Carrier Flotronic 30GT080-420 Installation, Start-Up And Service Instructions Manual
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Carrier Flotronic 30GT080-420 Installation, Start-Up And Service Instructions Manual

Carrier Flotronic 30GT080-420 Installation, Start-Up And Service Instructions Manual

50/60 hz reciprocating liquid chillers
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SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can
be hazardous due to system pressures, electrical compo-
nents, and equipment location.
Only trained, qualified installers and service mechanics
should install, start up, and service this equipment.
Untrained personnel can perform basic maintenance func-
tions, such as cleaning coils. All other operations should be
performed by trained service personnel.
When working on the equipment, observe precautions in
the literature, and on tags, stickers, and labels attached to the
equipment.
• Follow all safety codes.
• Wear safety glasses and work gloves.
• Use care in handling, rigging, and setting bulky
equipment.
ELECTRIC SHOCK HAZARD.
Open all remote disconnects before serv-
icing this equipment.
IMPORTANT: This equipment generates, uses, and can
radiate radio frequency energy and if not installed
and used in accordance with these instructions may cause
radio interference. It has been tested and found to
comply with the limits of a Class A computing de-
vice as defined by FCC (Federal Communications
Commission, U.S.A.) regulations, Subpart J of Part 15,
which are designed to provide reasonable protection
against such interference when operated in a commer-
cial environment.
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Step 1 — Rig and Place the Unit . . . . . . . . . . . . . 2
Step 2 — Join Modules A and B
(230-420 Units Only) . . . . . . . . . . . . . . . . . . . . .
Step 3 — Check Compressor Mounting . . . . 27
Step 4 — Cooler Fluid and Drain
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . 27
• PREPARATION FOR YEAR-ROUND
OPERATION
• PREPARATION FOR WINTER SHUTDOWN
Step 5 — Make Electrical Connections . . . . . 28
• FIELD POWER CONNECTIONS
• FIELD CONTROL POWER CONNECTIONS
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. 533-005
Tab
5c
Flotronic™ Reciprocating Liquid Chillers
Installation, Start-Up and
Service Instructions
Page
27
Printed in U.S.A.
Step 6 — Install Accessories . . . . . . . . . . . . . . 43
• ELECTRICAL
• LOW-AMBIENT OPERATION
• HOT GAS BYPASS
• MISCELLANEOUS ACCESSORIES
Pre-Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-50
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
• A. QUICK TEST STEPS 1-15:
UNIT CONFIGURATION
• B. QUICK TEST STEPS 16-30: THERMISTORS
AND SET POINT POTENTIOMETERS
• C. QUICK TEST STEPS 31-42: OUTPUT RELAYS
Start-Up And Operation . . . . . . . . . . . . . . . 50-56
Digital Display Action . . . . . . . . . . . . . . . . . . . . . 50
Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operating Limitations . . . . . . . . . . . . . . . . . . . . . 50
• TEMPERATURES
• VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
Operation Sequence . . . . . . . . . . . . . . . . . . . . . . 51
• UNITS WITH ELECTRONIC EXPANSION
VALVE (EXV)
• 30GT080-110 UNITS WITH OPTIONAL
THERMOSTATIC EXPANSION VALVE
(TXV)
• LOAD SHED
• TEMPERATURE RESET
• HEAD PRESSURE CONTROL
• REMOTE ON-OFF
• REMOTE ALARM
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-68
Diagnostics And Troubleshooting . . . . . . . . . . . 57
Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 57
• LEAK TESTING
• DEHYDRATION
• REFRIGERANT CHARGE
Electronic Components . . . . . . . . . . . . . . . . . . . . 57
• CONTROL COMPONENTS
• 30GT080-110 AND 230B-315B
UNIT CONTROL BOX
• 30GT130-210, 230A-315A, AND
330A/B-420A/B UNIT CONTROL AND
MAIN POWER BOXES
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• COMPRESSOR REMOVAL
• OIL CHARGE
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
• COOLER REMOVAL
• REPLACING COOLER
• SERVICING COOLER
Form 30GT-50SI
Pg 1
30GT080-420
50/60 Hz
Page
12-96
Replaces: 30GT-45SI

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Summary of Contents for Carrier Flotronic 30GT080-420

  • Page 1 30GT080-420 Flotronic™ Reciprocating Liquid Chillers 50/60 Hz Installation, Start-Up and Service Instructions Page SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment can Step 6 — Install Accessories ....43 be hazardous due to system pressures, electrical compo- •...

  • Page 2: Introduction

    Table 1 — Unit Sizes and Modular Combinations CONTENTS (cont) Page UNIT MODEL NOMINAL SECTION A SECTION B 30GT TONS UNIT 30GT UNIT 30GT Condenser Coils ......60 —...
  • Page 3 NOTES: CENTER OF GRAVITY 1. Unit must have clearances for airflow (from solid sur- (ft-in.) faces) as follows: Top — Do not restrict in any way 30GT 080,230B 090,245B Ends — 5 ft [1524 mm] SIZE Sides — 6 ft [1829 mm] ⁄...
  • Page 4 NOTES: 1. Unit must have clearances for airflow (from solid sur- faces) as follows: Top — Do not restrict in any way Ends — 5 ft [1524 mm] Sides — 6 ft [1829 mm] 2. Mounting holes may be used to mount unit to con- crete pad.
  • Page 5 NOTES: CENTER OF GRAVITY 1. Unit must have clearances for airflow (from solid sur- (ft-in.) faces) as follows: Top — Do not restrict in any way 30GT Ends — 5 ft [1524 mm] UNIT SIZE Sides — 6 ft [1829 mm] ⁄...
  • Page 6 DIMENSIONS (ft-in.) 30GT UNIT SIZE 190,290A,360A (50 Hz), 11-4 [3454] 4-2 ⁄ [1283] 1-5 ⁄ [448] 6- 3 ⁄ [1916] 7-8 ⁄ [2343] 8 ⁄ [219] 1- 9 [533.4] 6- 4 ⁄ [1941.3] 360A/B (60 Hz), 390B 210,315A, 11-3 ⁄ [3444] 4-2 ⁄...
  • Page 7 NON-FUSED DISCONNECT OPTION Fig. 5 — Location of Optional Non-Fused Disconnect; 130-210 and 230A-315A,330A/B-420A/B Units (130-170,230A-270A,330A/B,360B 50 Hz Shown)
  • Page 8 *Points A, B, C, and D are in the corners of the unit. See Fig. 1 and 2 for dimensions. 60 Hz 30GT CONDENSER UNIT SIZE COIL C-AL 1624 1690 1666 1650 080,230B 1797 1880 1847 1831 C-AL 1817 1793 1720 1685 090,245B...
  • Page 9 60 Hz 30GT CONDENSER UNIT SIZE COIL C-AL 1466 1156 1411 1365 1469 1439 1051 1593 1283 1601 1556 1659 1622 C-AL 1563 1160 1438 1375 1747 1438 150,230A-255A 1053 1690 1287 1628 1566 1938 1629 C-AL 1732 1333 1497 1629 1816 1462...
  • Page 10 50 Hz 30GT CONDENSER UNIT SIZE COIL C-AL 1569 1160 1438 1375 1764 1444 1056 1696 1287 1628 1566 1954 1635 C-AL 1591 1160 1438 1375 1829 1502 150,230A-255A 1075 1719 1287 1628 1566 2020 1692 C-AL 1744 1348 1527 1673 1849 1466...

  • Page 27: Step 3 — Check Compressor Mounting

    Locate the unit so that the condenser airflow is un- restricted both above and on the sides of the unit. See Fig. 1-5 for required clearances. The unit may be mounted on a level pad directly on the base rails or on a raised perimeter rail around the unit.

  • Page 28: Field Power Connections

    4. Open one of the thermistor connections to allow air to 30GT080-110 and 230B-315B Units — All field power en- escape the vessel and the anti-freeze to enter. ters the unit through the control box at the left end when facing the compressors.
  • Page 29 30GT130-210, 230A-315A, and 330-420 Units — The field power wiring enters the unit through the left side of the cooler side power box. The control power enters the control box on the compressor side of the unit. NOTE: If optional non-fused disconnect is installed, power wiring must enter through center panel of unit (disconnect location).

  • Page 30: Field Control Power Connections

    FIELD CONTROL POWER CONNECTIONS (See Fig. 16 and 17) — For 208/230-, 460- and 575-3-60 units: If the accessory transformer is not used, provide a 115-1-60 power source for the control circuit, through a field-supplied fused disconnect (per NEC). This conductor must be copper only.
  • Page 31 For 30GT130-210, 230A-315A, and 330A/B-420A/B units pump interlock (CWPI) is provided between terminals TB6-3 with 380-3-60 and 380/415-3-50 power: Control voltage is and TB6-4 for field use. To use this circuit, remove the fac- tapped from line to neutral. No additional power supply is tory jumper and install the switches.
  • Page 32 FROM GRN/YEL RACEWAY EQUIP. GROUND CONTROL BOX WIRING FOR NON-FUSED DISCONNECT OPTION ONLY Fig. 17 — Field Control Power Wiring; Unit Sizes 130-210, 230A-315A, 330A/B-420A/B Table 4A — Unit Electrical Data, 30GT080-110 VOLTAGE STANDARD CONDENSER FAN HIGH-STATIC CONDENSER FAN 30GT Nameplate UNIT Supplied*...
  • Page 33 Table 4B — Unit Electrical Data, 30GT130-210 VOLTAGE STANDARD CONDENSER FAN HIGH STATIC CONDENSER FAN 30GT Nameplate UNIT Supplied* Fuse Size Fuse Size V-Hz MOCP MOCP SIZE (3 Phase) 208/230-60 610.2 1111.1 835.1 701.8 1202.7 926.7 460-60 271.8† 534.1 397.0 303.8 567.0 429.0...
  • Page 34 Table 4C — Unit Electrical Data, 30GT230-420 MODULE A VOLTAGE Standard Condenser Fan High-Static Condenser Fan 30GT UNIT Nameplate Supplied* SIZE Fuse Size Fuse Size V-Hz MOCP MOCP (3 Phase) 208/230-60 664.2 1165.1 889.1 755.8 1256.7 980.7 460-60 312.9 576.1 438.1 334.9 608.1...
  • Page 35 Table 4C — Unit Electrical Data, 30GT230-420 (cont) MODULE B VOLTAGE Standard Condenser Fan High-Static Condenser Fan 30GT UNIT Nameplate Supplied* SIZE Fuse Size Fuse Size V-Hz MOCP MOCP (3 Phase) 208/230-60 398.5 896.9 620.9 446.5 951.9 675.9 460-60 185.8 442.8 305.4 204.7...
  • Page 36 Table 5 — Control Circuit CONTROL POWER AMPS 080-110 and 130-210,230A-315A, and UNIT POWER SUPPLY 230B-315B Units 330A/B-420A/B Units (V-Ph-Hz) V-Ph-Hz With Cooler Without With Cooler Without Heater Cooler Heater Heater Cooler Heater 203/230-3-60 115-1-60 460-3-60 115-1-60 575-3-60 115-1-60 380-3-60 230-1-60 346-3-50 230-1-50...
  • Page 37 Table 6B — Compressor Electrical Data, 30GT130-210 COMPRESSOR NUMBERS 30GT NAMEPLATE UNIT V-Hz SIZE (3 Phase) 208/230-60 107.7 151.3 — — 107.7 151.3 460-60 46.8 64.5 — — 46.8 65.4 575-60 41.7 57.1 — — 41.7 57.1 130-XL 380-60 55.8 80.2 —...
  • Page 38 Table 6C — Compressor Electrical Data, 30GT230-420 MODULE A 30GT NAMEPLATE Compressor Numbers UNIT V-Hz SIZE (3 Phase) 208/230-60 89.8 89.8 89.8 151.3 151.3 460-60 44.9 44.9 44.9 65.4 65.4 575-60 36.6 36.6 36.6 57.1 57.1 230-XL — — — —...
  • Page 39 Table 6C — Compressor Electrical Data, 30GT230-420 (cont) MODULE B 30GT NAMEPLATE Compressor Numbers UNIT V-Hz SIZE (3 Phase) 208/230-60 106.4 67.9 147.7 460-60 46.8 34.6 65.4 575-60 40.4 28.8 57.1 230-XL — — — — — — — — 380-60 52.6 34.6...
  • Page 40 Table 6C — Compressor Electrical Data, 30GT230-420 (cont) MODULE A 30GT NAMEPLATE Compressor Numbers UNIT V-Hz SIZE (3 Phase) RLA/ 208/230-60 89.8 89.8 89.8 107.7 107.7 151.3 151.3 460-60 44.9 44.9 44.9 46.8 46.8 65.1 65.4 575-60 36.6 36.6 36.6 41.7 41.7 57.1...
  • Page 41 Table 6C — Compressor Electrical Data, 30GT230-420 (cont) MODULE B 30GT NAMEPLATE Compressor Numbers UNIT V-Hz SIZE (3 Phase) 208/230-60 89.7 147.4 89.7 106.4 460-60 43.6 65.4 43.6 46.8 575-60 36.5 57.1 36.5 40.4 315-XL — — — — — —...
  • Page 42 Table 6C — Compressor Electrical Data, 30GT230-420 (cont) MODULE A 30GT NAMEPLATE Compressor Numbers UNIT V-Hz SIZE (3 Phase) 208/230-60 89.8 89.8 89.8 107.7 107.7 151.3 151.3 460-60 44.9 44.9 44.9 46.8 46.8 65.4 65.4 575-60 36.6 36.6 36.6 41.7 41.7 57.1 57.1...

  • Page 43: Installation

    Table 7 — Condenser Fan Electrical Data STANDARD/LOW NOISE CONDENSER FANS HIGH STATIC CONDENSER FANS NAMEPLATE 30GT (Quantity) (Quantity) (Quantity) (Quantity) VOLTAGE Total Total UNIT SIZE Quantity Hp Quantity Hp (V-Ph-Hz) (ea) (ea) (ea) (ea) 208/230-3-60 (4) 6.6, (2) 5.5 (4) 31.6, (2) 30.0 (6) 14.6 (6) 41.6 460-3-60...

  • Page 44: Quick Test

    24 hours. See Oil Charge control prior to unit start-up. This check ensures that all con- section on page 57 for Carrier-approved oils. trol options, thermistors, and status switches are in proper working order.
  • Page 45 DISPLAY BUTTON FUSE 1 *EPROM HT207101-1-XX. NOTES: 1. Refer to Controls and Troubleshooting literature for details. LEGEND 2. Processor board is rotated 90 degrees counterclockwise from — Dual In-Line Package position shown when installed in unit. EPROM — Erasable, Programmable, Read-Only Memory 3.
  • Page 46 A. QUICK TEST STEPS 1 - 15: UNIT CONFIGURATION C. QUICK TEST STEPS 31 - 42: OUTPUT RELAYS — — Microprocessor in unit control system is programmed by These quick test steps allow microprocessor to check output 2 switch assemblies located on processor board (Fig. 19). signals from relay boards in unit control system.
  • Page 47 Table 8 — Quick Test SECTION A. — Configuration and Switch Check HEADER POSITON QUICK TEST NORMAL STEP DESCRIPTION STEP NO. DISPLAY CONTROL SWITCH Type Unit — Air-Cooled Chiller Configuration Header: 1 and 2 No. of Compressors Configuration Header: 3, 4, and 5 = 080, 230B = 090-110, 130 (60 Hz), 245B-315B = 130 (50 Hz), 150, 230A-255A...
  • Page 48 Table 8 — Quick Test (cont) SECTION B. — Thermistor and Potentiometer Checkout THERMISTOR QUICK TEST NORMAL STEP DESCRIPTION STEP NO. DISPLAY POTENTIOMETER — Thermistor OK T1 — Cooler Leaving Fluid Thermistor — Thermistor Faulty — Thermistor OK T2 — Cooler Entering Fluid Thermistor —...
  • Page 49 — Terminal Block — Thermostatic Expansion Valve *Do not change select switch to brine on units that do not have modifications for brine. Special modifications are required. Contact Carrier for details. †Display is for Flotronic™ EXV units only. Display is for 080-110 Flotronic FIOP units (with TXV).

  • Page 50: Actual Start-Up

    Low-Ambient Operation — If operating temperatures be- held in. Code numbers on display have following low 0° F (−18 C) are expected, refer to separate installa- significance: tion instructions for low-ambient operation/Motormaster III control. Contact your Carrier representative for details. CODE OPERATIONAL NUMBER STATUS...

  • Page 51: Operation Sequence

    VOLTAGE Consult application data and job design requirements to determine flow rate requirements for particular installation. Main Power Supply — Minimum and maximum acceptable supply voltages are listed in Tables 4A-4C. Unbalanced 3-Phase Supply Voltage: Table 12 — Nominal and Minimum Cooler Fluid Flow Rates Never operate a motor where a phase imbalance between phases is greater than 2%.
  • Page 52 UNITS WITH ELECTRONIC EXPANSION VALVE (EXV) HEAD PRESSURE CONTROL — The EXV remains closed for 10 seconds to purge cooler Units with EXV — Microprocessor controls EXV to and suction line of any liquid refrigerant that may have mi- maintain a superheat of 30° F (16.7° C) entering compressor grated to these areas during off period.
  • Page 53 Table 13 — Capacity Control Steps LOADING SEQUENCE A LOADING SEQUENCE B 30GT CONTROL UNIT SIZE STEPS Compressors Compressors Displ. Displ. A1*,B1* A1*,B1* 080,230B A1*, B1 A1,B1* (60 Hz) A1,B1 A1,B1 A1†, B1† A1*,A2,B1 A1*,A2,B1 A1,A2,B1 A1,A2,B1 A1*,B1* A1*,B1* 080,230B A1*,B1 A1,B1* (50 Hz)
  • Page 54 Table 13 — Capacity Control Steps (cont) LOADING SEQUENCE A LOADING SEQUENCE B 30GT CONTROL UNIT SIZE STEPS Displ. Compressors Displ. Compressors (Approx) (Approx) A1*,B1* A1*,B1* A1*,B1 A1,B1* A1,B1 A1,B1 (60 Hz) A1*,A2,B1 A1,B1*,B2 A1†, B1† A1,A2,B1 A1,B1,B2 A1*,A2,B1,B2 A1,A2,B1*,B2 A1,A2,B1,B2 A1,A2,B1,B2 A1*,B1*...
  • Page 55 Table 13 — Capacity Control Steps (cont) LOADING SEQUENCE A LOADING SEQUENCE B 30GT CONTROL UNIT SIZE STEPS Displ. Compressors Displ. Compressors (Approx) (Approx) A1,B1 A1,B1 190,290A, A1,A2,B1 A1,B1,B2 360A/B,390B A1,A2,B1,B2 A1,A2,B1,B2 (60 Hz) A1,A2,A3,B1,B2 A1,A2,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1,A2,A3,B1,B2,B3 A1*,B1 A1*,B1 A1,B1 A1,B1 190,290A,...
  • Page 56 LEGEND EXV — Electronic Expansion Valve — Thermistor TXV — Thermostatic Expansion Valve Fig. 21 — Typical Thermistor Locations SIZE 080-110* SIZE 130-210* *And associated modular units (see Table 1). Fig. 22 — Thermistor T3 and T4 Locations...

  • Page 57: Diagnostics And Troubleshooting

    After leaks are repaired, system must be evacuated and dehydrated. IMPORTANT: All compressor mounting hardware and DEHYDRATION — Refer to Carrier Standard Service Tech- support brackets removed during servicing must be re- niques Manual, Chapter 1, Refrigerants, Sections 6 and 7 for installed prior to start-up.

  • Page 58: Cooler

    2. Close the shutoff valves, if installed, in the cooler fluid Cooler — The cooler is easily accessible from the cooler lines, and remove the cooler fluid piping. Remove the cooler side of the unit. The refrigerant feed components are acces- fluid-side strainer (130-210, 230A-315A, and 330A/B- sible from the control box end of the unit.
  • Page 59 flange bolts to 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 60 1. Install all bolts finger tight. 2. Bolt tightening sequence is outlined in Fig. 26. Follow the numbering sequence so that pressure is evenly ap- plied to gasket. 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.
  • Page 61 SIZES 080,090* WITH SIZES 080,090* WITH SIZES 100,110* WITH SIZES 100,110* WITH 18-BOLT HEADS 14-BOLT HEADS 22-BOLT HEADS 16-BOLT HEADS SIZES 130,150* SIZES 170,190* SIZE 210* *And associated modular units (see Table 1). Fig. 26 — Cooler Head Bolt Tightening Sequence (Typical Tube Sheet) The microprocessor controls the valve.
  • Page 62 1. Check color coding and wire connections. Make sure wires are connected to correct terminals at J7 and EXV plug connections. 2. Check for continuity and tight connection at all pin terminals. 3. Check plug connections at J7 and at EXVs. Be sure EXV connections are not crossed.
  • Page 63 Table 15 — Sensor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ Chiller TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE DROP (V) (OHMS) DROP (V) (OHMS) DROP (V) (OHMS) - 25 4.684 98,010 2.581 7,091 0.655 1,007 - 24 4.673 94,707 2.549 6,911...
  • Page 64 Table 16 — Sensor Temperature (°C) vs Resistance/Voltage Drop; Flotronic™ Chiller TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE DROP (V) (OHMS) DROP (V) (OHMS) DROP (V) (OHMS) -32.0 4.690 100 049 16.0 2.651 7507 64.0 0.698 1090 -31.5 4.680 97 006 16.5...
  • Page 65 filter drier(s). There is one stricted metering slots in the EXV. Formation of ice or frost filter drier on each circuit. Refer to Carrier Standard Service on lower body of EXV is one symptom of restricted meter- Techniques Manual, Chapter 1, Refrigerants, for details on ing slots.
  • Page 66 Saturated Condensing Temperature Thermistors, T3 and T4 — Thermistors T3 and T4 are each clamped to the outside of a return bend on condenser coil. Exact locations for all units are shown in Fig. 21 and 22. Evaporator Refrigerant Thermistors, T5 and T6 — Ther- mistors T5 and T6 are located next to refrigerant inlet in cooler head.
  • Page 67 CRANKCASE HEATERS — Each compressor has a 180-w Safety Devices — Chillers contain many safety crankcase heater to prevent absorption of liquid refrigerant devices and protection logic built into electronic control. Fol- by oil in crankcase when compressor is not running. Heater lowing is a brief summary of major safeties.
  • Page 68 These are both designed to relieve pressure on a temperature Controls and Troubleshooting literature. rise to approximately 210 F (99 C). Copyright 1996 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.

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