first log on as shown in Table 12. Also refer to Set Point Function section, page 38, for information on entering reset set points using reset feature.
  • Page 43: Display

    NOTES: 1. Select 2 for internally powered 4 to 20 mA signal load limiting. 2. Select 3 for Carrier Comfort Network loadshed. 3. Select 4 for externally powered 4 to 20 mA signal load limiting. Example 7B — Using Demand Limit (4-20 mA)
  • Page 44: Display

    Factory Configuration Codes — the factory configuration subfunction. Under this subfunc- tion, there are 7 groups of configuration codes that are down- loaded at the factory. Each group is made up of 8 digits. If processor module is replaced in the field, these 7 groups of configuration codes must be entered through the keypad and display module.
  • Page 45: Display

    1 = ON/OFF Controlled Remote Alarm Option Select 0 = Not Selected 1 = Selected Local/Enable-Stop-CCN Switch Usage† 0 = Not Allowed 1 = Allowed LEGEND CCN — Carrier Comfort Network EXV — Electronic Expansion Valve FACTORY SERVICE CONFIGURATION REPLACEMENT CODE CODE 9600...
  • Page 46: Schedule Function

    TUE NO no for period 1 Example 9 — Using the Schedule Function (cont) PROGRAMMING PERIOD 2: . Pass- through COMMENT CCN — Carrier Comfort Network KEYPAD DISPLAY COMMENT ENTRY PERIOD 2 Define schedule period 2 OCC 00.00 Start of occupied time Occupied time will start OCC 7.00...
  • Page 47: Troubleshooting

    Periods 4 and 5 can be programmed in the same manner, flagging Thursday and Friday yes for period 4 and Saturday yes for period 5. For this example, periods 6, 7, and 8 are not used: they should be programmed OCC 00.00, UNO 00.00.
  • Page 48: Unit Shutoff

    Unit Shutoff — To shut unit off, move LOCAL/ENABLE- STOP-CCN switch to STOP position. Any refrigeration cir- cuit operating at this time continues to complete the pum- pout cycle. Lag compressors stop immediately, and lead compressors run to complete pumpout. Complete Unit Stoppage —...
  • Page 49 ALARM DISPLAY DESCRIPTION ALERT — No Alarms or Alerts Exist Compressor A1 failure 2, 3, 4 Compressor A2, A3, A4 failure Alert Compressor B1 failure 6, 7, 8 Compressor B2, B3, B4 failure Leaving fluid thermistor failure Alarm Entering fluid thermistor failure Compressor A1 sensor failure Alert Compressor B1 sensor failure...
  • Page 50: Compressor Alarm/Alert Circuit

    ALARM DISPLAY DESCRIPTION ALERT Alarm Complete unit shutdown Loss of charge, circuit A Alert Loss of charge, circuit B Alarm FSM communication loss Alarm Transducer calibration date code failure 68,69 — Not used Alert High leaving chilled fluid temperature LEGEND CPCS —...
  • Page 51 Fig. 11A — 24-V Safety Circuit Wiring (040-070) Code 21 Reset thermistor failure (applies only to installa- tions having external temperature reset) (alert) If temperature measured by this thermistor is outside range of –40 to 240 F (–40 to 116 C), reset function is disabled and unit controls to normal set point.
  • Page 52 LEGEND — Contactor — Circuit Breaker COMM — Communications Bus CPCS — Compressor Protection Control Module — Discharge Gas Thermostat (Optional) DSIO — Relay Module (Low Voltage) — High-Pressure Switch — Low Voltage — Plug — Power — Terminal Block TRAN —...
  • Page 53: Error Codes

    LEGEND — Circuit Breaker — Ground Fault Module COMM — Communications Bus — Compressor Contactor Relay DSIO — Relay Module (Low Voltage) — High-Pressure Switch — Low Voltage — Plug — Snubber — Terminal Block TRAN — Transformer — Unloader Fig.
  • Page 54 If oil pressure differential is less than set point for more than 2 minutes at start-up, or more than one minute during normal operation, affected circuit shuts down without going through pumpout process. Reset is manual with LOCAL/ ENABLE-STOP-CCN switch, and start-up follows normal sequence.
  • Page 55: Electronic Expansion Valve (Exv)

    LOCAL/ENABLE-STOP-CCN switch. Most probable cause of this fault is shutdown or failure of chilled fluid pump to start. Other possibilities are improper configuration or wir- ing errors. Code 55 Cooler pump interlock failure — Contacts closed when pump is off (alarm) If the unit is configured for cooler pump control and cooler pump interlock, and the interlock is closed when the cooler pump relay is off, the cooler pump shall be shut down and...
  • Page 56 vapor). To control refrigerant flow for different operating con- ditions, sleeve moves up and down over orifice, thereby chang- ing orifice size. Sleeve is moved by a linear stepper motor. Stepper motor moves in increments and is controlled di- rectly by the processor module. As stepper motor rotates, motion is transferred into linear movement by lead screw.
  • Page 57: Thermostatic Expansion Valve (Txv)

    reading correctly. Connect a calibrated gage to lead compressor suction or discharge pressure connection to check transducer reading. e. Make sure transducer leads are properly connected in junction box and at processor board. Check trans- former 5 output. Check voltage transducer 5 vdc .2 v.
  • Page 58 Table 17 — Thermistor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ II TEMPERATURE VOLTAGE RESISTANCE DROP (V) (OHMS) −25.0 4.821 98010 −24.0 4.818 94707 −23.0 4.814 91522 −22.0 4.806 88449 −21.0 4.800 85486 −20.0 4.793 82627 −19.0 4.786 79871 −18.0 4.779 77212 −17.0 4.772...
  • Page 59 Table 18 — Thermistor Temperature (°C) vs Resistance/Voltage Drop; Flotronic™ II TEMPERATURE VOLTAGE DROP (V) −40 4.896 −39 4.889 −38 4.882 −37 4.874 −36 4.866 −35 4.857 −34 4.848 −33 4.838 −32 4.828 −31 4.817 −30 4.806 −29 4.794 −28 4.782 −27 4.769...
  • Page 60: Pressure Transducers

    LEGEND DPT — Discharge Pressure Transducer EXV — Electronic Expansion Valve OPT — Oil Pressure Transducer SPT — Suction Pressure Transducer — Thermistor Number Fig. 14 — Thermistor and Pressure Transducer Locations Pressure Transducers — A single style of pressure transducer is used for both high- and low-pressure sensing on Flotronic™...
  • Page 61 Fig. 15 — Thermistor Locations (Circuits A and B, Lead Compressor Only) COMPRESSOR SUCTION GAS TEMPERATURE FLUID-SIDE TEMPERATURE THERMISTOR T2 THERMISTORS T7 AND T8 (ALL UNITS) (ALL UNITS) AND FLUID-SIDE TEMPERATURE THERMISTOR T1 (ALL UNITS) Fig. 16 — Thermistors...
  • Page 62: Transducer Replacement

    Fig. 17 — Lead Compressor Transducer and Thermistor Locations TRANSDUCER REPLACEMENT Transducers are installed directly in the refrigerant cir- cuit. Relieve all refrigerant pressure using standard re- frigeration practices before removing. 1. Relieve refrigerant pressure using standard refrigeration practices. 2. Disconnect transducer wiring at transducer by pulling up on locking tab while pulling weathertight connection plug from end of transducer.
  • Page 63: 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 RELAY MODULE (DSIO-LV), AND EXV DRIVER MODULE (DSIO-EXV) — The PSIO, DSIO and SIO modules all perform continuous diagnostic evaluations of the condition of the hardware.
  • Page 64: Processor Module (Psio)

    Fig. 19 — Sensor Bus Wiring (Communications) PROCESSOR MODULE (PSIO) (Fig. 20) Inputs — Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are used. Always refer to individual unit wiring for terminal numbers.
  • Page 65: Installation

    (50 Hz), 150-210, and associated modular units (Table 1). Coil voltage depends on control circuit voltage. Consult cur- rent Carrier price pages for appropriate part numbers. NOTE: The accessory package will include all necessary com- ponents and wiring with the following exceptions: The field must provide screws, and on the 130-210, and associated modu- lar units, the field must also supply a 20 vdc (part number...
  • Page 66: *And Associated Modular Units

    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 COMPRESSOR SHUTS DOWN...
  • Page 67 5. Using test function, check unloaders. Press pad display reads OUTPUTS. Press reads UNA2 OFF. Press . Relay energizes. Press and relay deenergizes. Press UNB2 OFF. Press . Relay energizes. Press and relay deenergizes. 6. When unloader check has been performed, return LOCAL/ ENABLE-STOP-CCN to proper position.
  • Page 68 LEGEND — Contactor — Circuit Breaker COMM — Communications Bus TRAN — Transformer HGBPR — Hot Gas Bypass Relay Fig. 23 — Accessory Unloader Control Wiring, All Units LEGEND — Communications Bus HGBPR — Hot Gas Bypass Relay TRAN — Transformer —...
  • Page 69: Field Wiring

    NOTE: Contacts must be rated for dry circuit application, capable of reliably switching a 5 vdc, 1 mA to 20 mA load. Fig. 25 — Demand Limit — Two External Fig. 26 − Demand Limit — 4-20 mA Signal (Externally Powered) Fig.
  • Page 70: Replacing Defective Processor Module (Psio)

    The proper software and unit configuration data is factory installed by Carrier in the replacement module. Therefore, when ordering a replacement processor module (PSIO), specify complete replacement part number, full unit model number, and serial number.
  • Page 72: Book 2 Pc 903 Catalog No. 563-079 Printed In U.s.a

    Copyright 1995 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. 563-079 Printed in U.S.A. Form 30GN-3T Pg 72 7-95 Replaces: 30G-1T...

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