Carrier 040-420 User Manual

GY040-420Contrcwith h_.- - v----wICONTENTSPageSAFETY CONSIDERATIONS . . . + . . . . , e +. . , . . , . 1GENERAL . . . . . . , . . . . , . , . . . , .

Table 4B- Capacity Control Steps, 080-110 and Associated Modular Units (cant)rTUNIT30GNLOADING LOADING SEQUENCE BCONTROLSTEPS%Displacement(4wW7:;’ii4

Table 40- Capacity Control Steps, 080-I IO and Associated Modular Units (cant)UNIT30GN100, 2406,270B (60 Hz)Alr*,Blr100, 240B,2708 (50 Hz)A1tW-tWtf2

-Table 48- Capacity Control Steps, 080-110 and Associated Modular Units (cant)UNIT30GN110 (60 Hz)Al t**,Bl Y110 (50 Hz)Alt,BltLOADING SEQUENCE A%Disp

Table 4B- Capacity Control Steps, 080-110 and Associated Modular Units (cant)UNIT30GN110 (50 Hz)Alt**,Blt110 (50 Hz)Alt,Blv110 (50 Hz) zAlt**,Blt**i9

Table 4C- Capacity Control Steps, 130-210 and Associated Modular UnitsUNIT30GN130, 240A,130, 240A,130, 240A,130, 240A,130,24OA,T-LOADING%DisplacementM

Table 4C- Capacity Control Steps, 130-210 and Associated Modular Units (cant)UNIT30GN130, 24OA,130,24OA,130, 240A,CONTROLSTEPSrLOADING SEQUENCE A%Di

Table 4C- Capacity Control Steps, 130-210 and Associated Modular Units (cant)rEQUENCE ALOADING%Displacement(Apwxl6:::“;zi4953iii:ii:95100LOADING%Disp

Table 4C- Capacity Control Steps, 130-210 and Associated Modular Units (cant)SEQUENCE BLOADING SEQUENCE AUNITSIZE%Displacement(4wrox)CompressorsCompre

Table 4C -Capacity Control Steps, 130-210 and Associated Modular Units (cant)UNITSIZE170, 270A,300B,170,27OA, 300B,170,27OA, 300B,33oA/,$cH350 Hz)9LO

Table 4C -Capacity Control Steps, 130210 and Associated Modular Units (cant)UNITCONTROLSIZESTEPS170, 270A, 300B,33OA/z, t”fB,:“O Hz)I170, 270A, 3008

-%a-GENERALIMPORTANT: This publication contains controls, op-eration and troubleshooting data for 3OGNO40-420 and30GT225, 250, and 280 FlotronicTM

-Table 4C -Capacity Control Steps, 130-210 and Associated Modular Units (cant)l-rSEQUENCE BCompressorsLOADIN<%DisplacementOVvW241561;:UNITSIZECKEL

Table 4C -Capacity Control Steps, 130-210 and Associated Modular Units (cant)rl-LOADING SEQUENCE Ai SEQUENCE BCompressorsLOAD11%DisplacementPWprox)11:

r-ATable 4C -Capacity Control Steps, 130-210 and Associated Modular Units (cant)fLOAD11LOADING SEQUENCE Bi SEQUENCE ACompressorsUNITSIZE%Displacement

Table 4D- Capacity Control Steps, 225, 250,280UNIT30GT225 (60 Hz)225 (50 Hz)rLOAC%Displacement(Awox)12246E1:;\IGSEQUENCE ACompressors*1A’B1Al ,A2,61Al

UNIT30GT250 (60 Hz)*Unloaded compressor.JCompressor un!oader, standard**Compressor unloader, accessoryttTwo unloaders, both unloaded.NOTE: These capa

Table 4D- Capacity Control Steps, 225, 250, 280 (cant)UNIT30GT250 (50 Hz)280 (60 Hz)250 f& Hz),Al**250 $;; Hz),Al**,Bl**CONTROLSTEPS1G SEQUENCE A

Head Pressure Control - The microprocessor con-trols the condenser fans in order to maintain the lowest con-densing temperature possible, thus the hig

Table 5 -Condenser Fan Sequence (cant)FAN ARRANGEMENTFAN NUMBER(S) FAN C~;;jACToR CONTROLLED BY30GT22530GT250 (60 Hz)7, 8FC-1Compressor Al9, 10FC-4 Co

Keypad and Display Module (Also Called HSIOor LID)- The only function of this module is to allowthe operator to communicate with the processor. It is

Table 7 -Functions and SubfunctionsFUNCTIONSsu6FUNFT’oNStatusTestScheduleServiceHistory Set Point0STATclTESTICICHDclSRVC0HISTclSET1AutomaticoutputsOve

\- -.-...-KEYPAD;DISPLAYGROUND FAULT INTERRUPTERMODULE (HSIO/LID)208/230-, 460-f%!-3-60-V ONLYLEGENDCCN - cZarrier Comfort NetworkTB -1“erminal Bl

Table 9- Keypad DirectorySTATUS2 ALARMSI3 MODES4 STAGE5 SET POINT6 TEMPERATUREKEYPAD ENTRYDISPLAY 1LEGENDCCN- Carrier Comfort NetworkEXV- Electronic

Table 9 -Keypad Directory (cant)STATUS (cant)SUBFUNCTIONIKEYPADENTRY6TEMPERATURE (cant) cl 4qtcl 4cl 40 47 PRESSURE8 ANALOG9 1NPUTSDISPLAYSCTB XSSTB

Table 9- Keypad Directory (cant)SUBFUNCTION10 OUTPUTSSTATUS (cant)DISPLAYOUTPUTSALMR XFRAI XFRA2 XFRBI XFRB2 XCHWP X*ULAI XULA2 X*ULBI XULB2 X*EXVA XE

Table 9- Keypad Directory (cant)TEST (cant)SUBFUNCTIONKEYPAD ENTRY2 COMPRESSORS ANDUNLOADERSDuring compressor test, compressors start and run for10 se

Table 9- Keypad DirectorySCHEDULE (cant)DISPLAYPERIOD 1OCC HH.MMUN0 HH.MMMON XTUE XWED xTHU XFRl XSAT XSUN XHOL XTo toggle between inputs (Yes/No) P

Table 9- Keypad Directory (cant)SERVICE (cord)The next 3 subfunctions provide the ability to modify configurations Refer to separate Installation, S

Table 9- Keypad Directory (cant)SUBFUNCTION1 RUN TIMEKEYPAD ENTRYDISPLAY COMMENTr;lmRUN TIMERun Time lnformation0+HR X Total Hrs Unit Has a Comp Opera

Table 10- Operationat and Mode Display CodesThe operating modes are displayed by name or code num-ber, to indicate the operating status of the unit at

Example 2 -Reading Current Operating ModesKEYPADIDISPLAYENTRY RESPONSEICOMMENTSTUE 15:45Keypad has not been used for atLOCAL ONleast 10 minutes Rotati

Example 3 -Using Test FunctionKEYPAD DISPLAYIENTRY RESPONSECOMMENTScl+COMPCPA 1 OFFCPA 1 ONCPA 1 OFFCPA 2 OFFFactory/field test of compressorssubfunc

In the LOCAL/ENABLE position, the chiller is under lo-cal control and responds to the scheduling configuration andset point data input at its own loca

I. Maximum Reset Amount (CRST2) - allowable range0” to 20” F (0” to 11” C). This is maximum amount leav-ing chilled water set point is to be increased

Temperature Reset Based on External Temperature - If de-sired, temperature reset can be based on an external tem-perature, such as space or outdoor-ai

nPOINT NUMBER OFFIRST CHANNELQEKELIMIT(ALARM CODE 312(MODE 914 nw/4 OUJJUPWRI--e-------1---__-----a---mm-_------__----.__----------se___---c------

168600 2 4 6 8IO12 14161820RESET REFERENCE SIGNAL (4 -20 MA INPUT)Fig. 7 -4-20 mA Cooling Temperature ResetExample 7A- Using Demand LimitExample 7B -U

MAX DEMAND KIMAX)= 90DEMAND LlMlT SIGNAL (4-20 MA INPUT)Fig. 8 -4-20 mA Demand LimitingReading and Changing Time Displav - Time is enteredLogging

Table 12 -Factory Configuration KeystrokesTo change a configuration enter the new configurationand press q while on the correct configuration.SUB-FU

The schedule function can be programmed for inactive,single set point, or dual set point operation.When schedule is configured for inactive, chilled w

Example 10 -Holiday Schedule FunctionExample 9 -Using the Schedule Function (cant)ENTERKEENYTPRAYDIDISPLAYCOMMENTDISPLAYHOLIDAYJAN01 02 (Includes Jan

TROUBLESHOOTINGThe FlotronicTY II control has many features to aid thetechnicians in troubleshooting a Flotronic II Chiller. By us-ing keypad and disp

Alarm Codes -Following is a detailed description ofeach alarm code error and possible cause. Manual reset ofan alarm is accomplished by moving LOCAWE

OPERATION DATACapacity Control- The control system cyclescompressor to give capacity control steps as shown inTables 4A-4D. The unit controls leaving

Possible causes of failure:1.3d.3.4.5.6.High-Pressure Switch Open - High-pressure switch foreach compressor is wired in series with 24-v power thatene

Code 30 Reset input failure (4 to 20 mA)Code 31 Demand limit input failure (4 to 20 mA)These codes apply only if unit is configured for thesefunctions

Possible causes of fault are low refrigerant charge, pluggedfilter drier, or a faulty EXV or thermistor.Code 48 Low suction superheat, Circuit ACode 4

TE7 REOI24VACCONTROL 5CtlEliATICCN5TNANZ-32MP wIIlEO2 21VSECONDARY1DGTDSIOHPSE!PWRGLNULEGEND- Contactor- Communications Bus-Compressor Protection Con

PLEGENDCGFEM”E?kLSNBTBTRANUGround Fault ModuleCommunications BusCompressor Contactor RelayRelay Module (Low Voltage)High-Pressure SwitchLow VoltagePlu

c -CGF -Z” 1DGT -DSIO -EXV -HPS -/$ ::;b I:TB -PL12-7 Poll-7LEGENDContactorGround Fault ModuleCommonControl RelayDischarge Gas Thermostat (Optional

1.Electronic Expansion ValveEXV OPERATION - These valves control the flow of liq-uid refrigerant into the cooler. They are operated by pro-cessor to m

_I.:,/:.::.i .‘IBecause the EXVs are controlled by the processor mod-ule, it is possible to track valve position. During initialstart-up, EXV is full

MUFFLERSCOMPRESSORSCIRCUIT BrCIRCUIT AJ-FILTERI IcDRIERLEGENDDPT -Discharge Pressure Transducer:ppTT- Oil Pressure Transducer- Suction Pressure Transd

AIRVENTLEAVING:WATER/BRINETHERMISTOR (Tl)COOLERENTERINGFLUIDWATER/BRINEBAFFLE CONNECTIONSUCTIONCONNECTIONINLETCONNECTIONDRAINLEAVINGWATER/BRINECONNECT

Table 4A- Capacity Control Steps, 040-070 (cant)ILOADING SEQUENCE A LOADING SEQUENCE BUNIT30GNI.. . a1I18?I5673050 (50 Hz)060G Hz)Y1:;128050 (50 Hz)

Thermistors -All thermistors are identical in their tem-perature vs. resistance performance. Resistance at varioustemperatures are listed in Tables 15

Table 15- Thermistor Temperature (OF) vs Resistance/Voltage Drop; Flotronic’” IITEMP:;fTURE-2i.b-24.0-23.0-22.0-21.0-20.0-18.0-17.0-16.0- 15.0- 14.0-1

-Table 16 -Thermistor Temperature (“C) vs Resistance/Voltage Drop; Flotronic’” IITEMPERATURE(C)-40-39-38-37-36-35-34-33-32-31-30-29-28-27-26-25-24-23-

THERMISTOR* REFRIGERANTDISCHARGEENTERING TEMPERATUREPRESSURECYLINDERSTRANSDUCER*EQUALIZERLINEOIL PRESSURETRANSDUCER*SUCTION PRESSURETRANSDUCER*SIGHT G

Control ModulesTurn controller power off before servicing controls. Thisensures safety and prevents damage to controller.PROCESSOR MODULE (PSIO). 4

PSI0DSIO DSIOHSIOSIO( pRocEMssOp (RELAY) (EXVDRIVER)(LID) (4 I;W;UTFig. 19 -Sensor Bus Wiring(Communications)PROCESSOR MODULE (PSIO) (Fig. 20)Inputs

4 IN/4 OUT MODULE (SIO) (Fig. 22) - 4 In/4 Out mod-ule allows the following features to be utilized:1. Temperature Reset by outdoor air or space tempe

SYMPTOMSCOMPRESSOR DOESNOT RUNCOMPRESSOR CYCLES OFFON LOW PRESSURECOMPRESSOR SHUTS DOWN~N&-l;l;PFlESSUREUNIT OPERATES LONG ORCONTINUOUSLYSYSTEM NO

ACCESSORY UNLOADER INSTALLATIONSome of the 30G FlotronicT” II units come standard withunloader(s), and many permit additional unloader(s) to beadded i

~13014 115v 0R 230y;f;~RO~ SCHEMATICiFROM 115V OR 23OV CONTROL SCHEMATICTRAN-- 13 6 y‘.0\0\0\0\r--‘---------‘-‘-“--“‘-“-----------~\\1IDS00\!

Table 4A- Capacity Control Steps, 040-070 (cant)TLOADING SEQUENCE ALOADING S%Displacement(Approx)i!ii:83WENCE BUNIT30GN1 _ . .i;.060 (50 Hz)%Displace

130 (50 Hz), 150-210, 225, 250, AND 280 UNITS (andassociated modular units)1. Install control wiring. The minimum wire size for in-stallation is 16 AW

GdYEL&EELfh]f~gl1- - - - - - - - -cALARncooE31~ ---------~~ ------II-(AIJM CODE 21,301o(oocmI---------iI ’I I’ ! I Ir - - - - - - - -I ’ ’L-B-----

r----- --EXTERNAL3OGN040-210 AND ASSOCIATED MODULAR UNITS+---u3m-7---- 4-clTB-730GT225,250,280 FLOTRONIC II UNITSTB- Terminal BlockNOTE: The 30GT225,

&-jQ - 13 a--4 IN/4 OUTSWITCHMODULE,- - m - - - -f-J J7-10,~,. $$&i- - ___ - _-a J7-lfc,: *30GN040-210 AND ASSOCIATED MODULAR UNITS---- 1-ElT

8. Reinstall all 6 wire connectors and the green groundwire.9. Carefully check all wiring connections before restoringpower.10. Verify the LOCAL/ENABL

Copyright 1994 Carrier CorporationManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and

,Table 4B- Capacity Control Steps, 080-110 and Associated Modular UnitsrUNIT30GNILOADING SEQUENCE A LOADING SEQUENCE B%Displacement(4wWz!::iii100Compr

Table 4B- Capacity Control Steps, 080-110 and Associated Modular Units (cant)UNIT CONTROL30GNSTEPS090 (60 Hz)Aly*,Blt090 (60 Hz)Alt**,BlY**Unloaded c