30GT040-070 Flotronic Reciprocating Liquid Chillers 50/60 Hz

Installation, Start-Up and Service Instructions

SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.). Only trained, qualied installers and service mechanics should install, start up, and service this equipment. Untrained personnel can perform basic maintenance functions, 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 servicing this equipment. Page Step 5 Install Accessories . . . . . . . . . . . . . . . . . 9 ELECTRICAL LOW-AMBIENT OPERATION HOT GAS BYPASS MISCELLANEOUS ACCESSORIES PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 QUICK TEST STEPS 1-15: UNIT CONFIGURATION QUICK TEST STEPS 16-30: THERMISTORS AND SET POINT POTENTIOMETERS QUICK TEST STEPS 31-42: OUTPUT RELAYS START-UP AND OPERATION . . . . . . . . . . . . . . . 19-21 Digital Display Action . . . . . . . . . . . . . . . . . . . . . . . 19 Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . 19 TEMPERATURES VOLTAGE MINIMUM FLUID LOOP VOLUME FLOW RATE REQUIREMENTS Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . 20 UNITS WITH EXV UNITS WITH STANDARD TXV LOAD SHED TEMPERATURE RESET HEAD PRESSURE CONTROL REMOTE ON-OFF REMOTE ALARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32 Diagnostics and Troubleshooting . . . . . . . . . . . . 21 Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 21 LEAK TESTING REFRIGERANT CHARGE Electronic Components . . . . . . . . . . . . . . . . . . . . . 23 CONTROL COMPONENTS UNIT CONTROL BOX Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 COMPRESSOR REMOVAL OIL CHARGE Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 COOLER REMOVAL REPLACING COOLER SERVICING COOLER Condenser Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 COIL CLEANING Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 STANDARD CONDENSER FANS HIGH STATIC CONDENSER FANS Refrigerant Feed Components . . . . . . . . . . . . . . . 26 ELECTRONIC EXPANSION VALVE (EXV) THERMOSTATIC EXPANSION VALVE (TXV) MOISTURE-LIQUID INDICATOR FILTER DRIER LIQUID LINE SOLENOID VALVE LIQUID LINE SERVICE VALVE

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. This equipment has been tested and found to comply with the limits of a Class A computing device as dened 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 commercial environment.

CONTENTS
Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Step 1 Rig and Place the Unit . . . . . . . . . . . . . . 2 DOMESTIC UNITS EXPORT UNITS AND DOMESTIC UNITS WITH SKIDS PLACING UNIT Step 2 Check Compressor Mounting . . . . . . . 2 Step 3 Cooler Fluid and Drain Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PREPARATION FOR YEAR-ROUND OPERATION PREPARATION FOR WINTER SHUTDOWN Step 4 Make Electrical Connections . . . . . . . . 8 FIELD POWER CONNECTIONS FIELD CONTROL POWER CONNECTIONS

Manufacturer reserves the right to discontinue, or change at any time, specications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No. 533-002 Printed in U.S.A. Form 30GT-49SI Pg 1 12-96 Replaces: 30GT-41SI Tab 5c

CONTENTS (cont)
Page Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 LOCATION REPLACING THERMISTOR T2 REPLACING THERMISTORS T1, T5, T6, T7, AND T8 THERMISTORS T3 AND T4 THERMISTOR/TEMPERATURE SENSOR CHECK Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 COMPRESSOR PROTECTION LOW OIL PRESSURE PROTECTION CRANKCASE HEATERS COOLER PROTECTION Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 HIGH-SIDE PROTECTION LOW-SIDE PROTECTION COMPRESSOR PROTECTION Other Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 START-UP CHECKLIST . . . . . . . . . . . . . . CL-1 to CL-4

unit. When the skid is removed, the unit must be handled by overhead rigging as described previously. If it is necessary to remove the skid before the unit is in nal position and unit can be dragged, place unit on a large pad and drag by the pad. Do not apply force to the unit. When in nal position, raise from above to lift unit off the pad. PLACING UNIT Refer to Fig. 1 and 2 for airow clearances. Provide ample room for servicing and removing cooler, depending on unit location. Refer to cooler dimensions in Fig. 1 and 2. For multiple units, allow 8 ft (2440 mm) separation between units for airow and service. Placement area must be level and strong enough to support operating weight of unit (see Fig. 3 and Tables 1 and 2). Weights at unit support points are shown in Fig. 3. Bolt unit securely to pad when unit is positioned and leveled. Fasteners for mounting unit are eld supplied. Check that unit is mounted levelly to ensure proper oil return to compressors. If vibration isolators (eld supplied) are required for a particular installation, refer to unit weight distribution in Fig. 3 to aid in proper selection of isolators.

Step 2 Check Compressor Mounting All

compressors on 30GT040-070 units are mounted on pans and are held down by 4 bolts during shipment. After unit is installed, loosen each of these bolts until the at washer can be moved with nger pressure. See Fig. 4 and 5.

INTRODUCTION
These instructions cover installation, start-up and service of 30GT040-070 Flotronic liquid chillers with electronic controls and units with factory-installed options (FIOPs). Standard chillers are equipped with electronic expansion valves (EXVs) and FIOP units have conventional thermostatic expansion valves (TXVs) and liquid line solenoid valves (LLSVs). Differences in quick test procedures and operation sequence should be carefully noted when following these instructions. Inspect the unit upon arrival for damage. If damage is found, le a claim right away with the shipping company. When considering location for the unit, be sure to consult National Electrical Code (NEC, U.S.A.) and local code requirements. Allow sufficient space for airow, wiring, piping, and service. See Fig. 1 and 2. Be sure surface beneath the unit is level, and is capable of supporting the operating weight of the unit. See Fig. 3 and Tables 1 and 2.

Step 3 Cooler Fluid and Drain Piping Connections When facing cooler side of unit, inlet (return) uid connection is on the right, nearest the control box. Outlet (supply) uid connection is on the left. The cooler has uid-side victaulic-type connections (follow connection directions as provided by the coupling manufacturer). If accessory grilles have been added, holes must be cut in grilles for eld piping and insulation. Although cooler has an air vent, it is recommended that eld-supplied air vents be installed at the highest point in the system to facilitate servicing. Field-supplied shut-off valves should also be installed to facilitate servicing and ow balancing. Locate valves in return and supply cooler uid lines as close to the chiller as possible. Upon completion of the eld piping installation, in areas where the piping is exposed to 32 F (0 C) or lower ambient temperatures, freeze-up protection is recommended using inhibited ethylene glycol (or other suitable corrosion-inhibitive antifreeze) and electric heater tapes. Heater tapes should have a rating for area ambient temperatures, and should be covered with a suitable thickness of closed-cell insulation. Route power for the heater tapes from a separate fused disconnect. Mount the disconnect within sight from the unit as prescribed by local or NEC codes. Identify disconnect as heater tape power source, with warning that power must not be turned off except when servicing the unit. IMPORTANT: Before starting unit, be sure all of the air has been purged from the system. A drain connection is located at leaving uid (supply) end of cooler. See Fig. 1 and 2. PREPARATION FOR YEAR-ROUND OPERATION If unit is to operate all year round, add sufficient inhibited ethylene glycol (or other suitable corrosion-inhibitive antifreeze) to the cooler water to prevent freeze-up under cold operating conditions. Consult local water authority on characteristics of area water and a recommended inhibitor for the cooler uid loop.

INSTALLATION Step 1 Rig and Place the Unit These units are designed for overhead rigging. Lifting holes are provided in frame base channels (see rigging label on unit). Use spreader bars or frame to keep cables or chains clear of unit sides. Run cables to a central suspension point so that angle from horizontal is not less than 45 degrees. Raise and set down unit carefully. Export units and domestic units with skids are rigged and placed as described below.
DOMESTIC UNITS Standard units are shipped without skids. If overhead rigging is not possible, place chiller on skid or pad for rolling or dragging. When rolling, use minimum of 3 rollers. When dragging, pull the pad. Do not apply force to the unit. When in nal position, raise from above to lift unit off the pad. EXPORT UNITS AND DOMESTIC UNITS WITH SKIDS All units are mounted on skids with vertical coil protection. At the job site, leave unit on the skid until unit is in nal position. While on the skid, the unit can be rolled or skidded on the oor, with force applied to the skid, not the

LEGEND C Copper Fins, Copper Tubing Mtg Mounting NOTES: 1. Unit must have clearances for airow as follows: TOP Do not restrict in any way. ENDS [1524] 5 ft SIDES [1829] 6 ft 2. 2.00 dia holes are recommended for parallel conductors on 040 and 045 (208/230 V) units. 3. 358 dia hole is recommended for single entry power on 050 (208/230 V) units. 4. Mounting holes may be used to mount unit to concrete pad. They are not recommended for spring isolator location. 5. If spring isolators are used, a perimeter support channel between the unit and the isolators is recommended. 6. Dimensions in [ ] are millimeters. 7. Thru-the-door handles for non-fused disconnect option on 380/415 v and 460 v units only. When unit has non-fused disconnect option, power-side door opens from right side, NOT left side as shown for standard units. UNIT 30GT 040 040C 045 045C 050 050C DIMENSIONS B C 3-101316 4-512 [1189] [1359] 3-11 4-512 [1194] [1359] 3-101316 5-512 [1189] [1663] 3-11 5-512 [1194] [1663] 3-11 5-512 [1194] [1663] 5-512 3-11316 [1199] [1663]

Unit 30GT 040,045 050 040-050

A 3-51116 [1059] 3-578 [1064] 3-6116 [1069] 3-6316 [1072] 3-578 [1064] 3-6 [1067]

D 1-1118 [587.5] 1-1118 [587.5] 1-5316 [436.6] 1-5316 [436.6] 1-5316 [436.6] 1-5316 [436.6]

040-050 040-050 040,045 050 040,045 050

FIELD POWER SUPPLY CONNECTIONS Voltage Hz Diameter 358 208/230 60 [92.0] 212 208/230 60 [63.5] 212 460 60 [63.5] 212 575 60 [63.5] 212 380 60 [63.5] 212 346 50 [63.5] 358 346 50 [92.0] 212 380/415 50 [63.5] 358 380/415 50 [92.0]

Qty 1 2 1 1 1 1 1 1 1

Fig. 1 Dimensions, 30GT040-050 3

LEGEND C Copper Fins, Copper Tubing Mtg Mounting NOTES: 1. Dimensions in [ ] are millimeters. 2. Unit must have clearances for airow as follows: TOP Do not restrict in any way. ENDS [1524] 5 ft SIDES [1829] 6 ft 3. Mounting holes may be used to mount unit to concrete pad. They are not recommended for spring isolator location. 4. If spring isolators are used, a perimeter support channel between the unit and the isolators is recommended. 5. Thru-the-door handles for non-fused disconnect option on 380/415 v and 460 v units only. When unit has non-fused disconnect option, power-side door opens from right side, NOT left side as shown for standard units. UNIT 30GT 060 060C 070 070C DIMENSIONS A 3-678 [1090] 3-7 [1092] 3-6 [1067] 3-6316 [1072] B 4-10516 [1481] 4-10916 [1488] 4-1012 [1486] 4-1078 [1496]

Unit 30GT 060 070 060 070 060,070 060,070 060,070 060,070

FIELD POWER SUPPLY CONNECTIONS Voltage Hz Diameter 212 208/230 60 [63.5] 358 208/230 60 [92.0] 212 460 60 [63.5] 358 460 60 [92.0] 212 575 60 [63.5] 358 380 60 [92.0] 358 346 50 [92.0] 358 380/415 50 [92.0]

Qty 2 2 1 1 1 1 1 1

Fig. 2 Dimensions, 30GT060,070 4

CONTROL BOX

MOUNTING WEIGHTS*
60 Hz UNITS
30GT UNIT SIZE 040 045 050 060 070 CONDENSER COIL C-AL C-C C-AL C-C C-AL C-C C-AL C-C C-AL C-C LB A 972 1044 999 1071 1047 1155 1258 1362 1332 1489 B 876 948 895 967 948 1057 1130 1234 1212 1369 C 807 879 845 917 884 992 1130 1217 1184 1340 D 895 968 943 1015 976 1085 1113 1344 1301 1458 A 441 473 453 486 475 524 570 618 604 675 B 397 430 406 438 430 479 512 560 550 621 KG C 366 399 383 416 401 450 505 552 537 608 D 406 439 428 460 443 492 562 609 590 661

50 Hz UNITS
30GT UNIT SIZE 040 045 050 060 070 CONDENSER COIL C-AL C-C C-AL C-C C-AL C-C C-AL C-C C-AL C-C LEGEND C-AL Copper Tubing, Aluminum Fins C-C Copper Tubing, Copper Fins LB A 992 1064 1065 1137 1074 1182 1269 1373 1508 1664 B 886 959 934 1007 968 1076 1151 1255 1369 1526 C 808 880 812 883 889 997 1123 1227 1226 1383 D 904 976 925 998 986 1095 1238 1342 1350 1508 A 450 482 483 515 487 536 575 623 684 755 B 402 435 424 457 439 488 522 569 621 692 KG C 366 399 368 401 403 452 509 556 556 627 D 410 443 420 452 447 496 561 609 612 684

*Points A, B, C, and D are located in the corners of the unit. See Fig. 1 and 2 for dimensions. Contact your local Carrier representative for more information on Epoxy-coated and pre-coated aluminum ns. NOTE: If spring isolators are used, a perimeter support channel between the unit and the isolators is recommended.

RIGGING CENTER OF GRAVITY

30GT 040 045 050 060 070 UNIT in. mm in. mm in. mm in. mm in. mm SIZE X 461316 1189 461316 1189 47 1194 58516 1481 5812 1486 Dimension Y 11 1 7 7 Dimension 41 16 1059 42 16 1069 41 8 1064 42 8 1090 42 1067

Fig. 3 Mounting Weights (Approximate)

Table 1 Physical Data 60 Hz

ENGLISH
30GT UNIT SIZE APPROX OPERATING WEIGHT lb C-AL C-C 040 3550 3838 39/12 48/12 (1) 2250 (1) A250 4 50.0 50.0 25.0 1140 4...30 4...6.2 35,000 1750 12...30 4...14.8 40,000 0.375 17 2 80.5 2 10.9 045 3681 3969 050 3856 4289 060 4740 5157 070 5028 5656 70/15 69/15 (1) 6299 (1) F299 4 50.0 50.0 33.3 1140 4...30 6...9.3 51,000 1750 12...30 6...22.2 60,000 0.375 17 3 116.7 2 18.0

REFRIGERANT CHARGE lb Ckt A R-22 Total/Over Clear Glass Ckt B COMPRESSORS, Type...rpm (No.) Ckt A 06E* (No.) Ckt B Oil Charge Compressor/pt Capacity Control Steps Ckt A % Cap. Ckt B Minimum Step Capacity (%) CONDENSER FANS Type Standard Fan Speed rpm No. Blades...Diameter in. No. Fans...Total kW Total Airow cfm High Static Fan Speed rpm No. Blades...Diameter in. No. Fans...Total kW Total Airow cfm CONDENSER COILS Type Tubes (Copper), OD in. Fins/in. No. Rows Ckt A or B Face Area sq ft Ckt A and B Total Max Working Pressure Refrigerant psig COOLER No. ...Type No. Refrigerant Circuits Net Fluid Volume Gal. (includes nozzles) Max Working Pressure Refrigerant Side/Fluid Side psig Standard Cooler Australian Code Cooler FLUID CONNECTIONS in. Inlet and Outlet Drain

40/12 48/12 52/14 46/12 60/12 54/14 Reciprocating, Semi-Hermetic...1750 (1) 2250 (1) 6265 (1) 6275 (1) F265 (1) F275 (1) F299 250/14, 265/19, 275/19, 299/19 4 4 4 42.4 47.6 43.3 57.6 52.4 56.7 21.2 31.7 28.8 Propeller, Direct Drive 1140 4...30 4...6.2 35,000 1140 4...30 4...6.2 34,000 1140 4...30 6...9.3 52,000

1750 1750 1750 12...30 12...30 12...30 4...14.8 4...14.8 6...22.2 40,000 40,000 60,000 Vertical and Horizontal, Plate Fin, Enhanced Tubing 0.375 0.375 0.375 17 17 17 2 3 2 80.5 80.5 116.7 450 One...Direct Expansion, Shell and Tube 2 2 2 13.5 13.5 18.0 278/300 207/150 Cooler Inlet and Outlet; Victaulic Type 3 3 4 34 NPT

SI
30GT UNIT SIZE APPROX OPERATING WEIGHT kg C-AL C-C 040 1610 1741 17.7/5.4 21.8/5.4 (1) 2250 (1) A250 4 50.0 50.0 25.0 19 4...762 4...6.2 16 517 29 12...762 4...14.8 18 876 9.53 669 2 7.48 2 41.3 045 1669 1800 050 1749 1945 060 2150 2339 070 2280 2565 31.7/6.8 31.3/6.8 (1) 6299 (1) F299 4 50.0 50.0 33.3 19 4...762 6...9.3 24 068 29 12...762 6...22.2 28 314 9.53 669 3 10.84 2 68.3

REFRIGERANT CHARGE kg Ckt A R-22 Total/Over Clear Glass Ckt B COMPRESSORS, Type...r/s (No.) Ckt A 06E* (No.) Ckt B Oil Charge Compressor/L Capacity Control Steps Ckt A % Cap. Ckt B Minimum Step Capacity (%) CONDENSER FANS Type Standard Fan Speed r/s No. Blades...Diameter mm No. Fans...Total kW Total Airow L/s High Static Fan Speed r/s No. Blades...Diameter mm No. Fans...Total kW Total Airow L/s CONDENSER COILS Type Tubes (Copper), OD mm Fins/m No. Rows Ckt A or B Face Area m2 Ckt A and B Total Max Working Pressure Refrigerant kPa COOLER No. ...Type No. Refrigerant Circuits Net Fluid Volume L (includes nozzles) Max Working Pressure Refrigerant Side/Fluid Side kPa Standard Cooler Australian Code Cooler FLUID CONNECTIONS in. Inlet and Outlet Drain LEGEND C-AL Copper Tubing Aluminum Fins Condenser Coil C-C Copper Tubing Copper Fins Condenser Coil OD Outside Diameter

18.1/5.4 21.8/5.4 23.6/6.3 20.9/5.4 27.2/5.4 24.5/6.3 Reciprocating, Semi-Hermetic...29.2 (1) 2250 (1) 6265 (1) 6275 (1) F265 (1) F275 (1) F299 250/6.6, 265/9.0, 275/9.0, 299/9.0 4 4 4 42.4 47.6 43.3 57.6 52.4 56.7 21.2 31.7 28.8 Propeller, Direct Drive 19 4...762 4...6.2 16 517 19 4...762 4...6.2 16 045 19 4...762 6...9.3 24 540

29 29 29 12...762 12...762 12...762 4...14.8 4...14.8 6...22.2 18 876 18 876 28 314 Vertical and Horizontal, Plate Fin, Enhanced Tubing 9.53 9.53 9.53 669 669 669 2 3 2 7.48 7.48 10.84 3103 One...Direct Expansion, Shell and Tube 2 2 2 51.2 51.2 68.3 1916/2068 1430/1034 Cooler Inlet and Outlet; Victaulic Type 3 3 4 34 NPT

*06E250 compressors have 4 cylinders; all others have 6. Based on rated external static pressure of 0.4 or 1.0 in. wg (100 Pa or 250 Pa) as appropriate. NOTE: Facing the compressors, Circuit A is on the right and Circuit B is on the left.

Table 2 Physical Data 50 Hz

ENGLISH
30GT UNIT SIZE APPROX OPERATING WEIGHT lb C-AL C-C 040 3550 3878 39/12 48/12 (1) 2250 (1) F265 4 42.4 57.6 21.2 950 6...30 4...6.2 35,000 1445 12...30 4...14.8 40,000 0.375 17 2 80.5 2 10.9 045 3736 4024 050 3916 4349 060 4780 5197 070 5453 6081

REFRIGERANT CHARGE lb Ckt A R-22 Total/Over Clear Glass Ckt B COMPRESSORS, Type...rpm (No.) Ckt A 06E* (No.) Ckt B Oil Charge Compressor/pt Capacity Control Steps Ckt A % Cap. Ckt B Minimum Step Capacity (%) CONDENSER FANS Type Standard Fan Speed rpm No. Blades...Diameter in. No. Fans...Total kW Total Airow cfm High Static Fan Speed rpm No. Blades...Diameter in. No. Fans...Total kW Total Airow cfm CONDENSER COILS Type Tubes (Copper), OD in. Fins/in. No. Rows Ckt A or B Face Area sq ft Ckt A and B Total Max Working Pressure Refrigerant psig COOLER No. ...Type No. Refrigerant Circuits Net Fluid Volume Gal. (includes nozzles) Max Working Pressure Refrigerant Side/Fluid Side psig Standard Cooler Australian Code Cooler FLUID CONNECTIONS in. Inlet and Outlet Drain

40/12 48/12 52/14 71/15 46/12 60/12 54/14 69/15 Reciprocating, Semi-Hermetic...1450 (1) 6265 (1) 6275 (1) 6299 (1) 6265, (1) F265 (1) F275 (1) F299 (1) F299 (1) F299 250/14, 265/19, 275/19, 299/19 4 4 4 6 47.6 43.3 50.0 58.0 52.4 56.7 50.0 42.0 31.7 28.8 33.3 19.3 Propeller, Direct Drive 950 6...30 4...6.2 35,000 950 6...30 4...6.2 34,000 950 6...30 6...9.3 52,000 950 6...30 6...9.3 51,000

1445 1445 1445 1445 12...30 12...30 12...30 12...30 4...14.8 4...14.8 6...22.2 6...22.2 40,000 40,000 60,000 60,000 Vertical and Horizontal, Plate Fin, Enhanced Tubing 0.375 0.375 0.375 0.375 17 17 17 17 2 3 2 3 80.5 80.5 116.7 116.7 450 One...Direct Expansion, Shell and Tube 2 2 2 2 13.5 13.5 18.0 18.0 278/300 207/150 Cooler Inlet and Outlet; Victaulic Type 3 3 4 34 NPT

SI
30GT UNIT SIZE APPROX OPERATING WEIGHT kg REFRIGERANT CHARGE kg Ckt A R-22 Ckt B COMPRESSORS, Type...r/s (No.) Ckt A 06E* (No.) Ckt B Oil Charge Compressor/L Capacity Control Steps Ckt A % Cap. Ckt B Minimum Step Capacity (%) CONDENSER FANS Type Standard Fan Speed r/s No. Blades...Diameter mm No. Fans...Total kW Total Airow L/s High Static Fan Speed r/s No. Blades...Diameter mm No. Fans...Total kW Total Airow L/s CONDENSER COILS Type Tubes (Copper), OD mm Fins/m No. Rows Ckt A or B Face Area m2 Ckt A and B Total Max Working Pressure Refrigerant kPa COOLER No. ...Type No. Refrigerant Circuits Net Fluid Volume L (includes nozzles) Max Working Pressure Refrigerant Side/Fluid Side kPa Standard Cooler Australian Code Cooler FLUID CONNECTIONS in. Inlet and Outlet Drain C-AL C-C Total/Over Clear Glass 040 1628 1759 17.7/5.4 21.8/5.4 (1) 2250 (1) F265 4 42.4 57.6 21.2 15.8 6...762 4...6.2 16 517 24 12...762 4...14.8 18 876 9.53 669 2 7.48 2 41.3 045 1694 1825 050 1776 1972 060 2168 2357 070 2473 2758 32.2/16.8 31.3/16.8 (1) 6265, F265 (1) F299 6 58.0 42.0 19.3 15.8 6...762 6...9.3 24 068

18.1/5.4 21.8/5.4 23.6/6.3 20.9/5.4 27.2/5.4 24.5/6.3 Reciprocating, Semi-Hermetic...24.2 (1) 6265 (1) 6275 (1) 6299 (1) F275 (1) F299 (1) F299 250/6.6, 265/9.0, 275/9.0, 299/9.0 4 4 4 47.6 43.3 50.0 52.4 56.7 50.0 31.7 28.8 33.3 Propeller, Direct Drive 15.8 6...762 4...6.2 16 517 15.8 6...762 4...6.2 16 045 15.8 6...762 6...9.3 24 540

24 24 24 24 12...762 12...762 12...762 12...762 4...14.8 4...14.8 6...22.2 6...22.2 18 876 18 876 28 314 28 314 Vertical and Horizontal, Plate Fin, Enhanced Tubing 9.53 9.53 9.53 9.53 669 669 669 669 2 3 2 3 7.48 7.48 10.84 10.84 3103 One...Direct Expansion, Shell and Tube 2 2 2 2 51.2 51.2 68.3 68.3 1916/2068 1430/1034 Cooler Inlet and Outlet; Victaulic Type 3 3 4 34 NPT

LEGEND C-AL Copper Tubing Aluminum Fins Condenser Coil C-C Copper Tubing Copper Fins Condenser Coil OD Outside Diameter

*06E250 compressors have 4 cylinders; all others have 6. Based on rated external static pressure of 0.4 or 1.0 in. wg (100 Pa or 250 Pa) as appropriate. NOTE: Facing the compressors, Circuit A is on the right and Circuit B is on the left.

eld power side on the right and control power supply on the left. See Fig. 6. FIELD POWER CONNECTIONS (See Fig. 7) All power wiring must comply with applicable local and national codes. Install eld-supplied, branch circuit fused disconnect(s) of a type that can be locked off or open. Disconnect(s) must be located within sight from and readily accessible from unit in compliance with NEC Article 440-14 or local codes. See Tables 3-6 for unit electrical data. All eld main power enters the unit through the control box at the left end when facing the compressors. An access hole is under the control box. All units have a single location for power connection (except size 050-070, 208/230 units) to simplify the eld power wiring. For all sizes, maximum wire size that the unit terminal block will accept is 500 kcmil. Unit may use copper, copper-clad aluminum, or aluminum conductors at all voltages. For 208/230-3-60 units (sizes 050-070), parallel conductors are required. Power must be supplied by 6 parallel conductors for these units. FIELD CONTROL POWER CONNECTIONS (See Fig. 7) For 208/230-, 460- and 575-3-60 units: If the accessory transformer is not used, provide a single-phase power source for the control circuit through a eld-supplied fused disconnect (per NEC or local code). This conductor must be copper only. Control power enters the control box through a 78-in. (22.2-mm) conduit connection located on the right side of the control section. For 380-3-60 and 380/415-3-50 units: Control circuit voltage is taken from the line voltage, therefore, no additional power supply is required for the unit. If a separate power source is required for a particular application, disconnect the wires between the control and power terminal blocks. For 346-3-50 Units: Provide a 230-1-50 power source for the control circuit through a eld-supplied fused disconnect (per NEC or local code). This conductor must be copper only. Control power enters the control box through a 78-in. (22 mm) conduit connection located on the right side of the control section. Units with a power supply of 208/230-, 460- and 5753-60 require 115-1-60 control circuit power. Units with a power supply of 380-3-60 have 230-1-60 control circuit power, which is taken from the units power supply voltage. Units with a power supply of 380/415-3-50 have 230-1-50 control circuit power, which is also taken from the units power supply voltage. Units with a 346-3-50 power supply require a separate 230-1-50 control power source. For control circuit current draw, see Table 4. Control circuit power draw includes the compressor crankcase heaters at 180 watts each, the cooler heaters (if equipped) at 210 watts each, and the electronic board heater at 120 watts. Sizes 040-050 have 2 cooler heaters; sizes 060 and 070 have 4 cooler heaters.

BOLT FLAT WASHER

Fig. 4 Compressor Mounting View

PAN

FLAT WASHER

BOLT

Fig. 5 Compressor Mounting Bolt PREPARATION FOR WINTER SHUTDOWN Do not shut off control power disconnect during off-season shutdown. At end of cooling season: 1. Drain the water from the system. 2. Replace the drain plug and add 2 gal. (8 L) of ethylene glycol to the cooler to prevent freezing of any remaining water in system. Glycol can be added through the vent on top of cooler. 3. Open one of the thermistor connections to allow air to escape the vessel and the glycol to enter. 4. For units with optional cooler heaters, remove fuse no. 1 (FU1). 5. At the beginning of the next cooling season, replace FU1 (if removed), rell cooler, and add recommended inhibitor.

Crankcase and cooler heaters are all wired into the control circuit ahead of the control circuit switch. Therefore, they are always active even if the control circuit switch is OFF. An interlock circuit for external safeties, such as the Chilled Water (Fluid) Flow Switch (CWFS), Remote On-Off, and Chilled Water (Fluid) Pump Interlock (CWPI) is provided between terminals TB6-3 and TB6-4 for eld use. To use this circuit, remove the factory jumper and install the switches.

Step 4 Make Electrical Connections The

electrical characteristics of the available power supply must agree with the unit nameplate rating. Supply voltage must be within the limits shown. The control box is divided into

FU SE

SE FU

E6
SE
FU

30GT510568

Fig. 6 Control Box

Step 5 Install Accessories

ELECTRICAL Several electrical accessories are available to provide the following optional features (for details, refer to the Controls and Troubleshooting book): Accessory temperature reset board and accessory thermistor (used for any of the following types of temperature reset): Return-uid temperature reset Space temperature reset (requires accessory thermistor) Outdoor-air temperature reset (requires accessory thermistor) Chilled uid ow switch LOW-AMBIENT OPERATION If operating temperatures below 0 F (18 C) are expected, refer to separate installation instructions for low-ambient operation, Motormaster III control. HOT GAS BYPASS Hot gas bypass usually is not recommended because it results in application of equipment out of its normal design application range. However, if its use is required, the appropriate hot gas bypass package may be used. For installation details, refer to separate instructions supplied with the accessory package. MISCELLANEOUS ACCESSORIES For applications requiring special accessories, the following packages are available: Condenser Hail Guard, Gage Panel, Security Grille Package, Condenser Fan Sound Reduction Kit, and CPCS (Compressor Protection Control System) packages.

PRE-START-UP
IMPORTANT: Before beginning Pre-Start-Up or StartUp, complete Start-Up Checklist for Flotronic Chiller Systems at center of this publication. The Checklist assures proper start-up of a unit and provides a record of unit condition, application requirements, system information, and operation at initial start-up. Do not attempt to start the chiller until following checks have been completed.

System Check
1. Check all auxiliary components, such as the chilled fluid circulating pump, air-handling equipment, or other equipment to which the chiller supplies liquid. Consult manufacturers instructions. If the unit has eld-installed accessories, be sure all are properly installed and wired correctly. Refer to unit wiring diagrams. 2. Backseat (open) compressor suction and discharge shutoff valves. Close valves one turn to allow refrigerant pressure to reach the test gages. 3. Open liquid line service valves. 4. Fill the chiller uid circuit with clean water (with recommended inhibitor added) or other noncorrosive uid to be cooled. Bleed all air out of high points of system. An air vent is included with the cooler. If outdoor temperatures are expected to be below 32 F (0 C), sufficient inhibited ethylene glycol (or other suitable corrosion-inhibitive antifreeze) should be added to the chiller uid circuit to prevent possible freeze-up.

LEGEND A Alarm CWFS Chilled Water (Fluid) Flow Switch Water (Fluid) Pump CWPI Chilled Interlock GND NEC O.A. TB Ground National Electrical Code, U.S.A. Outdoor Air Terminal Block Field Power Wiring Field Control Wiring Factory Installed Wiring

NOTES: 1. Factory wiring is in accordance with NEC. Field modications or additions must be in compliance with all applicable codes. 2. Wiring for main eld power supply must be rated 75 C minimum. Use copper, copper-clad aluminum, or aluminum conductors for all units. 3. Power for control circuit should be supplied from a separate source through a eld-supplied fused disconnect with 30 amp maximum protection for 115-v control circuits, 15 amp maximum protection for 230-v control circuit for a unit with cooler heaters, and 5 amp maximum for a unit without cooler heaters. Connect control circuit power to terminals 1 and 2 of TB4. Connect neutral side of supply to terminal 2 of TB4. Control circuit conductors for all units must be copper only. 4. Terminals 3 and 4 of TB6 are for eld connection of remote ON-OFF control, CWPI, and CWFS. The contacts must be rated for dry circuit application capable of reliably switching a 5 vdc, .5 mA. load. Remove jumper between 3 and 4 of TB6 if remote ON-OFF is installed. 5. The maximum load allowed for the remote alarm circuit is 75 va sealed, 360 va inrush at 115 or 230 v, depending on model. Remove resistor across terminals 1 and 2 of TB5 when using remote alarm. 6. Dimensions in [ ] are millimeters.

Fig. 7 Field Wiring 10

Table 3 Unit Electrical Data

30GT UNIT SIZE VOLTAGE Nameplate V-Hz (3 phase) 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 Supplied* Min Max 187 253 414 506 518 633 342 418 325 380 342 440 187 253 414 506 518 633 342 418 325 380 342 440 187 253 414 506 518 633 342 418 325 380 342 440 187 253 414 506 518 633 342 418 325 380 342 440 187 253 414 506 518 633 342 418 325 380 342 440 XL 177.2 101.2 100.0 100.0 107.0 102.9 204.4 101.3 100.0 107.1 129.8 115.9 247.1 114.3 100.6 126.9 170.8 142.4 328.5 142.0 125.4 174.5 205.3 167.9 369.5 166.0 148.9 200.7 215.6 189.7 MCA PW 177.2 101.2 100.0 100.0 107.0 103.2 204.4 101.6 100.0 105.0 129.8 119.6 247.1 118.0 100.0 127.8 170.8 147.4 328.5 147.0 121.0 176.6 205.3 173.5 369.5 171.6 141.5 202.3 215.6 195.4 STANDARD CONDENSER FAN Rec MOCP Fuse Size XL 225 100 100 125 150 125 250 125 125 150 175 150 350 150 125 175 250 200 450 200 175 250 250 225 500 225 200 250 250 250 PW 225 100 100 100 150 125 250 125 100 150 175 150 350 150 100 175 250 200 450 200 150 250 250 225 500 225 175 250 250 250 XL 200 100 90 110 125 125 225 125 100 125 150 150 300 125 125 150 200 175 400 175 150 200 250 200 450 200 175 225 250 225 PW 200 100 90 100 125 125 225 125 100 125 150 150 300 150 100 150 200 175 400 175 150 200 250 200 450 200 175 225 250 225 XL 437.3 219.8 162.4 241.2 297.9 271.4 538.3 269.8 206.4 297.2 342.5 337.4 620.1 308.8 226.1 341.1 453.4 405.6 828.8 410.6 336.8 458.0 487.9 431.1 869.8 429.2 353.5 484.2 498.2 452.9 ICF PW 299.3 149.5 113.7 163.9 198.9 181.1 360.3 179.5 139.8 196.9 230.5 210.7 418.1 209.1 152.9 228.5 300.4 269.5 552.8 274.5 218.7 306.2 334.9 295.6 593.8 293.7 239.2 331.9 345.2 317.5 XL 211.2 114.2 107.2 114.0 124.2 118.3 238.4 114.3 107.2 121.1 147.0 131.3 281.1 128.3 108.0 140.9 188.0 157.8 378.3 161.0 136.2 195.5 231.1 191.0 475.5 196.0 159.7 221.7 241.4 212.8 MCA HIGH STATIC CONDENSER FAN Rec MOCP Fuse Size XL 250 125 125 125 150 150 300 150 125 150 200 175 350 175 125 175 250 225 500 225 175 250 300 250 600 250 200 300 300 275 PW 250 125 125 125 150 150 300 150 125 150 200 175 350 175 125 175 250 225 500 225 175 250 300 250 600 250 200 300 300 275 XL 250 125 100 125 125 150 300 150 110 150 150 150 350 150 125 175 175 175 450 200 175 225 225 225 500 225 175 250 225 250 PW 250 125 100 125 125 150 300 150 100 150 150 150 350 150 125 175 175 175 450 200 175 225 225 225 500 225 175 250 225 250 XL 471.3 232.2 169.6 255.2 315.1 286.8 572.3 282.8 213.6 311.2 359.7 352.8 654.1 321.8 233.3 355.1 470.6 421.0 878.6 429.6 347.6 479.0 513.7 454.2 919.6 448.2 364.3 505.2 524.0 455.2 ICF PW 333.3 162.5 120.9 177.9 216.1 196.5 394.3 192.5 147.0 210.9 247.7 226.1 452.1 222.1 160.1 242.5 317.6 284.9 602.6 293.5 229.5 327.2 360.7 318.7 643.6 312.7 250.0 352.9 371.0 340.6

PW 211.2 114.2 107.2 114.0 124.2 118.6 238.4 114.3 107.2 118.0 147.0 135.0 281.1 131.0 107.2 141.8 188.0 162.8 378.3 166.0 131.8 197.6 231.1 196.6 475.5 190.4 152.3 223.3 241.4 218.5

040

045

050

060

070

Table 4 Control Circuit

UNIT POWER V-Ph-Hz 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 V-Ph-Hz 115-1-60 115-1-60 115-1-60 230-1-60 230-1-50 230-1-50 CONTROL POWER Min 104 104 104 207 198 198 Max 127 127 127 254 254 254 AMPS 30 30 30 15/5 15/5 15/5

LEGEND AND NOTES FOR ELECTRICAL DATA FOR TABLES 3 - 6

LEGEND FLA ICF Full Load Amps (Fan Motors) Maximum Instantaneous Current Flow during starting (the point in the starting sequence where the sum of the LRA for the starting compressor, plus the total RLA for all running compressors, plus the total FLA for all running fan motors is maximum) kW Total condenser fan motor power input LRA Locked Rotor Amps MCA Minimum Circuit Amps (for wire sizing) complies with NEC Section 430-24 MOCP Maximum Overcurrent Protective Device Amps NEC National Electrical Code, U.S.A. PW Part Wind Start Rec Fuse Recommended dual-element fuse amps: 150% of largest comSize pressor RLA plus 100% of sum of remaining compressor RLAs. Size up to the next larger standard fuse size. RLA Rated Load Amps (Compressors) XL Across-the-Line Start *Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits. Maximum allowable phase imbalance is voltage, 2%; amps, 10%. First value is for chiller with cooler heater. Second value (if applicable) is for chiller without cooler heater. **Numbers in ( ) indicate quantity. NOTES: 1. All units have single point primary power connection. Main power must be supplied from a eld-supplied disconnect. 2. The unit control circuit power (115 v, 1-ph for 208/230-, 460-, and 575-v units; 230 v, 1-ph for all other voltages) must be supplied from a separate source, through a eld-supplied disconnect. The control circuit transformer accessory may be applied to power from primary unit power. 3. Crankcase and cooler heaters are wired into the control circuit so they are always operable as long as the control circuit power supply disconnect is on, even if any safety device is open or the unit ON-OFF circuit switch is off. 4. Units have the following power wiring terminal blocks and parallel conductors: 30GT UNIT SIZE VOLTAGE 208/230 460 575 380 346 380/415 TERMINAL BLOCKS 1 1 1 1 1 1 PARALLEL CONDUCTORS 3 (040,045),6 (050-070) 3 3 3 3 3

040 to 070

5. Maximum incoming wire size for each terminal block is 500 kcmil. 6. Power draw of control circuits includes both crankcase heaters (where used) and cooler heaters. Each compressor has a crankcase heater which draws 180 watts of power. Units ordered with cooler heater option have 2 cooler heaters (040-050) or 4 cooler heaters (060,070), 210 w each, and a 120-w circuit board heater.

11

Table 5 Compressor Electrical Data

30GT UNIT SIZE NAMEPLATE VOLTAGE 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 208/230-3-60 460-3-60 575-3-60 380-3-60 346-3-50 380/415-3-50 A1 RLA 67.9 34.6 28.8 34.6 33.3 34.6 67.9 33.3 28.2 33.3 33.3 33.3 67.9 34.6 28.8 34.6 44.9 43.6 67.9 33.3 28.2 33.3 44.9 44.9 89.7 43.6 36.5 45.5 53.8 46.8 89.7 44.9 33.3 44.9 53.8 48.7 106.4 46.8 40.4 52.6 79.5 65.4 106.4 48.7 33.3 53.8 79.5 67.9 147.7 65.4 57.1 78.8 44.9 43.6 147.4 67.9 53.8 79.5 44.9 44.9 LRA 345 173 120 191 191 173 207 104 72 115 115 104 345 173 120 191 247 223 207 104 72 115 148 134 446 223 164 247 280 280 268 134 98 148 168 152 506 253 176 280 382 345 304 152 106 168 229 207 690 345 276 382 247 223 414 207 165 229 148 134 COMPRESSOR NUMBERS A2 RLA LRA 44.9 247 43.6 223 44.9 247 44.9 223 B1 RLA 67.9 34.6 28.8 34.6 44.9 43.6 67.9 33.3 28.2 33.3 44.9 44.9 89.7 43.6 36.5 45.5 53.8 46.8 89.7 44.9 33.3 44.9 53.8 48.7 106.4 46.8 40.4 52.6 79.5 65.4 106.4 48.7 33.3 53.8 79.5 67.9 147.7 65.4 57.1 78.8 79.5 67.9 147.4 65.4 57.1 78.8 79.5 65.4 147.4 65.4 57.1 78.8 79.5 65.4 147.4 67.9 53.8 79.5 79.5 67.9 LRA 345 173 120 191 247 223 207 104 72 115 148 134 446 223 164 247 280 280 268 134 98 148 168 152 506 253 176 280 382 345 304 152 106 168 229 207 690 345 276 382 382 345 414 207 165 229 229 207 690 345 276 382 382 345 414 207 165 229 229 207

040-XL

040-PW

045-XL

045-PW

050-XL

050-PW

060-XL

060-PW

070-XL

070-PW

See Legend and Notes on page 11.

12

Table 6 Condenser Fan Electrical Data

30GT UNIT SIZE NAMEPLATE VOLTAGE V-Hz (3 Phase) 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 208/230-60 460-60 575-60 380-60 346-50 380/415-50 STANDARD CONDENSER FAN No. Hp kW FLA (ea)** (2) 6.7, (2) (2) 3.3, (2) (4) 3.4 (4) 3.9 (4) 4.4 (4) 3.5 (2) 6.7, (2) (2) 3.3, (2) (4) 3.4 (4) 3.9 (4) 4.4 (4) 3.5 (2) 6.7, (2) (2) 3.3, (2) (4) 3.4 (4) 3.9 (4) 4.4 (4) 3.5 (4) 6.7, (2) (4) 3.3, (2) (6) 3.4 (6) 3.9 (6) 4.4 (6) 3.5 (4) 6.7, (2) (4) 3.3, (2) (6) 3.4 (6) 3.9 (6) 4.4 (6) 3.5 5.5 2.8 LRA (ea)** (2) 31.6, (2) 30.0 (2) 31.6, (2) 30.0 (4) 30.0 (4) 20.9 (4) 20.9 (4) 30.0 (2) 31.6, (2) 30.0 (2) 31.6, (2) 30.0 (4) 30.0 (4) 20.9 (4) 20.9 (4) 30.0 (2) 31.6, (2) 30.0 (2) 31.6, (2) 30.0 (4) 30.0 (4) 20.9 (4) 20.9 (4) 30.07.3 (4) 31.6, (2) 30.0 (4) 31.6, (2) 30.0 (6) 30.0 (6) 20.9 (6) 20.9 (6) 30.0 (4) 31.6, (2) 30.0 (4) 31.6, (2) 30.0 (6) 30.0 (6) 20.9 (6) 20.9 (6) 30.0 No. HIGH-STATIC CONDENSER FAN Hp kW FLA (ea) 14.6 6.3 5.2 7.4 8.7 7.3 14.6 6.3 5.2 7.4 8.7 7.3 14.6 6.3 5.2 7.4 8.7 7.3 14.6 6.3 5.2 7.4 8.7 7.3 14.6 6.3 5.2 7.4 8.7 7.3 LRA (ea) 41.6 41.6 42.0 54.0 53.0 41.0 41.6 41.6 42.0 54.0 53.0 41.0 41.6 41.6 42.0 54.0 53.0 41.0 41.6 41.6 42.0 54.0 53.0 41.0 41.6 41.6 42.0 54.0 53.0 41.0

040

0.746

3.73

5.5 2.8

045

0.746

3.73

5.5 2.8

050

0.746

3.73

5.5 2.8

060

0.746

3.73

5.5 2.8

070

0.746

3.73

See Legend and Notes on page 11.

5. Check tightness of all electrical connections. 6. Oil should be visible in the compressor sight glasses. See Fig. 8. An acceptable oil level in the compressor is from 18 to 38 of sight glass. Adjust the oil level as required. No oil should be removed unless the crankcase heater has been energized for at least 24 hours. See Oil Charge section on page 23 for Carrier-approved oils. 7. Electrical power source must agree with unit nameplate. 8. Crankcase heaters must be rmly locked into compressors, and must be on for 24 hours prior to start-up. 9. Fan motors are 3 phase. Check rotation of fans during the quick test. Fan rotation is clockwise as viewed from top of unit. If fan is not turning clockwise, reverse 2 of the power wires. 10. Check compressor suspension. Snubber washers (for noise suppression) can be moved with nger pressure. 11. Perform quick test to verify proper settings. See Controls and Troubleshooting literature for more details.

IMPORTANT: Do not allow unit control circuit to remain energized with showing in display for more than 2 minutes. If display button is not pressed within this time, control will attempt to start unit.

Quick Test (See Fig. 9 and Table 7) Both main

power and control circuit power must be on. The quick test program utilizes a 2-digit LED display (Fig. 9) on set point board to show status of all input and output signals to microprocessor control. Display action and quick test procedure are described as follows: The quick test is a 42-step program that provides a means of checking all input and output signals of microprocessor control prior to unit start-up. Check ensures that all control options, thermistors, and status switches are in proper working order. To initiate the quick test program, rst turn unit control switch to the ON position. When a appears in display, immediately press display button once. An will appear in display and alarm light will be energized; this indicates that microprocessor in control system is ready to run quick test program.

*Lead compressor only.

Fig. 8 Compressor Connections (Lead Compressor Shown) 13

DISPLAY BUTTON

FUSE 1

GROUND FAULT INTERRUPTER CONVENIENCE OUTLET (GFI-CO) (ACCESSORY)

*EPROM HT207101-1-XX. LEGEND DIP Dual In-line Package EPROM Electronic Programmable Read-Only Memory EXV Electronic Expansion Valve LED Light-Emitting Diode LWT Leaving-Water (Fluid) Temperature TP Test Pin

NOTES: 1. Refer to Controls and Troubleshooting publication for details. 2. Processor board is rotated 90 degrees counterclockwise from position shown when installed in unit. 3. Do not remove label covering EPROM. Removal causes program to be erased.

Fig. 9 Center of Flotronic Control System

14

Table 7 Quick Test SECTION A. Conguration and Switch Check QUICK TEST STEP NO. NORMAL DISPLAY STEP DESCRIPTION Type Unit Air-Cooled Chiller No. of Compressors =040-060 (50 Hz), 040-070 (60 Hz) = 070 (50 Hz) No. of Unloaders = Switch 6 On, Switch 7 Off = Switch 6 Off, Switch 7 On = Water = Brine* = EXV = TXV = 50 Hz = 60 Hz = External Reset = Return Fluid Reset = Reset Disabled = Reset Enabled = Pulldown Disabled = Pulldown Enabled = Demand Limit Disabled = Demand Limit Enabled = Remote On-Off Switch/Jumper Open = Remote On-Off Switch/Jumper Closed = Loss-of-Charge Switch A Open = Loss-of-Charge Switch A Closed = Loss-of-Charge Switch B Open = Loss-of-Charge Switch B Closed = Low Oil Pressure Switch A Open = Low Oil Pressure Switch A Closed = Low Oil Pressure Switch B Open = Low Oil Pressure Switch B Closed Circuit A Loss-of-Charge Switch Circuit B Loss-of-Charge Switch Circuit A Low Oil Pressure Switch Circuit B Low Oil Pressure Switch TB6-3 and TB6-4 DIP Switch 5 DIP Switch 3 DIP Switch 2 DIP Switch 1 Conguration Header: 7 Conguration Header: 6 DIP Switch 8 DIP Switches 6 and 7 HEADER POSITION OR CONTROL SWITCH Conguration Header: 1 and 2 Conguration Header: 3, 4, and 5

(Quick test continued on page 16; see page 17 for legend and notes.)

15

Table 7 Quick Test

(cont)

SECTION B. Thermistor and Potentiometer Checkout QUICK TEST STEP NO. NORMAL DISPLAY STEP DESCRIPTION Thermistor OK Thermistor Faulty Thermistor OK Thermistor Faulty Thermistor OK Thermistor Faulty Thermistor OK Thermistor Faulty ** Thermistor OK Thermistor Faulty or Not Used ** Thermistor OK Thermistor Faulty or Not Used ** Thermistor OK Thermistor Faulty or Not Used ** Thermistor OK Thermistor Faulty or Not Used Thermistor OK Thermistor Faulty or Not Used Potentiometer OK Potentiometer Faulty No Signicance Potentiometer OK Potentiometer Faulty or Option Not Used Potentiometer(s) OK Potentiometer(s) Faulty or Option Not Used Potentiometer OK Potentiometer Faulty or Option Not Used Potentiometer OK Potentiometer Faulty or Option Not Used T8 Compressor Thermistor, Circuit B (EXV Units) T10 Accessory Remote Thermistor P1 Leaving Fluid Set Point Potentiometer P3 Accessory Reset Limit Potentiometer P4 Accessory Demand Limit Potentiometer(s) P5 Accessory Reset Ratio Potentiometer P6 Accessory Reset Set Point Potentiometer THERMISTOR OR POTENTIOMETER T1 Cooler Leaving Fluid Thermistor T2 Cooler Entering Fluid Thermistor T3 Saturated Condensing Thermistor, Circuit A T4 Saturated Condensing Thermistor, Circuit B T5 Evaporator Refrigerant Thermistor, Circuit A (EXV Units) T6 Evaporator Refrigerant Thermistor, Circuit B (EXV Units) T7 Compressor Thermistor, Circuit A ( EXV Units)

16

Table 7 Quick Test

(cont)

SECTION C. Output Relay Check QUICK TEST STEP NO. NORMAL DISPLAY STEP DESCRIPTION Energize First Stage of Condenser Fans 040-050 OFM3 060, 070 OFM3, OFM4 Energize Second Stage of Condenser Fans 040-050 OFM4 060, 070 OFM5, OFM6 Energize Liquid Line Solenoid Valve (TXV only), Circuit A Energize Liquid Line Solenoid Valve (TXV only), Circuit B Energize Compressor A1, and OFM1 Energize Compressor A2 No action 040-060 (50 Hz), 040-070 (60 Hz) No Action Energize Unloader A1 Energize Compressor B1 and OFM2 No Action No Action Energize Unloader B1
CPCS DIP EXV FIOP OFM TB TXV LEGEND Compressor Protection Control System Dual In-Line Package Electronic Expansion Valve Factory-Installed Option Outdoor (Condenser) Fan Motor Terminal block Thermostatic Expansion Valve

RELAY NO.

K11

K12 K9 K10 K1 K2

K3 K4 K5 K6 K7 K8

IMPORTANT: If TB6-3 and TB6-4 jumper is not installed, chiller remains in standby mode. No compressors or fans start and Code 26 is displayed. This is not a fault code. If circuit between TB6-3 and TB6-4 is open, processor is programmed to initiate a shutdown and hold machine in standby. This feature makes remote shutdown of chiller easier.

*Do not change select switch to brine on units that do not have modications for brine. Special factory modications are required. Contact Carrier for details. is always displayed if oil pressure switch is not installed. **Display is Display is for Flotronic EXV units only. for Flotronic FIOP units (with TXV).

Compressors will be energized for 10 seconds. indicates open CPCS module contacts; indicates closed CPCS module contacts.

17

For each step of the 42-step program, display button must be pressed twice. On rst press, step number is displayed; second press initiates required action and code, as shown in Table 7. NOTE: Step number is a numeral followed by a decimal point (a 2-digit number has a decimal point after each numeral). Action code number is one or 2 digits with no decimal point(s). IMPORTANT: Once quick test is initiated, display button must be pressed at least once every 10 minutes for control to remain in quick test mode. If button is not pressed within this time, control will attempt to start unit. To recheck any step in quick test, control must be recycled by turning unit control circuit switch off for a few seconds, then on again. Restart quick test program as described above and proceed through quick test steps. Press display button twice for each step until step to be rechecked is reached. The quick test program is divided into 3 sections as described below and shown in Table 7. For more detailed information refer to Controls and Troubleshooting publication. QUICK TEST STEPS 1 - 15: UNIT CONFIGURATION Microprocessor in unit control system is programmed by 2 switch assemblies located on processor board (Fig. 9). Conguration header is factory set and cannot be changed in the eld. The DIP (dual in-line package) switch assembly contains 8 microswitches that must be set in accordance with various options and accessories selected. As shipped from factory, all DIP switches except those controlling pulldown option (switch no. 3), and compressor unloaders on compressor B1 (switch no. 7) are in OFF position. Switch no. 8 is in OFF position for water units, and in ON position for brine units. All DIP switches should be checked and set to proper position for options selected during quick test. The DIP switch assembly, functions and display codes are shown in Fig. 9 and in Table 8. Refer to Controls and Troubleshooting publication for details. QUICK TEST STEPS 16 - 30: THERMISTORS AND SET POINT POTENTIOMETERS In these steps, microprocessor checks resistance values of all sensors and set point potentiometers to ensure they are functional and set within proper range for unit conguration. Nominal resistance values for all sensors range from 363,000 to 216 ohms. Normal display code for good sensors and potentiometers is . Display code indicates a faulty

potentiometer, thermistor, or wiring. A display indicates a particular option is not being used, i.e., demand limit not installed. Tables 7 and 9 show set point potentiometer function, location, and quick test display codes. QUICK TEST STEPS 31 - 42: OUTPUT RELAYS These quick test steps allow microprocessor to check output signals from relay boards in unit control system. In addition, operation of all condenser fans and compressors is checked at each step. Normal display code for steps through is . In steps through , when appropriate, each compressor is started and allowed to run for approximately 10 seconds. At start-up will appear, followed by a in a few seconds. At end of 10-second test, code returns to display indicating that test step has been successfully completed. Code indicates that CPCS (compressor protection circuit) was tested. Fan and compressor operating sequence for quick test steps through are shown in Table 7 and Fig. 10. If quick test steps do not operate as described, a defect exists in one or more of the following: Relay being tested, electronic control, and/or unit wiring. Refer to Controls and Troubleshooting publication for additional information. Table 8 DIP Switch Functions
DIP SWITCH NO. 1 2 3 4 5 6 7 8 SELECTED FUNCTION* Type of Reset Reset Pulldown Limit Not Used Demand Limit 1 Unloader 2 Unloaders Brine

DIP Dual, In-Line Package *Refer to Table 7, quick test steps 3. through 1.0.

Table 9 Potentiometer Locations

P1 P3 P4 P5 P6 POTENTIOMETER Leaving Fluid Set Point Reset Limit Set Point Demand Limit Reset Ratio Set Point Reset Temp Set Point LOCATION Set Point Board (Standard) Accessory Board (Option) Accessory Board (Option) Accessory Board (Option) Accessory Board (Option)

FAN ARRANGEMENT 30GT040-050

FAN NO. 1 2 3 4

QUICK TEST DISPLAY NUMBER* 3.5. 3.9. 3.1. 3.2. 3.5. 3.9. 3.1. 3.2.

CONTROLLED BY Compressor No. A1 Compressor No. B1 First Stage of Condenser Fans Second Stage of Condenser Fans Compressor No. A1 Compressor No. B1 First Stage of Condenser Fans Second Stage of Condenser Fans

30GT060,070

1 2 3,4 5,6

*During quick test only.

Fig. 10 Condenser Fan Sequence

18

START-UP AND OPERATION

NOTE: Complete Start-Up Checklist at center of publication (pages CL-1 to CL-4) prior to starting unit.

radiation. Exposure to direct solar radiation could affect the temperature switch controlling cooler heaters. Table 10 Temperature Limits
TEMPERATURES Maximum Ambient Temp Minimum Ambient Temp Maximum Cooler EWT* Maximum Cooler LWT Minimum Cooler LWT F 125 0 95 70 40 C 52 18 35 21 4.5

Digital Display Action The electronic control

system uses a 2-digit LED (light-emitting diode) display located on display set point board (see Fig. 9) to show operational information and diagnostic codes. When control ON-OFF switch is turned to ON position, display shows for 2 minutes to indicate control is in initialization mode. Electronic expansion valve (EXV) will be closed as part of initialization sequence. This does not occur on FIOP (factory-installed option) units, where a conventional thermostatic expansion valve (TXV) is used. After a 2-minute period, display turns off and unit is allowed to start. If button is pressed after the has been removed from display, operational status codes or diagnostic information will be shown as long as button is held in. Code numbers on display will have following signicance: CODE OPERATIONAL NUMBER STATUS 0-12 Capacity stage 20-26 Operational information 51-87 Overload information Under normal operation, only stage number will be displayed. If an operational status code or an overload code is displayed, the display will rotate every 2 seconds and will display up to 3 numbers. Overload information will take priority over all other codes. The codes will be stored by the microprocessor as long as board is energized. IMPORTANT: The memory is cleared when control power is removed.

EWT Entering-Fluid Temp LWT Leaving-Fluid Temp *For sustained operation, it is recommended that EWT NOT exceed 85 F (29.4 C). Unit and/or DIP switch requires modication below this temperature.

Low-Ambient Operation If operating temperatures below 0 F (18 C) are expected, refer to separate installation instructions for low-ambient operation/Motormaster III control. Contact your Carrier representative for details. High Cooler LWT (leaving uid temperature) During start-up with leaving-uid temperatures above approximately 60 F (16 C), expansion valves (EXV and optional factoryinstalled TXV) will limit suction pressure to approximately 90 psig (620 kPa) to avoid overloading compressor. Low Cooler LWT Application of chillers within 39.9 F to 34 F (4.4 C to 1.1 C) temperature range is possible in some situations with proper eld change of control conguration. This requires that DIP switch no. 8 (brine switch) of S1 on the processor board be set to ON position. See Tables 7 and 8.

Do not operate with leaving-water temperature below 34 F (1.1 C). Application in the range 34 F to 15 F (1 C to 9.4 C) requires chiller with factory modication for brine duty. Contact your Carrier representative for details. VOLTAGE Main Power Supply Minimum and maximum acceptable supply voltages are listed in Table 3. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance between phases is greater than 2%. To determine percentage of voltage imbalance: max voltage deviation from avg voltage % Voltage Imbalance = 100 x average voltage The maximum voltage deviation is the largest difference between a voltage measurement across 2 legs and the average across all 3 legs. Example: Supply voltage is 240-3-60.

Actual Start-Up Actual start-up should be done only

under supervision of a qualied refrigeration mechanic. 1. Be sure all service valves are open. The unit is shipped from the factory with the suction, discharge, and liquid line service valves closed. 2. Set leaving uid temperature using LWT setpoint knob on front of control. No cooling range adjustment is necessary. 3. If accessory reset boards are used, set potentiometers properly. Refer to Controls and Troubleshooting book for details. 4. Start chilled uid pump. 5. Turn ON-OFF switch to ON position. The display will read . The machine checks all potentiometers and thermistors for valid readings. In approximately 2 minutes, the reading is no longer displayed, and the machine is operational. Allow the unit to operate and conrm that everything is functioning properly. Check the leaving-uid temperature and be sure that it agrees with the set point potentiometer P1. If the temperature setting does not agree, the set point can be compensated by shifting the control point slightly. If temperature reset is in effect, the leaving-uid temperature may not agree with the set point.

AB = 243 v BC = 236 v AC = 238 v

Operating Limitations
TEMPERATURES (See Table 10) If unit is to be used in an area with high solar radiation, mounted position should be such that control box is not exposed to direct solar 19

1. Determine average voltage: 243 + 236 + 238 Average voltage = 3 717 = 3 = 239 v

2. Determine maximum deviation from average voltage: (AB) 243 - 239 = 4 v (BC) 239 - 236 = 3 v (AC) 239 - 238 = 1 v Maximum deviation is 4 v. 3. Determine % voltage imbalance: 4 % Voltage Imbalance = 100 x 239 = 1.7% This voltage imbalance is satisfactory as it is below the maximum allowable of 2%. IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately. Do not operate unit until imbalance condition is corrected. Control Circuit Power Electronic control includes logic to detect low control circuit voltage. Acceptable voltage range is shown in Table 4. MINIMUM FLUID LOOP VOLUME To obtain proper temperature control, loop uid volume must be at least 3 gallons per ton (3.25 L per kW) of chiller nominal capacity for air conditioning and at least 6 gallons per ton (6.5 L per kW) for process applications or systems that must operate in low ambients (below 32 F [0 C]). Refer to application information in Product Data literature for details. FLOW RATE REQUIREMENTS Standard chillers should be applied with nominal ow rates approximating those listed in Table 11. Higher or lower ow rates are permissible to obtain lower or higher temperature rises. Minimum ow rates must be exceeded to assure turbulent ow and proper heat transfer in the cooler.

Operation below minimum ow could subject tubes to frost pinching in tube sheet, resulting in failure of cooler. Consult application data and job design requirements to determine ow rate requirements for particular installation. Table 11 Nominal and Minimum Cooler Fluid Flow Rates
30GT UNIT SIZE 040 045 050 060 070 NOMINAL FLOW RATE* Gpm L/s 86 5.43 101 6.37 123 7.76 151 9.53 173 10.91 LEGEND ARI Air Conditioning and Refrigeration Institute (U.S.A.) N Liters per kW V Gallons per ton *Nominal ow rates required at ARI conditions 44 F (7 C) leavinguid temperature, 54 F (12 C) entering-uid temperature, 95 F (35 C) ambient. Fouling factor .00025 ft2 hr F/Btu (.000044 m2 K/W). NOTES: 1. Minimum ow based on 1.0 fps (0.30 m/s) velocity in cooler without special cooler baffling. 2. Minimum Loop Volumes: Gallons = V x ARI Cap. (tons) Liters = N x ARI Cap. (kW) APPLICATION Normal Air Conditioning Process Type Cooling Low Ambient Unit Operation V 3 6 to 10 6 to 10 N 3.25 6.5 to 10.8 6.5 to 10.8 MINIMUM FLOW RATE (See Notes) Gpm L/s 36.8 2.38 37.7 2.38 37.7 2.38 47.5 3.00 47.5 3.00

Operation Sequence During unit off cycle, crankcase heaters are energized. If ambient temperature is below 36 F (2 C), cooler heaters and a microprocessor board heater are also energized. When control ON-OFF switch is turned to ON position, control rst goes through a 2-minute initialization period, during which the display continuously shows . Ninety (90) seconds after leaves display, control begins to bring on compressors. Rate at which compressors are started depends on leaving chilled uid temperature and rate of change of leaving-uid temperature. On all units, an automatic lead-lag feature in control system determines by random selection either circuit A or B to start rst. At rst call for cooling, microprocessor starts rst compressor, deenergizes crankcase heater, and starts one condenser fan. UNITS WITH EXV The EXV remains closed for 10 seconds to purge cooler and suction line of any liquid refrigerant that may have migrated to these areas during off period. After 10 seconds, EXV starts to open. As more cooling is required, control brings on additional stages of capacity. Loading sequence for compressors is shown in Table 12. Lag compressor will shut down, and lead compressor will continue to run. After lag compressor has shut down, the EXV is signaled to close. Lead compressor remains on until EXV is less than 600 steps open, and either the saturated suction temperature is less than 25 F (4 C) as sensed by thermistor T5 or T6, or one minute has elapsed. UNITS WITH STANDARD TXV Liquid line solenoid valve is not energized for rst 10 seconds of compressor operation. This is called pumpout cycle. Microprocessor determines how rapidly capacity stages are added or subtracted, based on deviation from leaving chilled uid temperature set point and rate of change of leavinguid temperature. If uid temperature is very warm and pulldown option is being used, microprocessor limits rate of temperature drop of leaving uid to 1 F (0.56 C) per minute to avoid high peak kW charges. If the capacity is being limited by pulldown, the control display shows when the display button is pressed. Once capacity has been satised, the unit starts to shut down.
Lag compressor will be shut down and lead compressor continues to run for 10 seconds to purge cooler of any refrigerant. LOAD SHED If load shed option is being used, control limits maximum capacity to load shed input value. Refer to Controls and Troubleshooting publication for details. If capacity is limited by a load shed signal, display shows when display button is pressed. TEMPERATURE RESET If temperature reset is being used, microprocessor adjusts leaving-uid temperature to obtain greater part-load efficiency. Refer to Controls and Troubleshooting book for details. If leaving-uid temperature is being reset, display shows when the display button is pressed. HEAD PRESSURE CONTROL Units with EXV Microprocessor also controls EXV to maintain a superheat of 24 to 30 F (13.3 to 16.7 C) entering compressor cylinders.

20

Table 12 Capacity Control Steps

LOADING LOADING SEQUENCE A SEQUENCE B CONTROL % % STEPS DisplaceCompressors Displace- Compressors ment ment (Approx) (Approx) 1 25 A1* 25 A1* 040 2 50 A1 50 A1 (60 Hz) 3 75 A1*, B1 75 A1*, B1 A1 4 100 A1, B1 100 A1, B1 1 25 A1* 25 B1* 040 2 50 A1*, B1* 50 A1*, B1* (60 Hz) 3 75 A1*, B1 75 A1, B1* A1, B1** 4 100 A1, B1 100 A1, B1 1 22 A1* 22 A1* 040 (50 Hz) 2 44 A1 44 A1 045 (60 Hz) 3 78 A1*, B1 78 A1*, B1 A1 4 100 A1, B1 100 A1, B1 1 22 A1* 38 B1* 040 (50 Hz) 2 59 A1*, B1* 59 A1*, B1* 045 (60 Hz) 3 78 A1*, B1 81 A1, B1* A1, B1** 4 100 A1, B1 100 A1, B1 1 31 A1* 31 A1* 045 (50 Hz) 2 46 A1 46 A1 050 (60 Hz) 3 85 A1*, B1 85 A1*, B1 A1 4 100 A1, B1 100 A1, B1 1 31 A1* 36 B1* 045 (50 Hz) 2 67 A1*, B1* 66 A1*, B1* 050 (60 Hz) 3 85 A1*, B1 85 A1, B1* A1, B1** 4 100 A1, B1 100 A1, B1 30GT UNIT SIZE 050 (50 Hz) 060 (60 Hz) A1 050 (50 Hz) 060 (60 Hz) A1, B1** 060 (50 Hz) 070 (60 Hz) A1 060 (50 Hz) 070 (60 Hz) A1, B1** 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 29 43 86 100 29 67 86 100 33 50 83 100 33 67 83 100 19 29 62 72 90 100 19 48 62 72 91 100 A1* A1 A1*, B1 A1, B1 A1* A1*, B1* A1*, B1 A1, B1 A1* A1 A1*, B1 A1, B1 A1* A1*, B1* A1*, B1 A1, B1 A1* A1 A1*, B1 A1, B1 A1*, A2, B1 A1, A2, B1 A1* A1*, B1* A1*, B1 A1, B1 A1*, A2, B1 A1, A2, B1 29 43 86 100 38 67 81 100 33 50 83 100 33 67 83 100 19 29 62 72 90 100 29 48 57 72 91 100 A1* A1 A1*, B1 A1, B1 B1* A1*, B1* A1, B1* A1, B1 A1* A1 A1*, B1 A1, B1 B1* A1*, B1* A1, B1* A1, B1 A1* A1 A1*, B1 A1, B1 A1*, A2, B1 A1, A2, B1 B1* A1*, B1* A1, B1* A1, B1 A1*, A2, B1 A1, A2, B1

Units with TXV Thermostatic expansion valves, one for each refrigerant circuit, are factory set to maintain 8 to 10 F (5 to 6 C) superheat of vapor leaving cooler to control ow of liquid refrigerant into cooler. Superheat can be reset but should be done only if necessary. Logic to cycle microprocessor-controlled fans is based on saturated condensing temperature only. This temperature is sensed by thermistors T3 and T4 (Fig. 11 and 12). The microprocessor will turn on an additional stage of fans when either of coil thermistors (T3 or T4) is greater than 113 F (45 C) and will turn off a fan stage when T3 and T4 are both below 73 F (23 C). Between each change in fan stage, control will wait one minute to allow head pressure to stabilize unless either T3 or T4 is greater than 125 F (52 C), in which case all microprocessor-controlled fans will come on immediately. Condenser fan sequence is shown in Fig. 10. REMOTE ON-OFF When it is required to control the starting and stopping of the chiller from a remote location, such as a timeclock, the remote ON-OFF feature is used. See Fig. 7 for wiring information. If the chiller is being held OFF by the remote ON-OFF switch, appears in the display when the display button is pressed. REMOTE ALARM See Fig. 7 for remote alarm eld wiring. Remove the resistor across terminals 1 and 2 on TB5 when remote alarm is being used.

SERVICE
ELECTRIC SHOCK HAZARD. Turn off all power to unit before servicing. The ON-OFF switch on control panel does not shut off control power; use eld disconnect.

070 (50 Hz) A1

Diagnostics and Troubleshooting Refer to Controls and Troubleshooting book. For eld service use, a eld-installed Ground Fault Interrupter (GFI) convenience outlet is available as an accessory for the 208/230-, 460-, and 575-v units. The GFI outlet is rated for 15 amps. However, in units with active cooler heaters, only 8 amps are available.

070 (50 Hz) A1, B1**

*Compressor unloaded. Compressor unloader, standard. **Compressor unloader, accessory. NOTES: 1. The microprocessor has a random number generator that selects loading sequence A or B, which in turn determines the compressor circuit that is energized rst. This balances operating hours on each circuit over an extended period of time. 2. If unit operation is anticipated with system load below minimum unloaded capacity of chiller: a. Consider using 2 smaller units in place of the larger unit. b. Increase uid loop volume to ensure adequate run time (see Application Data in Product Data literature). c. Consider adding accessory hot gas bypass package.

Refrigerant Circuit
LEAK TESTING Units are shipped with complete operating charge of refrigerant R-22 (see Tables 1 and 2) and should be under sufficient pressure to conduct a leak test. If there is no pressure in the system, introduce enough nitrogen to search for the leak. Repair the leak using good refrigeration practices. After leaks are repaired, system must be evacuated and dehydrated. REFRIGERANT CHARGE (Refer to Tables 1 and 2) Immediately ahead of lter drier in each circuit is a factoryinstalled liquid line service valve. Each valve has a 14-in. Schrader connection for charging liquid refrigerant. Charging with Unit Off and Evacuated Close liquid line service valve before charging. Weigh in charge shown on unit nameplate (also in Tables 1 and 2). Open liquid line service valve; start unit and allow it to run several minutes fully loaded. Check for a clear sight glass. Be sure clear condition is liquid and not vapor.

Microprocessor control also cycles condenser fans on and off to maintain an adequate pressure differential across expansion valves. Fans are controlled by position of EXV and saturated condensing temperature thermistors (T3 and T4). When expansion valve is fully open and superheat is greater than 40 F (22 C), fan stages are removed; when the valve is approximately half open, fan stages are added. This allows unit to run at very low condensing temperatures at part load. Thus chiller has very high part-load EERs (energy efciency ratios). Fan sequence is shown in Fig. 10.

21

LEGEND DPT Discharge Pressure Transducer, Ckt A or B EXV Electronic Expansion Valve OPT Oil Pressure Transducer, Ckt A or B SPT Suction Pressure Transducer, Ckt A or B T Thermistor Number TXV Thermostatic Expansion Valve *Not used with TXV.

Fig. 11 Thermistor and Transducer Locations

Fig. 12 Thermistor T3 and T4 Locations 22

Charging with Unit Running If charge is to be added while unit is operating, all condenser fans and compressors must be operating. It may be necessary to block condenser coils at low ambient temperatures to raise condensing pressure to approximately 280 psig (1931 kPa) to turn all condenser fans on. Do not totally block a coil to do this. Partially block all coils in uniform pattern. Charge each circuit until sight glass shows clear liquid, then weigh in amount over a clear sight glass as listed in Tables 1 and 2. IMPORTANT: When adjusting refrigerant charge, circulate uid through cooler continuously to prevent freezing and possible damage to the cooler. Do not overcharge, and never charge liquid into low-pressure side of system.

Table 13 Oil Charge

COMPRESSOR 06E250 06E265 06E275 06E299 OIL REQUIRED Pts L 14 6.6 19 9.0 19 9.0 19 9.0

Do not reuse drained oil, and do not use any oil that has been exposed to atmosphere.

Electronic Components
CONTROL COMPONENTS Unit uses an advanced electronic control system that normally does not require service. For details on controls, refer to Controls and Troubleshooting book. UNIT CONTROL BOX Viewed facing compressors, control box is at left end of unit. All incoming power enters through box. Control box contains power components and electronic controls. Outer panels are hinged and latched for easy opening. Remove screws to remove inner panels. Outer panels can be held open for service and inspection by using door retainer on each panel. Remove bottom pin from door retainer assembly, swing retainer out horizontally, and engage pin in one of the retainer ears and the hinge assembly.

Cooler The cooler is easily accessible from the cooler side of the unit. The refrigerant feed components are accessible from the control box end of the unit. COOLER REMOVAL Cooler can be removed from the cooler side of the unit as follows: 1. To ensure the refrigerant is in the condenser, follow this procedure: a. For 30GT070 (50 Hz) only, open the circuit breaker and close the discharge valve for the lag compressor (A2).

Do not close the discharge valve of an operating compressor. Severe damage to the compressor can result. b. Close the liquid line service valve for one circuit. Allow the lead compressor to pump down that circuit until it reaches approximately 10 to 15 psig (68.8 to 103.2 kPa). c. As soon as the system reaches that pressure, shut down the lead compressor by opening the compressor circuit breaker, then quickly close the discharge service valve for that compressor. d. Repeat the procedure for the other circuit.

Compressors If lead compressor on either refrigerant circuit becomes inoperative for any reason, circuit is locked off and cannot be operated due to features built into the electronic control system. Do not attempt to bypass controls to force compressors to run.
COMPRESSOR REMOVAL Access to the pump end of the compressor is from the compressor side of the unit. Access to the motor end of the compressor is from the inside of the unit. All compressors can be removed from the compressor side of the unit. IMPORTANT: All compressor mounting hardware and support brackets removed during servicing must be reinstalled prior to start-up. Following the installation of the new compressor: Tighten discharge and suction service valves to Compressor(s) 20 - 25 ft-lb (27 - 34 N-m) 06E250 80 - 90 ft-lb (109 - 122 N-m) 06E265,275,299 Tighten suction valves to 80 - 90 ft-lb (109 - 122 N-m) 06E250 90 - 120 ft-lb (122 - 163 N-m) 06E265,275,299 Tighten the following ttings to 120 in.-lb (13.5 N-m) High-Pressure Switch 120 in.-lb (13.5 N-m) Loss-of-Charge Switch OIL CHARGE (Refer to Table 13) All units are factory charged with oil. Acceptable oil level for each compressor is from 18 to 38 of sight glass (see Fig. 8). When additional oil or a complete charge is required, use only Carrier-approved compressor oil. Approved oils are as follows: Petroleum Specialties, Inc. Cryol 150 (factory oil charge) Texaco, Inc. Capella WF-32 Witco Chemical Co. Suniso 3GS 23

Open and tag all electrical disconnects before any work begins. Keep in mind that cooler is heavy and both uid-side and refrigerant-side may be under pressure. 2. Close the shutoff valves, if installed, in the cooler uid lines, and remove the cooler uid piping. 3. Open the air vent at the top of the cooler, and open the drain on the bottom of the cooler near the leaving uid outlet to drain the cooler. Both the drain and the air vent are located on the leaving uid end of cooler. See Fig. 13. 4. Disconnect the conduit and cooler heater wires, if equipped. Remove all thermistors from the cooler, being sure to label all thermistors as they are removed. Thermistor T2 is immersed directly in the uid. Thermistors T1, T5, and T6 are friction-t, well-type thermistors. See Fig. 13. 5. Remove the insulation on the refrigerant connection end of the cooler. 6. Unbolt the suction anges from the cooler head. Save the bolts. 7. Remove the liquid lines by breaking the silver-soldered joints at the cooler liquid line nozzles. 8. Remove the screws in the cooler feet. Slide the cooler slightly to the left to clear the refrigerant tubing. Save all screws. Remove the cooler carefully.

LEGEND EXV Electronic Expansion Valve

Fig. 13 Cooler Thermistor Locations

REPLACING COOLER To replace the cooler: 1. Insert new cooler carefully into place. Reattach the screws into the cooler feet (using saved screws). 2. Replace the liquid lines and solder at the cooler liquid line nozzles. 3. Rebolt the suction anges onto the cooler head using bolts saved during removal. Use new gaskets for the suction line anges. Use compressor oil to aid in gasket sealing, and tighten the suction ange bolts to 70 to 90 ft-lb (94 to 122 N-m). NOTE: The suction ange is a 4-bolt pattern. See Carrier specied parts for replacement part number, if necessary. 4. Use adhesive, and reinstall the cooler insulation on the refrigerant connection end of the cooler. 5. Reinstall the thermistors. Refer to Thermistors section on page 30, and install as follows: a. Apply pipe sealant to the 14-in. NPT threads on the replacement coupling for the uid side, and install it in place of the original.

7. Close the air vent at the top of the cooler, and close the drain on the bottom of the cooler near the leaving uid outlet. Both the drain and the air vent are located on the leaving uid end of the cooler. See Fig. 13. 8. Reconnect the cooler uid piping, and open the shutoff valves (if installed). Purge the uid of all air before starting unit. 9. Open the discharge service valves, close the circuit breakers, and open the liquid line service valves for the compressors. SERVICING COOLER When cooler heads and partition plates are removed, tube sheets are exposed showing ends of tubes.

Certain tubes in the 10HB coolers cannot be removed. Eight tubes in the bundle are secured inside the cooler to the baffles and cannot be removed. These tubes are marked by a dimple on the tube sheet. See Fig. 14. If any of these tubes have developed a leak, plug the tube(s) as described under Tube Plugging section below. Tube Plugging A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon cooler must be retubed. Tubes plugged in the area of thermistor T2, particularly the tube that thermistor T2 is adjacent to, will affect unit reliability and performance. Thermistor T2 is used in the freeze protection algorithm for the controller. If several tubes require plugging, check with your local Carrier representative to nd out how number and location can affect unit capacity.

Do not use the packing nut to tighten the coupling. Damage to the ferrules will result. b. Reinstall thermistor T1 well, and insert thermistor T1 into well. c. Install thermistor T2 (entering uid temperature) so that it is not touching an internal refrigerant tube, but so that it is close enough to sense a freeze condition. The recommended distance is 18 in. (3.2 mm) from the cooler tube. Tighten the packing nut nger tight, and then tighten 114 turns more using a back-up wrench. 6. Install the cooler heater and conduit (if equipped), connecting the wires as shown in the unit wiring schematic located on the unit.

24

Figure 15 shows an Elliott tube plug and a cross-sectional view of a plug in place.

Tube information: in. mm Tube sheet hole diameter . . . . . . . . . . . . 0.631 16.03 Tube OD . . . . . . . . . . . . . . . . . . . . . . . . . 0.625 15.87 Tube ID after rolling . . . . . . . . . . . . . . . 0.581 14.76 (includes expansion due to to to clearance) 0.588 14.94 NOTE: Tubes next to gasket webs must be ush with tube sheet (both ends). Tightening Cooler Head Bolts Gasket Preparation When reassembling cooler heads, always use new gaskets. Gaskets are neoprene-based and are brushed with a light lm of compressor oil. Do not soak gasket. Use new gaskets within 30 minutes to prevent deterioration. Reassemble cooler nozzle end or plain end cover of the cooler with the gaskets. Torque all cooler bolts to the following specications and sequence:

Use extreme care when installing plugs to prevent damage to the tube sheet section between the holes.

Fig. 14 Typical Tube Sheets, Cover Off (Non-Removable Tubes)

Fig. 15 Elliott Tube Plug Retubing (See Table 14) When retubing is to be done, obtain service of qualied personnel experienced in boiler maintenance and repair. Most standard procedures can be followed when retubing the 10HB coolers. An 8% crush is recommended when rolling replacement tubes into the tube sheet. An 8% crush can be achieved by setting the torque on the gun at 48 to 50 in.-lb (5.4 to 5.6 N-m). The following Elliott Co. tube rolling tools are required: B3400 Expander Assembly B3401 Cage B3405 Mandrel B3408 Rolls Place one drop of Loctite No. 675 (or equivalent) on top of tube prior to rolling. This material is intended to wick into the area of the tube that is not rolled into the tube sheet, and prevent uid from accumulating between the tube and the tube sheet. Table 14 Plugs
COMPONENTS FOR PLUGGING For Tubes Brass Pin Brass Ring For Holes without Tubes Brass Pin Brass Ring Loctite Locquic *Order directly from: Elliott Tube Company, Dayton, Ohio Can be obtained locally. PART NUMBER 853103-500* 853002-570* 853103-1* 853002-631* No. 675 N

-in. Diameter Perimeter Bolts . . . . . . 150 to 170 ft-lb (201 to 228 N-m) 12-in. Diameter Flange Bolts . . . . . . . . . . 70 to 90 ft-lb (94 to 121 N-m) 1. Install all bolts nger tight. 2. Bolt tightening sequence is outlined in Fig. 16. Follow the numbering sequence so that pressure is evenly applied to gasket. 3. Apply torque in one-third steps until required torque is reached. Load all bolts to each one-third step before proceeding 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 refrigerant leaks with soap solution or Halide device. 6. Replace cooler insulation.
58

Condenser Coils
COIL CLEANING Clean coils with a vacuum cleaner, fresh water, compressed air, or a bristle brush (not wire). Units installed in corrosive environments should have coil cleaning as part of a planned maintenance schedule. In this type of application, all accumulations of dirt should be cleaned off the coil.

Do not use high-pressure water or air n damage can result.

Fig. 16 Cooler Head Bolt Tightening Sequence (Typical Tube Sheet)

25

Condenser Fans Each fan is supported by a formed

wire mount bolted to fan deck and covered with a wire guard. The exposed end of fan motor shaft is protected from weather by grease. If fan motor must be removed for service or replacement, be sure to regrease fan shaft, and reinstall fan guard. STANDARD CONDENSER FANS For proper performance, top of fan propeller center should be 78 in. (22 mm) below top of venturi on the fan deck for 60 Hz units. For 50 Hz units, distance between top of venturi and top of fan hub should be 12 in. (13 mm). Tighten set screws to 15 1 ft-lb (20 1.3 N-m). Figure 17 shows proper position of mounted fan. IMPORTANT: Check for proper fan rotation (clockwise viewed from above). If necessary to reverse fan rotation direction, switch any 2 power leads. HIGH STATIC CONDENSER FANS If the unit is equipped with the high static fan option, the fan must be set from the top of the fan deck to the plastic ring or center of the fan to a distance of 2.15 in. 0.12 in. (54.6 3 mm). This is different from standard fans, since there is no area available to measure from the top of the orice ring to the fan hub itself. See Fig. 18. IMPORTANT: Check for proper fan rotation (clockwise viewed from above). If necessary to reverse fan rotation direction, switch any 2 power leads.

Refrigerant Feed Components Each circuit has

all necessary refrigerant controls. ELECTRONIC EXPANSION VALVE (EXV) A cutaway drawing of valve is shown in Fig. 19. High-pressure liquid refrigerant enters valve through bottom. A series of calibrated slots have been machined in side of orice assembly. As refrigerant passes through orice, pressure drops and refrigerant changes to a 2-phase condition (liquid and vapor). To control refrigerant ow for different operating conditions, sleeve moves up and down over orice and modulates orice size. Sleeve is moved by a linear stepper motor. Stepper motor moves in increments and is controlled directly by processor board. As stepper motor rotates, motion is transferred into linear movement by lead screw. Through stepper motor and lead screw, 1500 discrete steps of motion are obtained. The large number of steps and long stroke results in very accurate control of refrigerant ow. The valve orice begins to be exposed at 320 steps. Since there is not a tight seal with the orice and the sleeve, the minimum position for operation is 120 steps. The microprocessor controls the valve. Two thermistor temperature sensors are used to determine superheat. One thermistor is located in the cooler and other is located in the passage between compressor motor and cylinders. The difference between the 2 temperatures controls superheat. On a normal TXV or EXV system, superheat leaving evaporator is 10 F (5.6 C). Motor then adds approximately 15 to 20 F (8 to 11 C), resulting in approximately 30 F (16.7 C) superheat entering cylinders. Because EXVs are controlled by processor board, it is possible to track valve position. By this means, head pressure is controlled and unit is protected against loss of charge and a faulty valve. During initial start-up, EXV is fully closed. After initialization period, valve position is tracked by processor by constantly observing amount of valve movement. The EXV is also used to limit cooler saturated suction temperature to 55 F (13 C). This makes it possible for chiller to start at higher cooler uid temperatures without overloading compressor. This is commonly referred to as MOP (maximum operating pressure). If it appears that EXV is not properly controlling operating suction pressure or superheat, there are a number of checks that can be made using quick test and initialization features built into the microprocessor control. See the following sections and Controls and Troubleshooting literature for more details.

NOTE: Fan rotation is clockwise as viewed from top of unit.

Fig. 17 Condenser Fan Adjustment for Units with Standard Condenser Fans

Fig. 18 Condenser Fan Adjustment for Units with High Static Fan Option Fig. 19 Electronic Expansion Valve (EXV) 26

Follow steps below to diagnose and correct EXV problems. Step 1 Check Processor EXV Outputs Check EXV output signals at appropriate terminals on J7 terminal strip as follows: 1. Turn power off. 2. Connect positive test lead of meter to terminal 8 on connector J7 (see Fig. 20). 3. Set meter for approximately 20 vdc. 4. Turn power on, but do not enter quick test mode. For the rst 50 seconds, valve motor windings are alternately energized to close valve in circuit 1. 5. During this time, connect negative test lead to terminals 9, 10, 11, and 12 in succession. Voltage should rise and fall at each pin. If it remains constant at a voltage or at 0 v, remove connector and recheck. If problem still exists, replace processor board. If problem no longer exists, check EXV. 6. Turn power off and connect positive lead to terminal 1 on connector J7. 7. Turn power on. After 50 seconds, motor windings in circuit 2 valve will begin to be energized. 8. During this time, connect negative test lead to terminals 2, 3, 4, and 5. Voltage should rise and fall at each pin. If it remains constant at a voltage or at 0 v, remove connector and recheck. If problem still exists, replace processor board. If there is no longer a problem, check EXV. Step 2 Check EXV Wiring Check wiring to EXVs from J7 terminal strip on processor board (see Fig. 20). 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. Step 3 Check Resistance of EXV Motor Windings Remove plug at J7 terminal strip and check resistance between common lead (red wire, terminal D) and remaining leads A, B, C, and E. Resistance should be 25 ohms 2 ohms. Step 4 Check Thermistors that Control EXV Check thermistors that control processor output voltage pulses to EXVs. Circuit A thermistors are T5 and T7, and circuit B thermistors are T6 and T8. Refer to Fig. 11 for location.

EXV Electronic Expansion Valve

1. Use quick test steps 2.0. through 2.3. to determine if thermistors are shorted or open. 2. Check thermistor calibration at a known temperature by measuring actual resistance and comparing value measured with values listed in Tables 15 and 16. 3. Make sure that thermistor leads are connected to proper pin terminals at J1 terminal strip on processor board and that thermistor probes are located in proper position in refrigerant circuit (Fig. 11 and 13). When above checks have been completed, actual operation of EXV can be checked by using procedures outlined in Step 5 Check Operation of the EXV section below. During quick test steps 3.5. and 3.9., each EXV is opened approximately 500 steps by processor. This quick test feature, along with initialization mode , can be used to verify proper valve operation. Step 5 Check Operation of the EXV Use following procedure to check actual operation of EXVs. 1. Close liquid line service valve for circuit to be checked and run through appropriate quick test step 3.5. or 3.9. to pump down low side of system. Repeat quick test step 3 times to ensure all refrigerant has been pumped from low side and that EXV has been driven fully open (1500 steps open). NOTE: Do not use control ON-OFF switch to recycle control during this step, and be sure to allow compressors to run full 10 seconds at each step. 2. Turn OFF control circuit switch and compressor circuit breaker(s). Close compressor service valves and remove any remaining refrigerant from low side of system. 3. Remove screws holding top cover of EXV. Carefully remove top cover, using caution to avoid damage to the O-ring seal and motor leads. If EXV plug was disconnected during this process, reconnect it after the cover is removed. 4. Note position of lead screw (see Fig. 19). If valve has responded properly to processor signals in Step 5.1 above, valve should be fully open and lead screw should protrude approximately 14 in. (6 mm) to 34 in. (19 mm) above top of motor. 5. Recycle control by turning control circuit switch to ON position. This puts control in initialization mode . During rst 100 seconds of initialization mode, each valve is driven to fully closed position (zero steps open) by processor. With cover lifted off EXV valve body, observe operation of valve motor and lead screw. The motor should turn in the counterclockwise (CCW) direction and lead screw should move down into motor hub until valve is fully closed. Lead screw movement should be smooth and uniform from fully open to fully closed position. 6. When test has been completed, carefully reassemble EXV. Be careful not to damage motor or O-ring when reassembling valve. Open compressor service valves and close compressor circuit breakers. Open liquid line service valve. Turn control circuit switch to ON position, and allow unit to operate. Verify proper operation of unit. This process of opening and closing EXV can be repeated by repeating quick test steps 3.5. or 3.9. and recycling control as described in proceeding steps. If valve does not operate as described when properly connected to processor and receiving correct signals, it should be replaced. If operating problems persist after reassembly, they may be due to out-of-calibration thermistor(s), or intermittent connections between processor board terminals and EXV plug. Recheck all wiring connections and voltage signals.

Fig. 20 Processor Board Connections

27

Table 15 Sensor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE (F) - 25 - 24 - 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7 - 6 - 5 - 4 - 3 - 2 - 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 VOLTAGE DROP (V) 4.684 4.673 4.662 4.651 4.640 4.628 4.616 4.604 4.591 4.578 4.565 4.551 4.537 4.523 4.509 4.494 4.479 4.463 4.448 4.431 4.415 4.398 4.381 4.363 4.345 4.327 4.308 4.289 4.270 4.250 4.230 4.209 4.188 4.167 4.145 4.123 4.101 4.078 4.055 4.032 4.008 3.984 3.959 3.934 3.909 3.883 3.858 3.831 3.805 3.778 3.751 3.723 3.696 3.668 3.639 3.611 3.582 3.553 3.523 3.494 3.464 3.434 3.404 3.373 3.343 3.312 3.281 3.250 3.219 3.187 3.156 3.124 3.093 3.061 3.029 2.997 2.965 2.933 2.901 2.869 2.837 2.805 2.772 2.740 2.708 2.676 2.644 2.612 RESISTANCE (OHMS) 98,010 94,707 91,522 88,449 85,485 82,627 79,871 77,212 74,648 72,175 69,790 67,490 65,272 63,133 61,070 59,081 57,162 55,311 53,526 51,804 50,143 48,541 46,996 45,505 44,066 42,678 41,339 40,047 38,800 37,596 36,435 35,313 34,231 33,185 32,176 31,201 30,260 29,351 28,472 27,624 26,804 26,011 25,245 24,505 23,789 23,096 22,427 21,779 21,153 20,547 19,960 19,392 18,843 18,311 17,796 17,297 16,814 16,346 15,892 15,453 15,027 14,614 14,214 13,826 13,449 13,084 12,730 12,387 12,053 11,730 11,416 11,111 10,816 10,529 10,250 9,979 9,717 9,461 9,213 8,973 8,739 8,511 8,291 8,076 7,868 7,665 7,468 7,277 TEMPERATURE (F) 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 151 VOLTAGE DROP (V) 2.581 2.549 2.517 2.486 2.454 2.423 2.391 2.360 2.329 2.299 2.268 2.237 2.207 2.177 2.147 2.117 2.088 2.058 2.029 2.000 1.972 1.943 1.915 1.887 1.859 1.832 1.805 1.778 1.751 1.725 1.699 1.673 1.647 1.622 1.597 1.572 1.548 1.523 1.500 1.476 1.453 1.430 1.407 1.385 1.362 1.341 1.319 1.298 1.277 1.256 1.236 1.216 1.196 1.176 1.157 1.138 1.120 1.101 1.083 1.065 1.048 1.030 1.013 0.997 0.980 0.964 0.948 0.932 0.917 0.902 0.887 0.872 0.857 0.843 0.829 0.815 0.802 0.788 0.775 0.762 0.750 0.737 0.725 0.713 0.701 0.689 0.678 0.655 RESISTANCE (OHMS) 7,091 6,911 6,735 6,564 6,399 6,237 6,081 5,929 5,781 5,637 5,497 5,361 5,229 5,101 4,976 4,855 4,737 4,622 4,511 4,403 4,298 4,195 4,096 4,000 3,906 3,814 3,726 3,640 3,556 3,474 3,395 3,318 3,243 3,170 3,099 3,031 2,964 2,898 2,835 2,773 2,713 2,655 2,598 2,542 2,488 2,436 2,385 2,335 2,286 2,238 2,192 2,147 2,103 2,060 2,018 1,977 1,937 1,898 1,860 1,822 1,786 1,750 1,715 1,680 1,647 1,614 1,582 1,550 1,519 1,489 1,459 1,430 1,401 1,373 1,345 1,318 1,291 1,265 1,239 1,214 1,189 1,165 1,141 1,118 1,095 1,072 1,050 1,007 TEMPERATURE (F) 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 VOLTAGE DROP (V) 0.644 0.634 0.623 0.613 0.602 0.592 0.582 0.573 0.563 0.554 0.545 0.536 0.527 0.518 0.509 0.501 0.493 0.484 0.476 0.468 0.461 0.453 0.446 0.438 0.431 0.424 0.417 0.410 0.403 0.397 0.390 0.384 0.378 0.371 0.365 0.360 0.354 0.348 0.342 0.337 0.332 0.326 0.321 0.316 0.311 0.306 0.301 0.297 0.292 0.288 0.283 0.279 0.274 0.270 0.266 0.262 0.258 0.254 0.250 0.247 0.243 0.239 0.236 0.232 0.229 0.225 0.222 0.219 0.215 0.212 0.209 0.206 0.203 0.200 RESISTANCE (OHMS) 986 965 945 925 906 887 868 850 832 815 798 782 765 749 734 719 705 690 677 663 650 638 626 614 602 591 581 570 560 551 542 533 524 516 508 501 494 487 480 473 467 461 456 450 444 439 434 429 424 419 415 410 405 401 396 391 386 382 377 372 366 361 356 350 344 338 332 325 318 311 304 297 289 282

28

Table 16 Sensor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE (C) -32.0 -31.5 -31.0 -30.5 -30.0 -29.5 -29.0 -28.5 -28.0 -27.5 -27.0 -26.5 -26.0 -25.5 -25.0 -24.5 -24.0 -23.5 -23.0 -22.5 -22.0 -21.5 -21.0 -20.5 -20.0 -19.5 -19.0 -18.5 -18.0 -17.5 -17.0 -16.5 -16.0 -15.5 -15.0 -14.5 -14.0 -13.5 -13.0 -12.5 -12.0 -11.5 -11.0 -10.5 -10.0 - 9.5 - 9.0 - 8.5 - 8.0 - 7.5 - 7.0 - 6.5 - 6.0 - 5.5 - 5.0 - 4.5 - 4.0 - 3.5 - 3.0 - 2.5 - 2.0 - 1.5 - 1.0 - 0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 VOLTAGE DROP (V) 4.690 4.680 4.671 4.661 4.651 4.641 4.630 4.620 4.609 4.597 4.586 4.574 4.562 4.550 4.537 4.525 4.512 4.499 4.485 4.471 4.457 4.443 4.428 4.413 4.398 4.383 4.367 4.351 4.334 4.318 4.301 4.283 4.266 4.248 4.230 4.211 4.193 4.174 4.154 4.135 4.115 4.094 4.074 4.053 4.032 4.010 3.989 3.967 3.944 3.922 3.899 3.876 3.852 3.829 3.805 3.781 3.756 3.732 3.707 3.682 3.656 3.631 3.605 3.579 3.553 3.526 3.500 3.473 3.446 3.419 3.392 3.364 3.337 3.309 3.281 3.253 3.225 3.197 3.169 3.140 3.112 3.083 3.054 3.026 2.997 2.968 2.939 2.911 2.882 2.853 2.824 2.795 2.766 2.737 2.708 2.680 RESISTANCE (OHMS) 100 049 97 006 94 061 91 209 88 449 85 777 83 191 80 687 78 264 75 918 73 648 71 451 69 324 67 265 65 272 63 344 61 477 59 670 57 921 56 228 54 589 53 003 51 467 49 980 48 541 47 148 45 799 44 492 43 228 42 003 40 817 39 668 38 556 37 478 36 435 35 424 34 444 33 495 32 576 31 685 30 821 29 984 29 173 28 386 27 624 26 884 26 168 25 472 24 798 24 144 23 509 22 893 22 296 21 716 21 153 20 606 20 076 19 561 19 061 18 575 18 103 17 645 17 199 16 766 16 346 15 937 15 539 15 153 14 777 14 412 14 057 13 711 13 375 13 048 12 730 12 420 12 119 11 826 11 541 11 263 10 992 10 729 10 472 10 223 9 979 9 742 9 512 9 287 9 068 8 855 8 647 8 444 8 247 8 055 7 868 7 685 TEMPERATURE (C) 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5 22.0 22.5 23.0 23.5 24.0 24.5 25.0 25.5 26.0 26.5 27.0 27.5 28.0 28.5 29.0 29.5 30.0 30.5 31.0 31.5 32.0 32.5 33.0 33.5 34.0 34.5 35.0 35.5 36.0 36.5 37.0 37.5 38.0 38.5 39.0 39.5 40.0 40.5 41.0 41.5 42.0 42.5 43.0 43.5 44.0 44.5 45.0 45.5 46.0 46.5 47.0 47.5 48.0 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 53.0 53.5 54.0 54.5 55.0 55.5 56.0 56.5 57.0 57.5 58.0 58.5 59.0 59.5 60.0 60.5 61.0 61.5 62.0 62.5 63.0 63.5 VOLTAGE DROP (V) 2.651 2.622 2.593 2.565 2.536 2.508 2.479 2.451 2.423 2.395 2.367 2.339 2.311 2.283 2.256 2.228 2.201 2.174 2.147 2.120 2.094 2.067 2.041 2.015 1.989 1.963 1.938 1.912 1.887 1.862 1.837 1.813 1.789 1.764 1.741 1.717 1.693 1.670 1.647 1.624 1.602 1.579 1.557 1.536 1.514 1.492 1.471 1.450 1.430 1.409 1.389 1.369 1.349 1.330 1.311 1.292 1.273 1.254 1.236 1.218 1.200 1.182 1.165 1.148 1.131 1.114 1.098 1.081 1.065 1.049 1.034 1.019 1.003 0.988 0.974 0.959 0.945 0.931 0.917 0.903 0.890 0.876 0.863 0.850 0.837 0.825 0.812 0.800 0.788 0.776 0.765 0.753 0.742 0.731 0.720 0.709 RESISTANCE (OHMS) 7507 7334 7165 7000 6840 6683 6531 6382 6237 6096 5959 5825 5694 5566 5442 5321 5203 5088 4976 4867 4760 4656 4555 4457 4360 4267 4175 4086 4000 3915 3832 3752 3674 3597 3523 3450 3379 3310 3243 3177 3113 3051 2990 2931 2873 2816 2761 2707 2655 2603 2553 2504 2457 2410 2364 2320 2276 2234 2192 2152 2112 2073 2035 1997 1961 1925 1890 1856 1822 1789 1757 1725 1694 1663 1634 1604 1575 1547 1519 1492 1465 1438 1412 1387 1362 1337 1313 1289 1265 1242 1219 1197 1175 1153 1132 1111 TEMPERATURE (C) 64.0 64.5 65.0 65.5 66.0 66.5 67.0 67.5 68.0 68.5 69.0 69.5 70.0 70.5 71.0 71.5 72.0 72.5 73.0 73.5 74.0 74.5 75.0 75.5 76.0 76.5 77.0 77.5 78.0 78.5 79.0 79.5 80.0 80.5 81.0 81.5 82.0 82.5 83.0 83.5 84.0 84.5 85.0 85.5 86.0 86.5 87.0 87.5 88.0 88.5 89.0 89.5 90.0 90.5 91.0 91.5 92.0 92.5 93.0 93.5 94.0 94.5 95.0 95.5 96.0 96.5 97.0 97.5 98.0 98.5 99.0 99.5 100.0 100.5 101.0 101.5 102.0 102.5 103.0 103.5 104.0 104.5 105.0 105.5 106.0 106.5 107.0 VOLTAGE DROP (V) 0.698 0.688 0.678 0.667 0.657 0.648 0.638 0.628 0.619 0.609 0.600 0.591 0.582 0.574 0.565 0.557 0.548 0.540 0.532 0.524 0.516 0.508 0.501 0.493 0.486 0.479 0.472 0.465 0.458 0.451 0.444 0.437 0.431 0.425 0.418 0.412 0.406 0.400 0.394 0.388 0.383 0.377 0.371 0.366 0.361 0.355 0.350 0.345 0.340 0.335 0.331 0.326 0.321 0.317 0.312 0.308 0.303 0.299 0.295 0.291 0.287 0.283 0.279 0.275 0.271 0.267 0.264 0.260 0.257 0.253 0.250 0.246 0.243 0.240 0.236 0.233 0.230 0.227 0.224 0.221 0.218 0.215 0.212 0.209 0.206 0.204 0.201 RESISTANCE (OHMS) 1090 1070 1050 1030 1011 992 973 955 937 919 902 885 868 852 836 820 805 790 775 761 746 733 719 706 693 681 669 657 645 634 623 613 602 592 583 573 564 556 547 539 531 524 516 509 502 496 489 483 477 472 466 461 456 451 446 441 436 432 427 423 419 415 410 406 402 398 393 389 385 380 376 371 367 362 357 352 346 341 335 330 324 318 312 305 299 292 285

29

Other possible causes of improper refrigerant ow control could be restrictions in liquid line, plugged lter drier(s), stuck liquid line solenoid valve(s), or restricted metering slots in the EXV. Formation of ice or frost on lower body of EXV is one symptom of restricted metering slots. Clean or replace valve if necessary. NOTE: Frosting of valve is normal during quick test steps 3.5. and 3.9. and at initial start-up. Frost should dissipate after a 5- to 10-minute operation of a system that is operating properly. If valve is to be replaced, wrap valve with a wet cloth to prevent excessive heat from damaging internal components. Superheat control built into valve is not adjustable. NOTE: The EXV orice is a screw-in type and may be removed for inspection and cleaning. Once the top cover has been removed, the EXV motor may be taken out by removing the 2 cap screws securing motor to valve body. Pull motor, lead screw, and the slide assembly up off the orice assembly. A slot has been cut in top of orice assembly to facilitate removal using a large screwdriver. Turn orice assembly counterclockwise to remove. When cleaning or reinstalling orice assembly, be careful not to damage orice assembly seals. The bottom seal acts as a liquid shut-off, replacing a liquid line solenoid valve. Reassembly of valve is made easier by screwing the slide and lead screw assembly out of the motor. Align hole in top of slide with the guide pin in orice assembly, and gently push slide and lead screw onto orice assembly about half way. Screw motor onto lead screw and secure EXV motor with cap screws. Be careful not to twist or pull on wires from EXV motor to valve cover pin connections. Check EXV operation in test steps outlined on page 27. THERMOSTATIC EXPANSION VALVE (TXV) The FIOP chiller is equipped with conventional TXV, one per circuit. This control system necessitates use of a liquid line solenoid valve. TXV is factory set to maintain 8 to 10 F (4.4 to 5.6 C) superheat of vapor leaving cooler by controlling flow of refrigerant into cooler. Superheat can be reset but should be done only if absolutely necessary. When TXV is used, thermistors T5, T6, T7, and T8 are eliminated (see Fig. 11). TXV also incorporates an MOP feature to limit cooler suction to 55 F (13 C), making it possible for compressor to start at higher cooler-uid temperatures without overloading. MOISTURE-LIQUID INDICATOR Clear ow of liquid refrigerant indicates sufficient charge in system. Bubbles in the sight glass indicate undercharged system or presence of noncondensables. Moisture in system measured in parts per million (ppm), changes color of indicator: Green moisture is below 45 ppm Yellow-green (chartreuse) 45 to 130 ppm (caution) Yellow (wet) above 130 ppm Change lter drier at rst sign of moisture in system. IMPORTANT: Unit must be in operation at least 12 hours before moisture indicator can give an accurate reading. With unit running, indicating element must be in contact with liquid refrigerant to give true reading. FILTER DRIER Whenever moisture-liquid indicator shows presence of moisture, replace lter driers. There is one lter drier on each circuit. LIQUID LINE SOLENOID VALVE All units have a liquid line solenoid valve to prevent liquid refrigerant migration to low side of system during the off cycle. 30

LIQUID LINE SERVICE VALVE This valve is located immediately ahead of lter drier, and has a 14-in. Schrader connection for eld charging. In combination with compressor discharge service valve, each circuit can be pumped down into the high side for servicing.

Thermistors Electronic control uses 4 to 9 thermistors to sense temperatures used to control the operation of chiller. See Table 17 for thermistors used. Table 17 Temperature Sensors (Thermistors)
SENSOR T1 T2 T3 T4 T5* T6* T7* T8* T10 TEMPERATURE Cooler Leaving Fluid Cooler Entering Fluid Saturated Condensing Temperature Circuit A Saturated Condensing Temperature Circuit B Evaporator Refrigerant Temperature Circuit A Evaporator Refrigerant Temperature Circuit B Compressor Return Gas Temperature Circuit A Compressor Return Gas Temperature Circuit B Remote Temperature Sensor (Accessory)

*Not used on units with thermostatic expansion valve.

All thermistors are identical in their temperature vs resistance and voltage drop performance. Resistances at various temperatures are listed in Table 15 or 16. LOCATION General locations of thermistor sensors are shown in Fig. 11. Cooler Leaving Fluid Sensor (T1) Sensor T1 is located in the leaving-uid nozzle. The probe is in a well immersed in the uid. Actual location is shown in Fig. 11 and 13. Cooler Entering Fluid Sensor (T2) Sensor T2 is located in the cooler shell in rst baffle space, in close proximity to tube bundle. The 14-in. coupling is used (Fig. 21). Actual location is shown in Fig. 11 and 13. Saturated Condensing Temperature Sensors (T3 and T4) Sensors T3 and T4 are each clamped to outside of a return bend on condenser coil. Exact locations for all units are shown in Fig. 11 and 12. Evaporator Refrigerant Sensors (T5 and T6) Sensors T5 and T6 are located next to refrigerant inlet in cooler head. Thermistors are well-type thermistors. Typical location is shown in Fig. 11 and 13. (Not used on units with TXV.) Compressor Return Gas Temperature Sensors (T7 and T8) Sensors T7 and T8 are located in lead compressor in each circuit in a suction passage between motor and cylinders above oil pump. They are well-type thermistors. Location is shown in Fig. 11. (Not used on units with TXV.) Remote Sensor (T10) Sensor T10 is an accessory sensor and is mounted remotely from unit. It is used for outdoor-air or space temperature reset.

Sensor T2 is installed directly in the uid circuit. Relieve all pressure or drain uid before removing. To troubleshoot a sensor, refer to separate Controls and Troubleshooting literature. REPLACING THERMISTOR T2 1. Remove and discard original sensor and coupling. Do not disassemble new coupling. Install assembly as received. 2. Apply pipe sealant to 14-in. NPT threads on replacement coupling, and install in place of original. Do not use the packing nut to tighten coupling. Damage to ferrules will result.

FLUID-SIDE TEMPERATURE SENSOR (T1) AND REFRIGERANT TEMPERATURE SENSOR (T5, T6, T7, T8)

FLUID-SIDE TEMPERATURE SENSOR (T2) NOTE: Dimensions in ( ) are in millimeters.

Fig. 21 Thermistors (Temperature Sensors) 3. Thermistor T2 (entering uid temperature) should not be touching an internal refrigerant tube, but should be close enough to sense a freeze condition. Recommended distance is 18 in. (3.2 mm) from cooler tube. Tighten packing nut nger tight to position ferrules, then tighten 114 turns more using a back-up wrench. Ferrules are now attached to the sensor, which can be withdrawn from coupling for service. REPLACING THERMISTORS T1, T5, T6, T7, AND T8 Add a small amount of thermal conductive grease to thermistor well. Thermistors are friction-t thermistors, which must be slipped into receivers located in the cooler leaving uid 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). THERMISTORS T3 AND T4 These thermistors are located on header end of condenser coil. They are clamped on a return bend. THERMISTOR/TEMPERATURE SENSOR CHECK A high quality digital volt-ohmmeter is required to perform this check. 1. Connect the digital voltmeter across the appropriate thermistor terminals at the J1 terminal strip on the processor board (see Fig. 22 and Fig. 9). Using the voltage reading obtained, read the sensor temperature from Table 15 or 16. To check thermistor accuracy, measure temperature at probe location with an accurate thermocoupletype temperature measuring instrument. Insulate thermocouple to avoid ambient temperatures from inuencing reading. Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close, 5 F (3 C) if care was taken in applying thermocouple and taking readings. 2. If a more accurate check is required, unit must be shut down and thermistor removed and checked at a known temperature (freezing point or boiling point of water) using either voltage drop measured across thermistor at the J1 terminals with unit in quick test mode or by determining the resistance with chiller shut down and thermistor disconnected from J1.
COMPR Compressor *Not used on FIOP (Factory-Installed Option) unit with TXV (Thermostatic Expansion Valve).

Fig. 22 Thermistor Connections to J1 Processor Board COMPRESSOR PROTECTION Circuit Breaker One manual-reset, calibrated-trip, magnetic circuit breaker for each compressor protects against overcurrent. Do not bypass or increase size of a breaker to correct problems. Determine cause for trouble and correct before resetting breaker. Circuit breaker must-trip amps (MTA) are listed on individual circuit breakers and on unit label diagrams. Compressor Protection Board (CPCS) or Control Relay (CR) The CPCS or CR is used to control and protect compressors and crankcase heaters. Each provides following features: Compressor contactor control Crankcase heater control Ground current protection (CPCS only) Status communication to processor board High-pressure protection One large relay located on CPCS board (or unit CR) controls crankcase heater and compressor contactor. In addition, relay provides a set of contacts that microprocessor monitors to determine operating status of compressor. If processor board determines that compressor is not operating properly through signal contacts, control locks compressor off. The CPCS contains logic that can detect if current-toground of any winding exceeds 2.5 amps; if so, compressor shuts down. A high-pressure switch with a trip pressure of 426 7 psig (2936 48 kPa) is mounted on each compressor; switch setting is shown in Table 18. Switch is wired in series with the CPCS or control relay. If switch opens, CPCS relay or CR opens, processor detects it through signal contacts, and compressor locks off. Table 18 Pressure Switch Settings, psig (kPa)
SWITCH High Pressure Loss-of-Charge CUTOUT 426 7 (2936 48) 7 (48.2) CUT-IN 320 20 (2205 138) 22 (151.6)

Safety Devices Chillers contain many safety devices and protection logic built into electronic control. Following is a brief summary of major safeties. For complete details refer to Controls and Troubleshooting literature.

31

If any of these switches opens during operation, the compressor stops and the failure is detected by processor when signal contacts open. On size 070, 50 Hz only, if lead compressor in either circuit is shut down by high-pressure switch, ground current protection, loss-of-charge switch, or oil pressure switch, both compressors in the circuit (if applicable) are locked off. LOW OIL PRESSURE PROTECTION Lead compressor in each circuit is equipped with a switch to detect low oil pressure. Switch is connected directly to processor board. Switch is set to open at approximately 5 psig (35 kPa) and to close at 9 psig (62 kPa) maximum. If switch opens when compressor is running, CR or processor board stops all compressors in circuit. During start-up, switch is bypassed for 2 minutes. CRANKCASE HEATERS Each compressor has a 180-w crankcase heater to prevent absorption of liquid refrigerant by oil in crankcase when compressor is not running. Heater power source is auxiliary control power, independent of main unit power. This assures compressor protection even when main unit power disconnect switch is off. IMPORTANT: Never open any switch or disconnect that deenergizes crankcase heaters unless unit is being serviced or is to be shut down for a prolonged period. After a prolonged shutdown or service, energize crankcase heaters for 24 hours before starting unit. COOLER PROTECTION Freeze Protection Cooler can be wrapped with heater cables (optional) as shown in Fig. 23, which are wired through an ambient temperature switch set at 36 F (2 C). Entire cooler is covered with closed-cell insulation applied over heater cables. Heaters plus insulation protect cooler against low ambient temperature freeze-up to 0 F (18 C). IMPORTANT: If unit is installed in an area where ambient temperatures fall below 32 F (0 C), it is recommended that inhibited ethylene glycol or other suitable corrosion-inhibitive antifreeze solution be used in chilled-uid circuit.

Low Fluid Temperature Microprocessor is programmed at the factory to shut chiller down if leaving-uid temperature drops below 35 F (1.7 C). When uid temperature rises 6 F (3.3 C ) above leaving-uid set point, safety resets and chiller restarts. Loss of Fluid Flow Protection Microprocessor contains internal logic that protects cooler against loss of cooler ow. Entering- and leaving-uid temperature sensors in cooler detect a no-ow condition. Leaving sensor is located in leaving uid nozzle and entering sensor is located in rst cooler baffle space in close proximity to cooler tubes, as shown in Fig. 13. When there is no cooler ow and the compressors start, leaving-uid temperature does not change. However, entering-uid temperature drops rapidly as refrigerant enters cooler. Entering sensor detects this temperature drop and when entering temperature is 5 F (2.8 C) below leaving temperature, unit stops and is locked off. Loss-of-Charge A pressure switch connected to high side of each refrigerant circuit protects against total loss-ofcharge. Switch settings are listed in Table 18. If switch is open, unit cannot start; if it opens during operation, unit locks out and cannot restart until switch is closed. Low charge is also monitored by the processor when an EXV is used. A low charge is detected by monitoring EXV position and superheat entering the compressor. If EXV is wide open, superheat is greater than 50 F (28 C), and saturated cooler suction is less than 55 F (13 C), circuit is stopped and locked off.

Relief Devices Fusible plugs are located in each circuit to protect against damage from excessive pressures. HIGH-SIDE PROTECTION One device is located between condenser and lter drier; a second is on lter drier. These are both designed to relieve on a temperature rise to approximately 210 F (99 C). LOW-SIDE PROTECTION A device is located on suction line, designed to relieve on a temperature rise to approximately 170 F (77 C).
COMPRESSOR PROTECTION Pressure Relief Valves Valves for unit sizes 040-070, 60 Hz, and 040-060, 50 Hz, are installed in compressors A1 and B1. Valves for unit size 070, 50 Hz are installed in compressors A2 and B1. These valves are designed to relieve at 450 psig (3103 kPa). These valves should not be capped. If a valve relieves, it should be replaced. If valve is not replaced, it may relieve at a lower pressure, or leak due to trapped dirt from the system, which may prevent resealing. The pressure relief valves are equipped with a 38-in. SAE (Society of Automotive Engineers, U.S.A.) are for eld connection. Some local building codes require that relieved gases be removed. This connection will allow conformance to this requirement.

Other Safeties There are several other safeties that

Fig. 23 Cooler Heater Cables are provided by microprocessor control. For details refer to Controls and Troubleshooting literature.

Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No. 533-002 Printed in U.S.A. Form 30GT-49SI Pg 32 12-96 Replaces: 30GT-41SI Tab 5c