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Carrier 30GTN Service And Troubleshooting Manual

Air-cooled reciprocating with comfortlink controls 50/60 hz controls, start-up, operation, service, and troubleshooting
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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 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. Fol-
low all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment,
and in handling all electrical components.
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
to restore power until work is completed.
This unit uses a microprocessor-based electronic con-
trol system. Do not use jumpers or other tools to short
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.
To prevent potential damage to heat exchanger tubes al-
ways run fluid through heat exchangers when adding or
removing refrigerant charge. Use appropriate brine so-
lutions in cooler and condenser 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 build-
ing. Outlet from relief valves must be vented outdoors
in accordance with the latest edition of ANSI/ASHRAE
(American National Standards Institute/American Soci-
ety of Heating, Refrigeration and Air Conditioning En-
gineers) 15 (Safety Code for Mechanical Refrigeration).
The accumulation of refrigerant in an enclosed space
can displace oxygen and cause asphyxiation. Provide ad-
equate ventilation in enclosed or low overhead areas.
Inhalation of high concentrations of vapor is harmful
and may cause heart irregularities, unconsciousness or
death. Misuse can be fatal. Vapor is heavier than air and
reduces the amount of oxygen available 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.
Book 2
PC 903
Catalog No. 533-099
Tab
5c
Air-Cooled Reciprocating Liquid Chillers
with ComfortLink™ Controls
DO NOT attempt to unbraze factory joints when ser-
vicing this equipment. Compressor oil is flammable and
there is no way to detect how much oil may be in any
of the refrigerant 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 com-
pressor oil.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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 Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Module Communication . . . . . . . . . . . . . . 3
Carrier Comfort Network Interface . . . . . . . . . . . . 3
OPERATING DATA . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• T1 - COOLER LEAVING FLUID SENSOR
• T2 - COOLER ENTERING FLUID SENSOR
• T3,T4 - SATURATED CONDENSING
TEMPERATURE SENSORS
• T5,T6 - COOLER SUCTION TEMPERATURE
SENSORS
• T7,T8 - COMPRESSOR SUCTION GAS
TEMPERATURE SENSORS
• T9 - OUTDOOR-AIR TEMPERATURE SENSOR
(CPCS) or Control Relay (CR) . . . . . . . . . . . . . . 15
(CGF) and Control Relay (CR) . . . . . . . . . . . . . . 15
Electronic Expansion Valve (EXV) . . . . . . . . . . . . 16
Energy Management Module . . . . . . . . . . . . . . . . . 16
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Printed in U.S.A.
Form 30GTN-1T
30GTN,GTR040-420
50/60 Hz
CONTENTS
Pg 1
5-99
Replaces: New
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  Summary of Contents for Carrier 30GTN

  • Page 1: Table Of Contents

    Control Module Communication ....3 control board or accompanying wiring may destroy the Carrier Comfort Network Interface ... . 3 electronic modules or electrical components.
  • Page 2 330A/B-420A/B) ......46 The 30GTN,R chillers are equipped with electronic ex- EXV Troubleshooting ......46 pansion valves (EXVs) or, on size 040-110 FIOP (factory- •...
  • Page 3: Major System Components

    Carrier Comfort Network (CCN) Interface — Energy Management Module (EMM) — The EMM 30GTN,R chiller units can be connected to the CCN if de- module is available as a factory-installed option or as a field- sired. The communication bus wiring is a shielded, 3-conductor installed accessory.
  • Page 4 Table 2 — Thermistor Designations It is important when connecting to a CCN communication bus that a color coding scheme be used for the entire net- work to simplify the installation. It is recommended that red THERMISTOR CONNECTION THERMISTOR INPUT be used for the signal positive, black for the signal negative, POINT and white for the signal ground.
  • Page 5 — Compressor Contactor RELAY NO. DESCRIPTION — Circuit Breaker Energize Compressor A1 and OFM1 (040-110*) — Carrier Comfort Network Energize Liquid Line Solenoid Valve for Ckt A (if used) — Compressor Ground Fault K0 (MBB) (040-110*) — Cooler Heater Thermostat Energize Compressor A1, OFM5, and OFM7 (130-210*) —...
  • Page 6: Typical Control Box Overview

    Fig. 1 — Typical Control Box (080-110 and Associated Modular Units Shown)
  • Page 7 Fig. 2 — 24 V Control Schematic, Unit Sizes 040-070...
  • Page 8 Fig. 3 — 24 V Control Schematic, Unit Sizes 080-110, 230B-315B...
  • Page 9 Fig. 4 — 24 V Control Schematic, Unit Sizes 130-210, 230A-315A, 330A/B-420A/B...
  • Page 10: Enable/Off/Remote Contact Switch

    RED LED - STATUS GREEN LED - YELLOW LED - LEN (LOCAL EQUIPMENT NETWORK) CCN (CARRIER COMFORT NETWORK) CEPL130346-01 STATUS Fig. 5 — Main Base Board EMERGENCY ON/OFF SWITCH ENABLE/OFF/REMOTE CONTACT SWITCH GFI-CONVENIENCE OUTLET ACCESSORY ON 208/230V 460 AND RESET BUTTON...
  • Page 11: Operating Data

    T5, T6 — COOLER SUCTION TEMPERATURE SEN- OPERATING DATA SORS — These thermistors are located next to the refrig- Sensors — The electronic control uses 4 to 10 ther- erant inlet in the cooler head, and are inserted into a friction- mistors to sense temperatures for controlling chiller opera- fit well.
  • 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,R210, 315A, 390A, 420A/B Shown)
  • Page 14: Sensors

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

    Thermostatic Expansion Valves (TXV) — pressor will be locked off. If the lead compressor in either Model 30GTN,R040-110 units are available from the fac- circuit is shut down by the high-pressure switch, loss-of- tory with conventional TXVs with liquid line solenoids. The...
  • Page 16: Electronic Expansion Valve (Exv)

    Electronic Expansion Valve (EXV) (See Fig. 14) — Standard units are equipped with a bottom seal EXV. This device eliminates the use of the liquid line solenoid pump- down at unit shutdown. An O-ring has been added to bottom of orifice assembly to complete a seal in the valve on shut- down.
  • Page 17 CEBD430351-0396-01C STATUS TEST 2 GREEN LED - RED LED - STATUS LEN (LOCAL EQUIPMENT NETWORK) Fig. 15 — Energy Management Module The capacity routine runs every 30 seconds. The routine −100 to + 100%. If the next stage of capacity is a compres- attempts to maintain the Control Point at the desired set point.
  • Page 18 Table 5A — Part Load Data Percent Displacement, Standard Units LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) — — — — 040 (60 Hz) A1*, B1 — — A1,B1 — —...
  • Page 19 Table 5A — Part Load Data Percent Displacement, Standard Units (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1*,B1* A1*,B1* A1,B1 A1,B1 A1,B1 A1,B1 100, 255B, A1*,A2,B1* A1*,B1*,B2 270B (50 Hz)
  • Page 20 Table 5A — Part Load Data Percent Displacement, Standard Units (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1*,B1* A1*,B1* A1*,B1 A1,B1* A1,B1 A1,B1 A1*,A2,B1* A1*,B1*,B2 150, 230A, 245A, A1*,A2,B1 A1,B1*,B2...
  • Page 21 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) 040 (60 Hz) A1*,B1 A1,B1* A1,B1 A1,B1 040 (50 Hz) A1*,B1* A1*,B1* 045 (60 Hz)
  • Page 22 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1† B1† A1†,B1 A1,B1† A1*,B1 A1,B1* A1,B1 A1,B1 A1†,A2,B1† A1*,B1†,B2 090, 245B (50 Hz) A1†,A2,B1*...
  • Page 23 Table 5B — Part Load Data Percent Displacement, with Accessory Unloaders (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1† B1† A1†,B1* A1*,B1† A1†,B1 A1,B1† A1*,B1 A1,B1* A1,B1 A1,B1 A1†,A2,B1† A1†,B1†,B2 130 (60 Hz) A1†,A2,B1*...
  • Page 24 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1† B1† A1†,B1* A1*,B1† A1†,B1 A1,B1† A1*,B1 A1,B1* A1,B1 A1,B1 A1†,A2,B1* A1*,B1†,B2 A1†,A2,B1...
  • Page 25 Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) LOADING SEQUENCE A LOADING SEQUENCE B UNIT CONTROL 30GTN,GTR STEPS Displacement Compressors Displacement Compressors (Approx) (Approx) A1*,B1* A1*,B1* A1*,B1 A1,B1* A1,B1 A1,B1 A1*,A2,B1* A1*,B1*,B2 A1*,A2,B1 A1,B1*,B2 A1,A2,B1 A1,B1,B2...
  • Page 26: Minutes Left For Start

    figured Cooling Ramp Loading value (CRMP), the control LOADING SEQUENCE — The 30GTN,R compressor ef- does not allow any changes to the current stage of capacity. ficiency is greatest at partial load. Therefore, the following Low Entering Fluid Temperature Unloading —...
  • Page 27: Head Pressure Control

    2 STARTS DEADBAND EXAMPLE 1000 3 STARTS TIME (SECONDS) STANDARD DEADBAND MODIFIED LEGEND DEADBAND LWT — Leaving Water Temperature Fig. 16 — Deadband Multiplier T4 is greater than 125 F (51.6 C), in which case all MBB- Head Pressure Control controlled fans start immediately.
  • Page 28 6, 8 — Compressor No. B1 1, 2 First Stage of Condenser Fans 3, 4, 9, 10 Second Stage of Condenser Fans 30GTN,R130 (50 Hz), 150-210, 5, 7 — Compressor No. A1 230A-315A, 330A/B-420A/B† 6, 8 — Compressor No. B1...
  • Page 29: Marquee Display Usage

    The Service Test function should be used to verify proper Marquee Display Usage (See Fig. 18 and operation of compressors, unloaders, hot gas bypass (if in- Tables 6-24) — The Marquee display module provides stalled), cooler pump and remote alarm relays, EXVs and the user interface to the ComfortLink™...
  • Page 30 LEAVING RETURN MASTER CHILLER FLUID FLUID SLAVE CHILLER INSTALL MASTER CHILLER LEAVING FLUID THERMISTOR (T1) HERE Fig. 19 — Dual Chiller Thermistor Location Table 6 — Marquee Display Menu Structure) SERVICE TIME OPERATING TEMPERATURES PRESSURES POINTS INPUTS OUTPUTS CONFIGURATION ALARMS STATUS TEST CLOCK...
  • Page 31 Table 7 — Run Status Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM DISPLAY ITEM EXPANSION COMMENT ENTRY VIEW XXX.X °F ENTERING FLUID TEMP ENTER XXX.X °F LEAVING FLUID TEMP SETP XXX.X °F ACTIVE SETPOINT CTPT XXX.X °F CONTROL POINT MODE CONTROL MODE 0 = SERVICE TEST 1 = OFF —...
  • Page 32 Table 8 — Service Test Mode and Sub-Mode Directory KEYPAD SUB-MODE ITEM DISPLAY ITEM EXPANSION COMMENT ENTRY TEST ON/OFF SERVICE TEST MODE Use to Enable/Disable Manual Mode ENTER OUTS FR.A1 ON/OFF FAN A1 RELAY Fan 3 (040-050) ENTER Fans 3,4 (060-110, 230B-315B) Fans 1,2 (130 [60 Hz]) Fan 1 (130 [50 Hz], 150, 170, 230A- 270A, 330A/B, 360B [50 Hz])
  • Page 33 Table 9 — Temperature Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT UNIT CEWT XXX.X °F COOLER ENTERING FLUID ENTER CLWT XXX.X °F COOLER LEAVING FLUID XXX.X °F OUTSIDE AIR TEMPERATURE XXX.X °F SPACE TEMPERATURE CIR.A SCT.A XXX.X °F SATURATED CONDENSING TMP...
  • Page 34 Table 13 — Inputs Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT GEN.I STST STRT/STOP START/STOP SWITCH Enable/Off/Remote Contact Switch Input ENTER FLOW ON/OFF COOLER FLOW SWITCH DLS1 ON/OFF DEMAND LIMIT SWITCH 1 DLS2 ON/OFF DEMAND LIMIT SWITCH 2 ICED ON/OFF ICE DONE...
  • Page 35 On = Metric LANG LANGUAGE SELECTION Default: 0 0 = English 1 = Espanol 2 = Francais 3 = Portugues LEGEND CCN — Carrier Comfort Network EMM — Energy Management Module — Electronic Expansion Valve LCW — Leaving Chilled Water...
  • Page 36 ON/OFF COOLER PUMP CONTROL Default: Off CA.UN NO. CIRCUIT A UNLOADERS CB.UN NO. CIRCUIT B UNLOADERS YES/NO EMM MODULE INSTALLED LEGEND CCN — Carrier Comfort Network EMM — Energy Management Module — Electronic Expansion Valve LCW — Leaving Chilled Water...
  • Page 37 Table 15 — Configuration Mode and Sub-Mode Directory (cont) SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT OPT2 CTRL CONTROL METHOD Default: 0 ENTER 0 = Switch 1 = 7 Day Schedule 2 = Occupancy 3 = CCN Control CCNA CCN ADDRESS Default: 1 Range: 1 to 239...
  • Page 38 Table 16 — Example of Temperature Reset (Outdoor Air) Configuration SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT RSET CRST COOLING RESET TYPE 0 = No reset ENTER 1 = 4 to 20 mA input 2 = Outdoor Air Temp 3 = Return Fluid 4 = Space Temperature Scrolling stops...
  • Page 39 Table 17 — Example of Configuring Dual Chiller Control SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT RSET CRST ENTER LLDY LAG START DELAY Scrolling stops ENTER Value flashes ENTER Select 10 Change accepted ENTER LLDY ESCAPE LLBD LEAD/LAG BALANCE DELTA No change needed.
  • Page 40 Table 18 — Example of Compressor Lead/Lag Configuration SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT OPT2 CTRL CONTROL METHOD ENTER CCNA CCNB BAUD LOAD LLCS LEAD/LAG CIRCUIT SELECT DEFAULT: 2 (040-070); 1 (080-420) Scrolling stops ENTER Value flashes ENTER Select 3 NOTE: Options 1 and/or 3 not valid for sizes 040-070 with- out Circuit B accessory unloader installed...
  • Page 41 Table 20 — Setting an Occupied Time Schedule SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT MON.O 00.00 MONDAY OCCUPIED TIME TIME IN MILITARY FORMAT (HH.MM) ENTER 00.00 Scrolling stops ENTER 00.00 Hours flash ENTER 07.00 Select 7 AM SCHD 07.00 Change accepted, minutes flash ENTER...
  • Page 42 Table 22 — Operating Modes MODE NO. ITEM EXPANSION DESCRIPTION FSM CONTROLLING CHILLER Flotronic™ System Manager (FSM) is controlling the chiller WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller MASTER/SLAVE CONTROL Lead/Lag Chiller control is enabled. LOW SOURCE PROTECTION Not currently supported.
  • Page 43: Temperature Reset

    Table 23 — Alarms Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM ITEM EXPANSION COMMENT Alarms are shown as AXXX. CRNT AXXX or TXXX CURRENTLY ACTIVE ALARMS ENTER Alerts are shown as TXXX. RCRN YES/NO RESET ALL CURRENT ALARMS ENTER Alarms are shown as AXXX.
  • Page 44 Table 25 — Configuring Temperature Reset MODE KEYPAD SUB-MODE KEYPAD ITEM ITEM DISPLAY COMMENT GREEN LED) ENTRY ENTRY EXPANSION CONFIGURATION DISP TEST ON/OFF TEST DISPLAY LEDs ENTER ENTER UNIT TYPE UNIT TYPE ENTER OPT1 FLUD COOLER FLUID ENTER OPT2 CTRL CONTROL METHOD ENTER RSET...
  • Page 45: Demand Limit

    lowest demand takes priority if both demand limit inputs are Demand Limit — Demand Limit is a feature that allows closed. If the demand limit percentage does not match unit the unit capacity to be limited during periods of peak energy staging, the unit will limit capacity to the closest capacity usage.
  • Page 46: Troubleshooting

    J6 and J7 ter- Compressor Ground Current (CGC) Board minal strips and EXV plug connections. Check for cor- (30GTN,R130-210, 230A-315A, and 330A/B- rect wiring at driver board input and output terminals. See 420A/B) —...
  • Page 47: Step 5 - Check Operation Of The Exv

    3. Make sure that thermistor leads are connected to the proper liquid line service valve. Turn the ENABLE/OFF/REMOTE pin terminals at the J5 terminal strip on EXV board and contact switch and allow unit to operate. Verify proper that thermistor probes are located in proper position in operation of unit.
  • Page 48: Alarm And Alert Codes

    Table 27 — Alarm and Alert Codes ALARM/ ALARM WHY WAS THIS ACTION TAKEN RESET PROBABLE ALERT DESCRIPTION ALARM BY CONTROL METHOD CAUSE CODE ALERT GENERATED? Alert Circuit A, Compressor 1 Compressor feedback Circuit A shut down. Manual High-pressure or loss-of- Failure signal does not match charge switch open, faulty...
  • Page 49 *Freeze is defined as 34° F (1.1 C) for water. For brine fluids, freeze is CSP.1 −8° F (4.4 C) for single set point and lower of CSP.1/CSP.2 — Carrier Comfort Network −8° F (4.4 C) for dual set point configuration.
  • Page 50 Table 27 — Alarm and Alert Codes (cont) ALARM/ ALARM WHY WAS THIS ACTION TAKEN RESET PROBABLE ALEERT DESCRIPTION ALARm BY CONTROL METHOD CAUSE CODE ALERT GENERATED? Alarm Emergency Stop CCN emergency stop Chiller shutdown with- Automatic once CCN CCN Network command received out going through command for EMSTOP...
  • Page 51 *Freeze is defined as 34° F (1.1 C) for water. For brine fluids, freeze is CSP.1 −8° F (4.4 C) for single set point and lower of CSP.1/CSP.2 — Carrier Comfort Network −8° F (4.4 C) for dual set point configuration.
  • Page 52: Service

    OIL CHARGE (Refer to Table 28) — All units are factory 8. On 30GTN,GTR080-110 and 230B-315B units, remove charged with oil. Acceptable oil level for each compressor is the vertical support(s) under the condenser coil in front from ⁄...
  • Page 53: Replacing Cooler

    NOTE: The suction flange has a 4-bolt pattern. See SERVICING THE COOLER — When cooler heads and par- Carrier specified parts for replacement part number, if tition plates are removed, tube sheets are exposed showing necessary. ends of tubes.
  • Page 54 T2 is used in the freeze protection algorithm for the Fig. 24 — Eliott Tube Plug controller. If several tubes require plugging, check with your local Carrier representative to find out how number and lo- Table 29 — Plugs cation can affect unit capacity.
  • Page 55: Condenser Coils

    Tightening Cooler Head Bolts installed in corrosive environments should have coil clean- ing as part of a planned maintenance schedule. In this type Gasket Preparation — When reassembling cooler heads, al- of application, all accumulations of dirt should be cleaned ways use new gaskets.
  • Page 56: Refrigerant Feed Components

    High-pressure liquid refrigerant enters valve through bot- tom. A series of calibrated slots have been machined in side of orifice assembly. As refrigerant passes through orifice, pres- sure drops and refrigerant changes to a 2-phase condition (liquid and vapor). To control refrigerant flow for different operating conditions, a sleeve moves up and down over ori- fice and modulates orifice size.
  • Page 57: Moisture-Liquid Indicator

    Fig. 30 — Thermistors (Temperature Sensors) FILTER DRIER — Whenever moisture-liquid indicator shows presence of moisture, replace filter drier(s). There is one fil- ter drier on each circuit. Refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, for details on servicing filter driers.
  • Page 58: Replacing Thermistors T1,T5,T6,T7, And T8

    REPLACING THERMISTORS T1, T5, T6, T7, AND T8 — Add a small amount of thermal conductive grease to ther- MAIN BASE BOARD mistor well. Thermistors are friction-fit thermistors, which must be slipped into receivers located in the cooler leaving fluid nozzle for T1, in the cooler head for T5 and T6 (EXV units only), and in the compressor pump end for T7 and T8 (EXV units only).
  • Page 59 Table 30A — 5K Thermistor Temperatures (°F) vs Resistance/Voltage Drop (For Thermistors T1-T9) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −25 4.538 98,010 2.200 7,868 0.525 1,190 −24 4.523 94,707 2.168 7,665 0.515 1,165 −23...
  • Page 60 Table 30B — 5K Thermistor Temperatures (°C) vs Resistance/Voltage Drop (For Thermistors T1-T9) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −32 4.547 100 260 2.143 7 499 0.487 1 079 −31 4.520 94 165 2.087 7 161...
  • Page 61 Table 31A — 10K Thermistor Temperatures (°F) vs Resistance/Voltage Drop (For Thermistor T10) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −25 4.758 196,453 2.994 14,925 0.890 2,166 −24 4.750 189,692 2.963 14,549 0.876 2,124 −23...
  • Page 62 Table 31B — 10K Thermistor Temperatures (°C) vs Resistance/Voltage Drop (For Thermistor T10) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −32 4.762 200,510 3.056 15,714 0.940 2,315 −31 4.748 188,340 3.000 15,000 0.913 2,235 −30...
  • Page 63: Safety Devices

    24 hours before starting unit. diagrams. 30GTN,R070 (50 Hz), 080-110 and 230B-315B Compres- COOLER PROTECTION sor Protection Board (CPCS) — The CPCS is used to con- Freeze Protection — Cooler can be wrapped with heater cables trol and protect compressors and crankcase heaters.
  • Page 64: Relief Devices

    24 hours. See Oil Charge rise to approximately 170 F (77 C). section on page 52 for Carrier-approved oils. PRESSURE RELIEF VALVES (208/230, 460, 575 v; 7. Electrical power source must agree with unit 60 Hz Units Only) —...
  • Page 65: Start-Up And Operation

    Motor- 3 gallons per ton (3.25 L per kW) of chiller nominal capac- master III control. Contact your Carrier representative for ity for air conditioning and at least 6 gallons per ton (6.5 L details.
  • Page 66: Operation Sequence

    On units with thermostatic expansion valve (TXV) 110,290B,315B 16.65 84.1 5.30 (30GTN,R040,045 units with brine option), head pressure 18.9 control is based on set point control. When the lead com- 150,230A-255A 21.9 pressor starts, the liquid line solenoid valve (LLSV) is kept 170,270A,330A/B, 24.2...
  • Page 67: Appendix A - Ccn Tables

    APPENDIX A — CCN TABLES UNIT (Configuration Settings) DESCRIPTION STATUS DEFAULT UNITS POINT Unit Type 1 = Air Cooled UNIT TYP 2 = Water Cooled 3 = Split System 4 = Heat Machine 5 = Air Cooled Heat Reclaim Unit Size 15 to 300 TONS SIZE...
  • Page 68 CONFIGURATION SCREEN (TYPE 10) OPTIONS2 (Options Configuration) DESCRIPTION STATUS DEFAULT UNITS POINT Control Method 0 = Switch CONTROL 1 = 7 day sched. 2 = Occupancy 3 = CCN Loading Sequence Select 1 = Equal loading SEQ TYPE 2 = Staged loading Lead/Lag Sequence Select 1 = Automatic LEAD TYP...
  • Page 69 RESETCON (Temperature Reset and Demand Limit) DESCRIPTION STATUS DEFAULT UNITS POINT COOLING RESET Cooling Reset Type 0 = No Reset CRST TYP 1 = 4-20 ma input 2 = External temp-OAT 3 = Return fluid 4 = External temp-SPT No Cool Reset Temp 0 to 125 °F CT NO...
  • Page 70 GENUNIT (General Unit Parameters) DESCRIPTION STATUS UNITS POINT FORCEABLE Control Mode 0 = Service Test MODE 1 = OFF - local control 2 = OFF-CCN control 3 = OFF-timeclock 4 = Emergency stop 5 = ON-local control 6 = ON-CCN control 7 = ON-timeclock Occupied Yes/No...
  • Page 71 CIRCB AN (Circuit B Analog Parameters) DESCRIPTION STATUS UNITS POINT FORCEABLE Circuit B Analog Values Percent Total Capacity 0-100 CAPB T Percent Available Cap 0-100 CAPB A Discharge Pressure nnn.n DP B Suction Pressure nnn.n SP B Saturated Condensing Tmp snnn.n °F TMP SCTB...
  • Page 72 STRTHOUR DESCRIPTION STATUS UNITS POINT Machine Operating Hours nnnnn hours HR MACH Machine Starts nnnnn CY MACH Circuit A Run Hours nnnnn hours HR CIRA Compressor A1 Hours nnnnn hours HR A1 Compressor A2 Hours nnnnn hours HR A2 Compressor A3 Hours nnnnn hours HR A3...
  • Page 73 CURRMODS DESCRIPTION STATUS UNITS POINT FSM controlling chiller ON/OFF MODE 1 WSM controlling chiller ON/OFF MODE 2 Master/Slave control ON/OFF MODE 3 Low source protection ON/OFF MODE 4 Ramp Load Limited ON/OFF MODE 5 Timed Override in effect ON/OFF MODE 6 Low Cooler Suction TempA ON/OFF MODE 7...
  • Page 74 CSM/FSM EQUIPMENT TABLE (Type 621H, Block 2) LINE DESCRIPTION POINT Chiller Status CHILSTAT 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 unused...
  • Page 76 Copyright 1999 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. 533-099 Printed in U.S.A. Form 30GTN-1T Pg 76 5-99 Replaces: New...
  • Page 77 ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES 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. 533-099 Printed in U.S.A. Form 30GTN-1T Pg CL-1 5-99 Replaces: New...
  • Page 78 B. Preliminary Equipment Check (YES or NO) IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE 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 79 C. Unit Start-Up (cont) CHECK VOLTAGE IMBALANCE: AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = MAXIMUM DEVIATION FROM AVERAGE VOLTAGE (MAX. DEVIATION) VOLTAGE IMBALANCE = x 100 = % VOLTAGE IMBALANCE AVERAGE VOLTAGE IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER! CALL LOCAL POWER COMPANY FOR ASSISTANCE.
  • Page 80 C. Unit Start-Up (cont) TO START THE CHILLER: (insert check mark as each item is completed) TURN THE EMERGENCY ON/OFF SWITCH (SW2) TO ON POSITION. LEAVE THE ENABLE/OFF/REMOTE CONTACT SWITCH (SW1) IN THE OFF POSITION. NOTE: USE ESCAPE KEY TO GO UP ONE LEVEL IN THE STRUCTURE. USE ARROW/ESCAPE KEYS TO ILLUMINATE CONFIGURATION LED.
  • Page 81 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. OPTIONS2 (Options Configuration) DESCRIPTION STATUS DEFAULT UNITS VALUE Control Method 0 = Switch 1 = 7 day sched. 2 = Occupancy 3 = CCN CCN Address...
  • Page 82 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: SLCT (Cooling Setpoint Select) DESCRIPTION STATUS DEFAULT UNITS VALUE Cooling Setpoint Select 0 = Single 1 = Dual Switch 2 = Dual Clock 3 = 4 to 20 mA Input Ramp Load Select...
  • Page 83 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. PRESS ENTER TO DISPLAY PASSWORD FIELD AND USE THE ENTER KEY FOR EACH OF THE FOUR PASSWORD DIGITS.
  • Page 84 Copyright 1999 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. 533-099 Printed in U.S.A. Form 30GTN-1T Pg CL-8 5-99 Replaces: New...