Carrier Refrigerator 30GN040 420 User Manual

30GN040-420

Flotronic™ II Reciprocating Liquid Chillers

50/60 Hz

Controls, Operation, and

Troubleshooting

with Microprocessor Controls and Electronic Expansion Valves

CONTENTS

Page

Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . 48

Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . 48

Lag Compressor Stoppage . . . . . . . . . . . . . . . . . . 48

Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48

• POWER FAILURE EXTERNAL TO THE UNIT

Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Compressor Alarm/Alert Circuit . . . . . . . . . . . . . 50

Electronic Expansion Valve (EXV) . . . . . . . . . . . 55

• EXV OPERATION

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 2

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-5

Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Low-Voltage Relay Module . . . . . . . . . . . . . . . . . . . 4

Electronic Expansion Valve Module . . . . . . . . . . . 4

Options Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Keypad and Display Module

(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . . 4

Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electronic Expansion Valve (EXV) . . . . . . . . . . . . 4

Thermostatic Expansion Valves (TXV) . . . . . . . . 4

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Compressor Protection Control

• CHECKOUT PROCEDURE

Thermostatic Expansion Valve (TXV) . . . . . . . . . 57

Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

• LOCATION

• THERMISTOR REPLACEMENT (T1, T2, T7, T8)

Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . 60

• TROUBLESHOOTING

Module (CPCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 24

• EXV UNITS

• TXV UNITS

Pumpout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

• EXV UNITS

• TRANSDUCER REPLACEMENT

Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

• PROCESSOR MODULE (PSIO), 4IN/4OUT

MODULE (SIO), LOW-VOLTAGE RELAY

MODULE (DSIO-LV), AND EXV DRIVER

MODULE (DSIO-EXV)

• RED LED

• GREEN LED

• PROCESSOR MODULE (PSIO)

• LOW-VOLTAGE RELAY MODULE (DSIO)

• 4IN/4OUT MODULE (SIO)

• TXV UNITS

Keypad and Display Module

(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . 24

• ACCESSING FUNCTIONS AND SUBFUNCTIONS

• AUTOMATIC DEFAULT DISPLAY

• AUTOMATIC DISPLAY OPERATION/DEFAULT

DISPLAY

• KEYPAD OPERATING INSTRUCTIONS

• STATUS FUNCTION

• TEST FUNCTION

• HISTORY FUNCTION

• SET POINT FUNCTION

• SERVICE FUNCTION

• SCHEDULE FUNCTION

ACCESSORY UNLOADER INSTALLATION . . . 64-68

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

• 040-110, 130 (60 Hz) UNITS

(And Associated Modular Units)

• 130 (50 Hz), 150-210 UNITS

(And Associated Modular Units)

FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,70

REPLACING DEFECTIVE PROCESSOR

MODULE (PSIO) . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 47-64

Checking Display Codes . . . . . . . . . . . . . . . . . . . . 47

Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2

PC 903

Catalog No. 563-079

Printed in U.S.A.

Form 30GN-3T

Pg 1

7-95

Replaces: 30G-1T

Tab 5c

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COMM 3

PWR

POINT NUMBER

FIRST CHANNEL

EXV

STATUS

COMM

COMM 1

COMM 3

PWR

EQUIP GND

99NA505322

FUSE

SW1

LOCAL/

ENABLE

STOP

CCN

FUSE

STAT

HIST

SRVC

TEST

EXPN

CLR

–

•

FUSE

GFI

SCHD

SET

(

AMP MAX

)

CB5

CB6

ENTR

30GT510568

–

LEGEND

CCN

—

Carrier Comfort Network

Terminal Block

Fig. 1 — 30GN Control Panel (040-110 Unit Shown)

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also controls the EXV driver module (as appropriate), com-

manding it to open or close each EXV in order to maintain

the proper superheat entering the cylinders of each lead com-

pressor. Information is transmitted between the processor mod-

ule and relay module, the EXV driver module, and the key-

pad and display module through a 3-wire communications

bus. The options module is also connected to the commu-

nications bus.

For the Flotronic™ II chillers, the processor monitors sys-

tem pressure by means of 6 transducers, 3 in each lead com-

pressor. Compressor suction pressure, discharge pressure, and

oil pressure are sensed. If the processor senses high dis-

charge pressure or low suction pressure, it immediately shuts

down all compressors in the affected circuit. During opera-

tion, if low oil pressure is sensed for longer than one minute,

all compressors in the affected circuit are shut down. At start-

up, the oil pressure signal is ignored for 2 minutes. If shut-

down occurs due to any of these pressure faults, the circuit

is locked out and the appropriate fault code is displayed.

Table 2 — LOCAL/ENABLE-STOP-CCN

Switch Positions and Operation

CONFIGURATION AND

SWITCH

POSITION

UNIT

OPERATION

SET POINT CONTROL

Keypad Control

CCN Control

STOP

Unit Cannot Run Read/Write

Read Only

LOCAL/ENABLE Unit Can Run

Read/Limited Write Read Only

CCN Stop —

Unit Cannot Run Read Only

Read/Write

Read/Limited

Write

Run —

Unit Can Run Read Only

In the CCN position, the chiller is under remote control

and responds only to CCN network commands. The occupied/

unoccupied conditions are deﬁned by the network. All key-

pad and display functions can be read at the chiller regard-

less of position of the switch.

CCN run or stop condition is established by a command

from the CCN network. It is not possible to force outputs

from the CCN network, except that an emergency stop com-

mand shuts down the chiller immediately and causes ‘‘ALARM

52’’ to be displayed.

Low-Voltage Relay Module — This module closes

contacts to energize compressor unloaders and/or compres-

sors. It also senses the status of the safeties for all compres-

sors and transmits this information to the processor.

Electronic Expansion Valve (EXV) — The micro-

processor controls the EXV (if so equipped) through the EXV

driver module. Inside the expansion valve is a linear actua-

tor stepper motor.

Electronic Expansion Valve Module (If So

Equipped) — This module receives signals from the pro-

cessor and operates the electronic expansion valves.

The lead compressor in each circuit has a thermistor and

a pressure transducer located in the suction manifold after

the compressor motor. The thermistor measures the tem-

perature of the superheated gas entering the compressor cyl-

inders. The pressure transducer measures the refrigerant pressure

in the suction manifold. The microprocessor converts the pres-

sure reading to a saturated temperature. The difference be-

tween the temperature of the superheated gas and the satu-

ration temperature is the superheat. The microprocessor controls

the position of the electronic expansion valve stepper motor

to maintain 30 F (17 C) superheat.

Options Module — This module allows the use of Flo-

tronic II features such as dual set point, remote reset, de-

mand limit, hot gas bypass, and accessory unloaders. The

options module also allows for reset and demand limit to be

activated from a remote 4-20 mA signal. The options mod-

ule is installed at the factory.

Keypad and Display Module (Also Called HSIO

At initial unit start-up, the EXV position is at zero. After

that, the microprocessor keeps accurate track of the valve

position in order to use this information as input for the other

control functions. The control monitors the superheat and

the rate of change of superheat to control the position of the

valve. The valve stroke is very large, which results in very

accurate control of the superheat.

or LID) — This device consists of a keypad with 6 func-

tion keys, 5 operative keys, 12 numeric keys, and an alpha-

numeric 8-character LCD (liquid crystal display). Key us-

age is explained in Accessing Functions and Subfunctions

section on page 24.

Control Switch — Control of the chiller is deﬁned by

the position of the LOCAL/ENABLE-STOP-CCN switch.

This is a 3-position manual switch that allows the chiller to

be put under the control of its own Flotronic II controls, manu-

ally stopped, or put under the control of a Carrier Comfort

Network (CCN). Switch allows unit operation as shown in

Table 2.

In the LOCAL/ENABLE position, the chiller is under lo-

cal control and responds to the scheduling conﬁguration and

set point data input at its own local interface device (keypad

and display module).

Thermostatic Expansion Valves (TXV) — Model

30GN040 and 045 units with factory-installed brine option

are equipped with conventional thermostatic expansion valves

with liquid line solenoids. The liquid line solenoid valves

are not intended to be a mechanical shut-off. When service

is required, use the liquid line service valve to pump down

the system.

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The TXV is set at the factory to maintain approximately

8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler

by monitoring the proper amount of refrigerant into the cooler.

All TXVs are adjustable, but should not be adjusted unless

absolutely necessary. When TXV is used, thermistors T7 and

T8 are not required.

The TXV is designed to limit the cooler saturated suction

temperature to 55 F (12.8 C). This makes it possible for unit

to start at high cooler ﬂuid temperatures without overload-

ing the compressor.

Sensors — The Flotronic™ II chiller control system gath-

ers information from sensors to control the operation of the

chiller. The units use 6 standard pressure transducers and

4 standard thermistors to monitor system pressures and tem-

peratures at various points within the chiller. Sensors are listed

in Table 3.

Fig. 2 — Compressor Protection Control Module

Table 3 — Thermistor and Transducer Locations

THERMISTORS

Sensor

Location

T10

Cooler Leaving Fluid Temp

Cooler Entering Fluid Temp

Compressor Suction Gas Temp Circuit A

Compressor Suction Gas Temp Circuit B

Remote Temperature Sensor (Accessory)

PRESSURE TRANSDUCERS

Location

Sensor

DPT-A

SPT-A

OPT-A

DPT-B

SPT-B

OPT-B

Compressor A1 Discharge Pressure

Compressor A1 Suction Pressure

Compressor A1 Oil Pressure

Compressor B1 Discharge Pressure

Compressor B1 Suction Pressure

Compressor B1 Oil Pressure

Fig. 3 — Compressor Ground Fault Module

Compressor Protection Control Module (CPCS)

ground of any compressor winding exceeds 2.5 amps. If this

condition occurs, the CPCS module shuts down the

compressor.

— Each compressor on models 30GN070 (50 Hz), 080-

110, and 230B-315B, has its own CPCS as standard equip-

ment. See Fig. 2. All 30GN040-060 and 070 (60 Hz) units

feature the CPCS as an accessory, and CR (control relay) as

standard equipment. The 30GN130-210 and associated modu-

lar units have a CR as standard equipment. The CPCS or CR

is used to control and protect the compressors and crankcase

heaters. The CPCS provides the following functions:

• compressor contactor control

A high-pressure switch with a trip pressure of 426

± 7 psig (2936 ± 48 kPa), is wired in series with the CPCS.

If this switch opens during operation, the compressor stops

and the failure is detected by the processor when the signal

contacts open. The compressor is locked off. If the lead com-

pressor in either circuit is shut down by the high-pressure

switch or ground current protector, all compressors in the

circuit are locked off.

• crankcase heater control

• compressor ground current protection

• status communication to processor board

OPERATION DATA

• high-pressure protection

The CR provides all of the same functions as the CPCS

with the exception of compressor ground current protection.

Ground current protection is accomplished by using a CGF

(compressor ground fault module) in conjunction with the

CR. The CGF (See Fig. 3) provides the same ground fault

function as the CPCS for units where the CPCS is not

utilized.

One large relay is located on the CPCS board. This relay

(or CR) controls the crankcase heater and compressor

contactor. The CPCS also provides a set of signal contacts

that the microprocessor monitors to determine the operating

status of the compressor. If the processor board determines

that the compressor is not operating properly through the sig-

nal contacts, it will lock the compressor off by deenergizing

the proper 24-v control relay on the relay board. The

CPCS board contains logic that can detect if the current-to-

Capacity Control — The control system cycles

compressor to give capacity control steps as shown in

Tables 4A-4C. The unit controls leaving chilled ﬂuid tem-

perature. Entering ﬂuid temperature is used by the micro-

processor in determining the optimum time to add or sub-

tract steps of capacity, but is not a control set point.

The chilled ﬂuid temperature set point can be automati-

cally reset by the return temperature reset or space and

outdoor-air temperature reset features. It can also be reset

from an external 4 to 20 mA signal, or from a network

signal.

The operating sequences shown are some of many pos-

sible loading sequences for the control of the leaving ﬂuid

temperature. If a circuit has more unloaders than another,

that circuit will always be the lead circuit.

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Table 4A — Capacity Control Steps, 040-070

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1*

A1*, B1

A1,B1

—

040 (60 Hz)

A1†,B1

100

A1*

A1*,B1

A1,B1

B1*

A1,B1*

A1,B1

040 (60 Hz)

A1†,B1**

100

A1*

A1*,B1

A1,B1

—

040 (50 Hz)

045 (60 Hz)

A1†,B1

100

A1*

A1*,B1*

A1*,B1

A1,B1

B1*

A1*,B1*

A1,B1*

A1,B1

040 (50 Hz)

045 (60 Hz)

A1†,B1**

100

—

B1††

B1*

040 (50 Hz)

045 (60 Hz)

A1†,B1**

A1,B1††

A1,B1*

A1,B1

100

A1*

A1*,B1

A1,B1

—

045 (50 Hz)

050 (60 Hz)

A1†,B1

100

A1*

A1*,B1*

A1*,B1

A1,B1

B1*

A1*,B1*

A1,B1*

A1,B1

045 (50 Hz)

050 (60 Hz)

A1†,B1**

100

A1††

A1*

A1††,B1

A1*,B1

A1,B1

—

045 (50 Hz)

050 (60 Hz)

A1†**,B1

100

A1††

A1*

—

045 (50 Hz)

050 (60 Hz)

A1†**,B1**

A1††,B1*

A1††,B1

A1*,B1

A1,B1

100

—

B1††

B1*

045 (50 Hz)

050 (60 Hz)

A1†,B1**

A1*,B1††

A1,B1††

A1,B1*

A1,B1

100

*Unloaded compressor.

†Compressor unloader, standard.

**Compressor unloader(s), accessory.

††Two unloaders, both unloaded.

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Table 4A — Capacity Control Steps, 040-070 (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1††

A1*

B1††

B1*

045 (50 Hz)

050 (60 Hz)

A1†**,B1**

A1††,B1*

A1††,B1

A1*,B1

A1,B1

100

—

A1,B1††

A1,B1*

A1,B1

—

100

A1*

A1*,B1

A1,B1

—

050 (50 Hz)

060 (60 Hz)

A1†,B1

100

A1*

A1*,B1*

A1*,B1

A1,B1

B1*

A1*,B1*

A1,B1*

A1,B1

050 (50 Hz)

060 (60 Hz)

A1†,B1**

100

A1††

A1*

A1††,B1

A1*,B1

A1,B1

—

050 (50 Hz)

060 (60 Hz)

A1†**,B1

100

A1††

A1*

—

050 (50 Hz)

060 (60 Hz)

A1†**,B1**

A1,B1*

A1††,B1

A1*,B1

A1,B1

100

—

B1††

B1*

050 (50 Hz)

060 (60 Hz)

A1†,B1**

A1,B1††

A1,B1*

A1,B1

100

A1††

A1*

B1††

B1*

050 (50 Hz)

060 (60 Hz)

A1†**,B1**

A1††,B1*

A1††,B1

A1*,B1

A1,B1

100

—

A1,B1††

A1,B1*

A1,B1

—

100

A1*

A1*,B1

A1,B1

—

060 (50 Hz)

070 (60 Hz)

A1†,B1

100

A1*

A1*,B1*

A1*,B1

A1,B1

B1*

A1*,B1*

A1,B1*

A1,B1

060 (50 Hz)

070 (60 Hz)

A1†,B1**

100

A1††

A1*

—

060 (50 Hz)

070 (60 Hz)

A1†**,B1

A1††,B1

A1*

100

A1,B1

A1††

A1*

—

060 (50 Hz)

070 (60 Hz)

A1†**,B1**

A1††,B1

A1*,B1

A1,B1

100

—

B1††

B1*

060 (50 Hz)

070 (60 Hz)

A1†,B1**

A1,B1††

A1,B1*

A1,B1

100

*Unloaded compressor.

†Compressor unloader, standard.

**Compressor unloader(s), accessory.

††Two unloaders, both unloaded.

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Table 4A — Capacity Control Steps, 040-070 (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1††

A1*

B1††

B1*

060 (50 Hz)

070 (60 Hz)

A1†**,B1ሻ

A1††,B1

A1*,B1

A1,B1

A1,B1††

A1,B1*

A1,B1

100

A1*

—

070 (50 Hz)

A1†,B1

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

100

A1*

B1*

A1*,B1*

A1*,B1

A1*,B1*

A1,B1*

070 (50 Hz)

A1†,B1**

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*

A1,A2,B1*

A1,A2,B1

100

A1††

A1*

—

A1††,B1

A1*,B1

070 (50 Hz)

A1†**,B1

A1,B1

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

100

A1††

A1*

—

A1††,B1*

A1††,B1

A1*,B1

070 (50 Hz)

A1†**,B1**

A1,B1

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

—

B1††

B1*

070 (50 Hz)

A1†,B1ሻ

A1*,B1*

A1,B1

A1,A2,B1*

A1,A2,B1

100

A1††

A1*

100

—

B1††

B1*

A1††,B1*

A1††,B1

A1*,B1

A1*,B1*

A1,B1

A1,A2,B1*

A1,A2,B1

—

070 (50 Hz)

A1†**,B1ሻ

A1,B1

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

—

*Unloaded compressor.

†Compressor unloader, standard.

**One compressor unloader, accessory.

††Two unloaders, both unloaded.

࿣ Two compressor unloaders, accessory.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

Compressors

Displacement

(Approx)

Compressors

(Approx)

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

B1*

A1*,B1*

A1,B1*

A1,B1

A1,A2,B1*

A1,A2,B1

080, 230B (60 Hz)

A1†,B1†

100

A1††

A1*

—

A1††,B1*

A1††,B1

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

080, 230B (60 Hz)

A1†**, B1†

100

—

B1††

B1*

080, 230B (60 Hz)

A1†,B1†**

A1,B1††

A1,B1*

A1,B1

A1,A2,B1*

A1,A2,B1

100

A1††

A1*

100

—

B1††

B1*

A1††,B1*

A1††,B1

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

A1,B1††

A1,B1*

A1,B1

A1,A2,B1*

A1,A2,B1

—

080, 230B (60 Hz)

A1†**,B1†**

100

A1*

B1*

A1*,B1*

A1, B1*

A1,B1

A1*,A2,B1*

A1,A2,B1*

A1,A2,B1

A1*,B1*

A1*,B1

080, 230B (50 Hz)

A1†,B1†

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

100

A1††

A1*

—

A1††,B1*

A1††,B1

A1*,B1

080, 230B (50 Hz)

A1†**,B1†

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

—

B1††

B1*

A1,B1*

A1,B1

A1*,A2,B1††

A1,A2,B1††

A1,A2,B1*

A1,A2,B1

080, 230B (50 Hz)

A1†,B1†**

100

A1††

A1*

100

—

B1††

B1*

A1††,B1*

A1††,B1

A1*,B1

A1,B1*

A1,B1

080, 230B (50 Hz)

A1†**,B1†**

A1*,A2,B1††

A1,A2,B1††

A1,A2,B1*

A1,A2,B1

—

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

—

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1,B1*

A1,B1

090, 245B (60 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

090, 245B (60 Hz)

A1†**,B1†

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

090, 245B (60 Hz)

A1†,B1†**

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1*,B1

A1,B1

A1,B1††

A1,B1*

A1,B1

090, 245B (60 Hz)

A1†**,B1†**

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1,B1*

A1,B1

090, 245B (50 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

090, 245B (50 Hz)

A1†**,B1†

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

Compressors

Displacement

(Approx)

Compressors

(Approx)

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

090, 245B (50 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B1

A1,A2,B1††,B1

A1,A2,B1*,B2

A1,2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

A1††,A2,B1††

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

090, 245B (50 Hz)

A1†**,B1†**

A1††,A2,B1††,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1*

100

A1*

A1*,B1*

A1*,B1

A1,B1

A1*,B1

A1,B1

100, 255B,

270B (60 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

100, 255B,

270B (60 Hz)

A1†**,B1†

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

100, 255B,

270B (60 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

100, 255B,

270B (60 Hz)

A1†**,B1†**

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1*

100

B1*

A1*,B1*

A1,B1

A1,B1*

A1,B1

100, 255B,

270B (50 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

100, 255B,

270B (50 Hz)

A1†**,B1†

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

100, 255B,

270B (50 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

A1††,A2,B1††

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,B1††,B2

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

100, 255B,

270B (50 Hz)

A1†**,B1†**

A1††,A2,B1††,B2

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,B1††,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1,B1*

A1,B1

110, 290B,

315B (60 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

110, 290B,

315B (60 Hz)

A1†**,B1†

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

110, 290B,

315B (60 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

110, 290B,

315B (60 Hz)

A1†**,B1†**

A1††,A2,B1††

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1††,A2,B1††,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1,B1*

A1,B1

110, 290B,

315B (50 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

110, 290B,

315B (50 Hz)

A1†**,B1†

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

110, 290B,

315B (50 Hz)

A1†,B1†**

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1*,B1

A1,B1

A1,B1††

A1,B1*

A1,B1

110, 290B,

315B (50 Hz)

A1†**,B1†**

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1,B1*

A1,B1

130 (60 Hz)

A1†,B1†

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

—

A1††,B1*

A1††,B1

A1*,B1

A1,B1

130 (60 Hz)

A1†**,B1†

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

—

100

B1††

B1*

A1*,B1††

A1,B1††

A1,B1*

A1,B1

130 (60 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1*

A1*,B1††

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

A1††,A2,B1††

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,B1††,B2

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

130 (60 Hz)

A1†**,B1†**

A1††,A2,B1††,B2

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,B1††,B2

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

130 (50 Hz)

A1†,B1†

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

100

A1††

A1*

—

A1††,B1*

A1††,B1

A1*,B1

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

130 (50 Hz)

A1†**,B1†

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

—

100

B1††

B1*

A1,B1*

A1,B1

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

130 (50 Hz)

A1†,B1†**

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1††,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

100

A1††

A1*

100

—

B1††

B1*

A1††,B1*

A1,B1*

A1,B1

A1††,B1

A1*,B1

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1††,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

—

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

130 (50 Hz)

A1†**,B1†**

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

—

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

150, 230A, 245A,

255A (60 Hz)

A1†,B1†

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

30GN

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1††

A1*

—

100

A1††,B1*

A1††,B1

A1*,B1

A1,B1

150, 230A, 245A,

255A (60 Hz)

A1†**,B1†

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

—

100

B1††

B1*

A1,B1*

A1,B1

150, 230A, 245A,

255A (60 Hz)

A1†,B1†**

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

A1††

A1*

100

—

B1††

B1*

100

A1††,B1*

A1,B1*

A1,kB1

A1††,B1

A1*,B1

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

—

A1,B1

150, 230A, 245A,

255A (60 Hz)

A1†**,B1†**

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

—

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1

A1*,A2,B1*

A1*,A2,B1

A1,A2,B1

A1,B1*

A1,B1

A1*,B1*,B2

A1,B1*,B2

A1,B1,B2

150, 230A, 245A,

255A (50 Hz)

A1†,B1†

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

100

A1††

A1*

—

A1††,B1

A1*,B1

A1,B1

150, 230A, 245A,

255A (50 Hz)

A1†**,B1†

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

—

100

B1††

B1*

A1,B1††

A1,B1*

A1,B1

150, 230A, 245A,

255A (50 Hz)

A1†,B1†**

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1††,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

100

A1††

A1*

100

B1††

B1*

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

150, 230A, 245A,

255A (50 Hz)

A1†**,B1†**

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,A3,B1††,B2

A1,A2,A3,B1*,B2

A1,A2,A3,B1,B2

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

170, 270A,

330A/B (60 Hz)

A1†,B1†

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1††

A1*

—

100

A1††,B1*

A1††,B1

A1*,B1

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

170, 270A,

330A/B (60 Hz)

A1†**,B1†

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1††,A2,A3,B1*,B2,B3

A1††,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

—

B1††

B1*

100

A1*,B1††

A1,B1††

A1,B1*

A1,B1

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

170, 270A,

330A/B (60 Hz)

A1†,B1†**

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1††,B2,B3

A1,A2,B1††,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1††,B2,B3

A1,A2,A3,B1††,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1††

A1*

B1††

B1*

100

A1††,B1*

A1*,B1††

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,B1††,B2

A1,B1††,B2

A1*,A2,B1

A1,A2,B1

A1,B1*,B2

A1,B1,B2

170, 270A,

330A/B (60 Hz)

A1†**,B1†**

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1††,A2,A3,B1*,B2,B3

A1††,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1††,B2,B3

A1,A2,B1††,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1††,B2,B3

A1,A2,A3,B1††,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

170, 270A,

330A/B,360B (50 Hz)

A1†,B1†

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1††

A1*

—

100

A1††,B1*

A1††,B1

A1*,B1

A1,B1

A1††,A2,B1*

A1††,A2,B1

A1*,A2,B1

A1,A2,B1

170, 270A,

330A/B, 360B (50 Hz)

A1†**,B1†

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1††,A2,A3,B1*,B2,B3

A1††,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

—

B1††

B1*

100

A1*,B1††

A1,B1††

A1,B1*

A1,B1

A1*,B1††,B2

A1,B1††,B2

A1,B1*,B2

A1,B1,B2

170, 270A,

330A/B, 360B (50 Hz)

A1†,B1†**

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1††,B2,B3

A1,A2,B1††,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1††,B2,B3

A1,A2,A3,B1††,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1††

A1*

B1††

B1*

100

A1††,B1*

A1*,B1††

A1††,B1

A1,B1††

A1*,B1

A1,B1*

A1,B1

A1††,A2,B1*

A1††,B1††,B2

A1*,B1††,B2

A1††,A2,B1

A1*,A2,B1

A1,B1††,B2

A1,A2,B1

A1,B1*,B2

A1††,A2,B1††,B2

A1††,A2,B1*,B2

A1††,A2,B1,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1,B1,B2

170, 270A,

330A/B, 360B (50 Hz)

A1†**,B1†**

A1*,A2,B1††,B2

A1,A2,B1††,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1††,A2,A3,B1††,B2

A1††,A2,A3,B1*,B2

A1††,A2,A3,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1††,A2,A3,B1††,B2,B3

A1††,A2,A3,B1*,B2,B3

A1††,A2,A3,B1,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1††,A2,B1††,B2,B3

A1*,A2,B1††,B2,B3

A1,A2,B1††,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1††,A2,A3,B1††,B2,B3

A1*,A2,A3,B1††,B2,B3

A1,A2,A3,B1††,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B3,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1,B1

190, 290A, 360A/B,

390B (60 Hz)

A1,B1

A1,A2,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

100

A1*

—

A1*,B1

A1,B1

A1*,A2,B1

190, 290A, 360A/B,

390B (60 Hz)

A1**,B1

A1,A2,B1

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

—

100

B1*

A1,B1*

A1,B1

A1,B1*,B2

190, 290A, 360A/B,

390B (60 Hz)

A1,B1**

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

190, 290A, 360A/B,

390B (60 Hz)

A1**,B1**

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

190, 290A, 360A,

390B (50 Hz)

A1,B1

A1,A2,B1

A1,B1,B2

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

100

A1*

—

A1*,B1

A1,B1

A1*,A2,B1

190, 290A, 360A,

390B (50 Hz)

A1**,B1

A1,A2,B1

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

—

100

B1*

A1,B1*

A1,B1

A1,B1*,B2

190, 290A, 360A,

390B (50 Hz)

A1,B1**

A1,B1,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

100

A1*

100

B1*

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

190, 290A, 360A,

390B (50 Hz)

A1**,B1**

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1,B1

210, 315A, 390A,

420A/B (60 Hz)

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

100

A1*

—

100

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

210, 315A, 390A,

420A/B (60 Hz)

A1**,B1

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

—

100

B1*

A1,B1*

A1,B1

A1,B1*,B2

A1,B1,B2

210, 315A, 390A,

420A/B (60 Hz)

A1,B1**

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)

LOADING SEQUENCE A

LOADING SEQUENCE B

UNIT

SIZE

CONTROL

STEPS

Displacement

(Approx)

Compressors

Displacement

(Approx)

Compressors

A1*

100

B1*

100

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

210, 315A, 390A,

420A/B (60 Hz)

A1**,B1**

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,B1

210, 315A, 390A,

420A/B (50 Hz)

A1,B1

A1,A2,B1

A1,A2,B1,B2

A1,A2,A3,B1,B2

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1,B1,B2

A1,A2,B1,B2

A1,A2,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

100

A1*

—

100

A1*,B1

A1,B1

A1*,A2,B1

A1,A2,B1

210, 315A, 390A,

420A/B (50 Hz)

A1**,B1

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

—

100

B1*

A1,B1*

A1,B1

A1,B1*,B2

A1,B1,B2

210, 315A, 390A,

420A/B (50 Hz)

A1,B1**

A1,A2,B1*,B2

A1,A2,B1,B2

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1*

100

B1*

100

A1*,B1*

A1*,B1

A1,B1*

A1,B1

A1*,A2,B1*

A1*,B1*,B2

A1*,A2,B1

A1,B1*,B2

A1,A2,B1

A1,B1,B2

A1*,A2,B1*,B2

A1*,A2,B1,B2

A1,A2,B1,B2

A1*,A2,B1*,B2

A1,A2,B1*,B2

A1,A2,B1,B2

210, 315A, 390A,

420A/B (50 Hz)

A1**,B1**

A1*,A2,A3,B1*,B2

A1*,A2,A3,B1,B2

A1,A2,A3,B1,B2

A1*,A2,A3,B1*,B2,B3

A1*,A2,A3,B1,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1*,A2,A3,A4,B1,B2,B3

A1,A2,A3,A4,B1,B2,B3

A1*,A2,B1*,B2,B3

A1,A2,B1*,B2,B3

A1,A2,B1,B2,B3

A1*,A2,A3,B1*,B2,B3

A1,A2,A3,B1*,B2,B3

A1,A2,A3,B1,B2,B3

A1*,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1*,B2,B3

A1,A2,A3,A4,B1,B2,B3

*Unloaded compressor.

NOTE: These capacity control steps may vary due to lag compressor

sequencing.

†Compressor unloader, standard.

**Compressor unloader, accessory.

††Two unloaders, both unloaded.

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Head Pressure Control

Keypad and Display Module (Also Called HSIO

or LID) — The only function of this module is to allow

the operator to communicate with the processor. It is used to

enter conﬁgurations and set points and to read data, perform

tests, and set schedules. This device consists of a keypad

with 6 function keys, 5 operative keys, 12 numeric keys

(0 to 9, •, and -), and an alphanumeric, 8-character LCD. See

Fig. 4. See Table 6 for key usage.

EXV UNITS (All 30GN units except 040 and 045 with op-

tional brine) — The microprocessor controls the condenser

fans in order to maintain the lowest condensing temperature

possible, thus the highest unit efficiency. Instead of using the

conventional head pressure control methods, the fans are con-

trolled by the position of the EXV and suction superheat.

As the condensing temperature drops, the EXV opens to

maintain the proper suction superheat. Once the EXV is fully

open, if the condensing temperature continues to drop, the

suction superheat begins to rise. Once the suction superheat

is greater than 40 F (22.2 C), a fan stage is removed after

2 minutes.

IMPORTANT: When entering multiple character in-

puts beginning with a zero, a decimal point must be

entered in place of the ﬁrst zero. When entering an in-

put of zero, only the decimal point need be entered.

As the condensing temperature rises, the EXV closes to

maintain the proper suction superheat. Once the EXV has

closed to 39.5% open (600 steps open), a fan stage is added

after 2 minutes.

During start-up, all the condenser fans are started when

the condensing temperature reaches 95 F (35 C) to prevent

excessive discharge pressure during pulldown. See Table 5

for condenser fan sequence of operation.

For low-ambient operation, the lead fan in each circuit can

be equipped with the optional or accessory Motormaster௡

III head pressure controller. This control has its own sensor

which is mounted on a return bend in the liquid portion of

the condenser. It will vary the fan speed to maintain a satu-

rated condensing temperature of 100 F. The controls auto-

matically default to condensing temperature control during

this ﬁrst stage of condenser-fan operation. When subsequent

fan stages start, the controls revert to EXV fan control.

ACCESSING FUNCTIONS AND SUBFUNCTIONS — See

Tables 6 - 8. Table 7 shows the 6 functions (identiﬁed by

name) and the subfunctions (identiﬁed by number).

AUTOMATIC DEFAULT DISPLAY — When keypad has

not been used for 10 minutes, display automatically switches

to the rotating automatic default display. This display has

7 parts, listed below, which appear in continuous rotating

sequence.

DISPLAY

TUE 15:45

LOCAL ON

CLOCK ON

8 MODE

EXPANSION

TODAY IS TUE, TIME IS 15:45 (3:45 PM)

UNIT IN LOCAL MODE

UNIT IS ON VIA CLOCK SCHEDULE

TEMPERATURE RESET IN EFFECT

NUMBER OF STAGES IS 1

THERE ARE 2 ALARMS

COOL 1

TXV UNITS (30GN040,045 with optional brine only) —

Head pressure control is based on set point control. The micro-

processor stages the condenser fans to maintain the set point

temperature speciﬁed by the controller.

2 ALARMS

3 MINUTES REMAINING IN THE OFF-TO-ON

TIME DELAY

3 MINS

Pumpout

EXV UNITS — When the lead compressor in each circuit

is started or stopped, that circuit goes through a pumpout

cycle to purge the cooler and refrigerant suction lines of

refrigerant.

The pumpout cycle starts immediately upon starting the

lead compressor and continues until the saturated suction tem-

perature is 10° F (5.6° C) below the saturated suction tem-

perature at start-up, is 10° F (5.6° C) below the cooler leav-

ing ﬂuid temperature, or reaches a saturated suction temperature

of –15 F (–26 C). No pumpout is necessary if the saturated

suction temperature is below –15 F (–26 C). At this point,

the EXV starts to open and continues to open gradually to

provide a controlled start-up to prevent liquid ﬂood-back to

the compressor.

At shutdown, the pumpout cycle continues until the satu-

rated suction temperature for that circuit is 10° F (5.5° C)

below the saturated suction temperature when pumpout is

initiated, or saturated suction temperature reaches –15 F

(–26 C). At that point, the compressor shuts down and the

EXV continues to move until fully closed.

TXV UNITS — Pumpout is based on timed pumpout. On a

command for start-up, the lead compressor starts. After

10 seconds, the liquid line solenoid opens. At shutdown, the

liquid line solenoid closes, and the lead compressor contin-

ues to run for 10 seconds before stopping.

Fig. 4 — Keypad and Display Module

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Table 5 — Condenser Fan Sequence

FAN ARRANGEMENT

30GN

FAN CONTACTOR

FAN NUMBER(S)

CONTROLLED BY

(FC)

040-050

060,070

FC-A1

FC-B1

Compressor A1

Compressor B1

First Stage

Microprocessor

FC-A2

FC-B2

Second Stage

Microprocessor

FC-A1

FC-B1

Compressor A1

Compressor B1

First Stage

3, 4

5, 6

FC-A2

FC-B2

Microprocessor

Second Stage

Microprocessor

080,090 (and associated modular units*)

FC-A1

FC-B1

FC-A2

FC-B2

Compressor A1

Compressor B1

First Stage

Microprocessor

FC-A2, FC-B2,

FC-A3, FC-B3

Second Stage

Microprocessor

3, 4, 5, 6

100,110 (and associated modular units*)

FC-A1

FC-B1

FC-A2

FC-B2

Compressor A1

Compressor B1

First Stage

Microprocessor

Second Stage

Microprocessor

5, 7, 6, 8

FC-A3, FC-B3

FC-A2, FC-A3,

FC-B2, FC-B3

Third Stage

Microprocessor

3, 4, 5, 6, 7, 8

130-170 (and associated modular units*)

5, 7

6, 8

FC-A1

FC-B1

Compressor A1

Compressor B1

3, 9

FC-A2

First Stage

Microprocessor

4, 10

FC-B2

1, 3, 9

2, 4, 10

5, 7

FC-A2, FC-A3

FC-B2, FC-B3

FC-A1

Second Stage

Microprocessor

190,210 (and associated modular units*)

Compressor A1

Compressor B1

6, 8

FC-B1

3, 9

FC-A2

First Stage

Microprocessor

4, 10

FC-B2

1, 3, 9, 11

2, 4, 10, 12

FC-A2, FC-A3

FC-B2, FC-B3

Second Stage

Microprocessor

*See Table 1.

†Control box.

AUTOMATIC DISPLAY OPERATION/DEFAULT DIS-

PLAY — This display automatically rotates as follows:

KEYPAD OPERATING INSTRUCTIONS (Refer to

Table 9.)

1. White keys on left side of keypad are shown and oper-

ated in these instructions according to the following ex-

ample: keypad entry

means press the

, then

the white key marked

2. The standard display uses abbreviations. Expanded in-

DOW

—

Day of Week

Hour(s)

Minute(s)

formation scrolls through the display whenever

is pressed.

key

The default rotating display is displayed every 2 seconds

if there has been no manual input from the keypad for

10 minutes.

To return to automatic display, enter

at any time.

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Table 6 — Keypad and Display Module Usage

3. All functions are made up of a group of subfunctions. To

enter a subfunction, ﬁrst press subfunction number de-

sired. Then press the function key in which the subfunc-

tion resides. To move within that subfunction, press

FUNCTION

USE

KEYS

STATUS — For displaying diagnostic codes and

current operating information about the machine.

the

arrow. For example, a

enters

HISTORY — For displaying run time, cycles and

previous alarms.

SERVICE — For entering speciﬁc unit conﬁgura-

tion information.

the Temperature Information subfunction.

4. At any time, another subfunction may be entered by press-

ing the subfunction number, then the function key.

TEST — For checking inputs and outputs for

proper operation.

SCHEDULE — For entering occupied/unoccupied

schedules for unit operation.

5. Prior to starting unit, check leaving ﬂuid set point for cor-

rect setting. Refer to Set Point Function section on

page 38.

6. Depending on system conﬁguration, all displays may not

be shown. All displays are shown unless marked with the

following symbol:

SET POINT — For entering operating set points

and day/time information.

OPERATIVE

USE

KEYS

†Must be conﬁgured.

EXPAND — For displaying a non-abbreviated ex-

pansion of the display.

For additional unit start-up procedures, see separate

Installation, Start-Up, and Service Instructions supplied

with unit.

CLEAR — For clearing the screen of all displays.

UP ARROW — For returning to previous display

position.

DOWN ARROW — For advancing to next display

position.

ENTER — For entering data.

Table 7 — Functions and Subfunctions

FUNCTIONS

Schedule

SUBFUNCTION

NO.

Status

Test

Service

History

Set Point

Automatic

Outputs

Override

Clock Select

Period 1

Period 2

Period 3

Log On and

Log Off

Run Time

Starts

Set Points

Display

(Chiller Fluid)

Alarm

Display

Compressors

and Unloaders

Version

(Software)

Reset

Set Points

Mode (Operating)

Display

Calibrate

Transducers

Factory

Conﬁguration

Alarm

History

Demand Limit

Set Points

Capacity

Stages

—

Field

Conﬁguration

—

Date and

Time

Set Points

(Current Operating)

Service

Conﬁguration

Leaving Chiller

Fluid Alert Limit

Temperatures

Pressures

Analog Inputs

Discrete Inputs

Outputs

—

Period 4

Period 5

Period 6

Period 7

Period 8

HOLIDAYS

—

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Table 8 — Accessing Functions and Subfunctions

KEYPAD

ENTRY

DISPLAY

RESPONSE

OPERATION

EXPANSION

To access a function, press

subfunction no. and function

name key. Display shows sub-

function group.

RESET

RESET SETPOINTS

To move to other elements,

scroll up or down using arrow

keys. NOTE: These

displays do not show if

control is not conﬁgured

for reset.

CRT1 x

COOL RESET AT 20 MA

CRT2N x

CRT2F x

CRT2D x

COOL RTEMP (NO RESET)

COOL RTEMP (FULL RESET)

COOL DEGREES RESET

When the last element in a

subfunction has been displayed,

the ﬁrst element is repeated.

RESET

CRT1 x

RESET SETPOINTS

COOL RESET AT 20 MA

To move to next subfunction

it is not necessary to use

subfunction number. Press

function name key to ad-

vance display through all

subfunctions within a

function and then back

to the ﬁrst.

DEMAND

TIME

DEMAND LIMIT SETPOINTS

CURRENT TIME AND DAY OF

WEEK

SETPOINT

UNIT SETPOINTS

To move to another function,

either depress function name

key for desired function

(display shows the ﬁrst

subfunction),

X ALARMS

STAGE

THERE ARE n ALARMS

Access a speciﬁc sub-

function by using the sub-

function number and the

function name key.

CAPACITY STAGING

INFORMATION

Table 9 — Keypad Directory

STATUS

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

1 AUTOMATIC DISPLAY

Refer to Automatic Display Operation/Default Display section on page 25.

2 ALARMS/ALERTS

X ALARMS

R S AL

Number of Tripped Alarms/Alerts

Reset all Alarms/Alerts

ALARM* X

Displays Tripped Alarms/Alerts

}

To toggle between inputs (Yes/No) Press:

(no) or

(yes)

3 MODES

X MODES

X MODE

Number of Modes in Effect

Displays Mode in Effect

}

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Table 9 — Keypad Directory (cont)

STATUS (cont)

SUBFUNCTION

4 STAGE

KEYPAD ENTRY

DISPLAY

STAGE

COOL X

CAPT X

CAPA X

CAPB X

AVAIL X

AV A X

COMMENT

Capacity Staging Information

Number of Requested Stages

Percent of Total Capacity

Percent Circuit A Total Capacity

Percent Circuit B Total Capacity

Percent Available Capacity

Percent Circuit A Available Capacity

Percent Circuit B Available Capacity

Demand Limit Set Point (percent)

Circuit A Compressor Relay Status

Circuit B Compressor Relay Status

AV B X

LMT X†

CIRA X

CIRB X

SMZ X

Load/Unload Factor for Compressors

Factor = 1 Unloader Factor = 0.6

5 SET POINT

SETPOINT

SET X

Fluid Set Point Information

Set Point (F)

MSP X

TW X

Modiﬁed Set Point = Set Point + Reset (F)

Actual Control Temperature (F)

6 TEMPERATURE

TEMPS

EWT X

LWT X

SCTA X

SSTA X

CTA X

Temperature Information (F)

Cooler Entering Fluid Temperature (F)

Cooler Leaving Fluid Temperature (F)

Circuit A Saturated Condenser Temperature (F)

Circuit A Saturated Suction Temperature (F)

Compressor A1 Suction Temperature (F)

Circuit A Suction Superheat (F)

SHA X

SCTB X

SSTB X

CTB X

SHB X

SPC X

OAT X

Circuit B Saturated Condenser Temperature (F)

Circuit B Saturated Suction Temperature (F)

Compressor B1 Suction Temperature (F)

Circuit B Suction Superheat (F)

Space Temperature (F)

Outdoor-Air Temperature (F)

LEGEND

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

CCN

EXV

MOP

—

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

**If applicable.

††Not manually resettable.

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

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Table 9 — Keypad Directory (cont)

STATUS (cont)

SUBFUNCTION

7 PRESSURE

KEYPAD ENTRY

DISPLAY

PRESSURE

MM DD YY

DPA X

COMMENT

Refrigerant System Pressure (psig)

Date of Last Calibration

Circuit A Discharge Pressure (psig)

Circuit A Suction Pressure (psig)

Circuit A Discharge/Suction (psig)

Circuit A Oil Pressure Differential (psig)

Circuit B Discharge Pressure (psig)

Circuit B Suction Pressure (psig)

Circuit B Discharge/Suction (psig)

Circuit B Oil Pressure Differential (psig)

SPA X

XXXX XXX

OPA X

DPB X

SPB X

XXXX XXX

OPB X

8 ANALOG

ANALOG

REF X

Status of Analog Inputs

Transducer Supply Voltage (volts)

Demand 4-20 mA Signal (mA)

Reset 4-20 mA Signal (mA)

LMT X†

RST X†

9 INPUTS

SW INPUT

SPW X†

DL1 X†

Status of Switch Inputs

Dual Set Point Switch (open/closed)

Demand Limit Switch 1 (open/closed)

Demand Limit Switch 2 (open/closed)

DL2 X†

10 OUTPUTS

OUTPUTS

ALMR X

FRA1 X

FRA2 X

FRB1 X

FRB2 X

CHWP X†

ULA1 X

ULA2 X†

ULB1 X

ULB2 X†

LLSA X

Status of Outputs

Alarm Relay K3 (on/off)

Fan Relay K1 (on/off)

Fan Relay K2 (on/off)

Fan Relay K4 (on/off)

Fan Relay K5 (on/off)

Cooler Water Pump Relay K6 (on/off)

Unloader A1 (on/off)**

Unloader A2 (on/off)**

Unloader B1 (on/off)**

Unloader B2 (on/off)**

Liquid Line Solenoid A

Liquid Line Solenoid B

EXVA Percent Open†

LLSB X

EXVA X

LEGEND

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

**If applicable.

CCN

EXV

MOP

—

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

††Not manually resettable.

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

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Table 9 — Keypad Directory (cont)

STATUS (cont)

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

10 OUTPUTS (cont)

EXVB X

EXVB Percent Open**

HGBA X†

HGBB X†

MMA X†

MMB X†

TEST

Hot Gas Bypass Relay Circuit A (on/off)**

Hot Gas Bypass Relay Circuit B (on/off)**

Motormasterா A Output Percent**

Motormaster B Output Percent**

To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position. To operate a test, scroll to desired test.

Then, press

SUBFUNCTION

1 OUTPUTS

to start test. Press

to stop test.

KEYPAD ENTRY

DISPLAY

COMMENT

OUTPUTS

Test Outputs

8.8.8.8.8.8.8.8

ALMR X

FRA1 X

FRA2 X

FRB1 X

FRB2 X

CHWP X†

LSVA X

Display Check

Energize Alarm Relay K3 (on/off)

Energize Fan Relay A1 K1 (on/off)

Energize Fan Relay A2 K2 (on/off)

Energize Fan Relay B1 K4 (on/off)

Energize Fan Relay B2 K5 (on/off)

Energize Cooler Water Pump K6 (on/off)

Energize Liquid Line Solenoid A (on/off)**

Energize Liquid Line Solenoid B (on/off)**

Enter Desired EXVA Position (percent)**

Enter Desired EXVB Position (percent)**

Energize Hot Gas Bypass Relay A (on/off)**

Energize Hot Gas Bypass Relay B (on/off)**

Enter Desired Motormaster A Output Signal (percent)**

Enter Desired Motormaster B Output Signal (percent)**

LSVB X

EXVA X

EXVB X

HGBA X†

HGBB X†

MMA X†

MMB X†

(yes)

To toggle between inputs (Yes/No) Press:

(no) or

During compressor test, compressors start and run for

10 seconds. Compressor service valves and liquid line

valves must be open. Energize crankcase heaters 24 hours

prior to performing compressor tests.

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

2 COMPRESSORS AND

UNLOADERS

COMP

Compressor and Unloader Test

CPA1 X

Test Compressor A1 (on/off)

Test Compressor A2 (on/off)**

CPA2 X†

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Table 9 — Keypad Directory (cont)

TEST (cont)

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

Test Compressor A3 (on/off)**

Test Compressor A4 (on/off)**

Test Compressor B1 (on/off)

Test Compressor B2 (on/off)**

Test Compressor B3 (on/off)**

Test Compressor B4 (on/off)**

Energize Unloader A1 (on/off)**

Energize Unloader A2 (on/off)**

Energize Unloader B1 (on/off)**

Energize Unloader B2 (on/off)**

2 COMPRESSORS AND

UNLOADERS (cont)

CPA3 X†

CPA4 X†

CPB1 X

CPB2 X†

CPB3 X†

CPB4 X†

UNA1 X

UNA2 X†

UNB1 X

UNB2 X†

3 CALIBRATE

TRANSDUCERS

XDR CAL

CDPA X

CSPA X

COPA X

CDPB X

CSPB X

COPB X

Transducer Calibration

Circuit A Discharge Pressure (psig)

Circuit A Suction Pressure (psig)

Circuit A Oil Pressure (psig)

Circuit B Discharge Pressure (psig)

Circuit B Suction Pressure (psig)

Circuit B Oil Pressure (psig)

SCHEDULE

The Schedule function key

is used to conﬁgure the occupancy schedule. The clock select subfunction can be used for

unoccupied shutdown or unoccupied setback depending on the cooling set point control conﬁguration. The Schedule function

described is for clock 1, which is the internal clock. Password required for all subfunctions except override.

SUBFUNCTION

1 OVERRIDE

KEYPAD ENTRY

DISPLAY

COMMENT

OVRD X

Number of Override Hrs (0 - 4 Hrs)

For example, to extend current occupied mode for 3 hrs, press:

OVRD 3

Extended Occupied Time

2 CLOCK SELECT

3 PERIOD 1

CLOCK XX

Type of Clock Control

0 = No Clock, 1 = Clock 1 (Internal)

PERIOD 1

OCC HH.MM

UNO HH.MM

MON X

Period 1 Time Schedule

Occupied Time

Yes = Schedule Opera-

tional for that day

Unoccupied Time

Monday Flag (yes/no)

Tuesday Flag (yes/no)

Wednesday Flag (yes/no)

Thursday Flag (yes/no)

TUE X

WED X

THU X

LEGEND

††Not manually resettable.

CCN

EXV

MOP

—

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

**If applicable.

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Table 9 — Keypad Directory (cont)

SCHEDULE (cont)

SUBFUNCTION

3 PERIOD 1 (cont)

KEYPAD ENTRY

DISPLAY

COMMENT

Friday Flag (yes/no)

FRI X

SAT X

SUN X

HOL X

(yes)

Saturday Flag (yes/no)

Sunday Flag (yes/no)

Holiday Flag (yes/no)

To toggle between inputs (Yes/No) Press:

4 PERIOD 2

(no) or

PERIOD 2

Period 2 Time Schedule

PERIOD 3 ...

PERIOD 7

5 PERIOD 3 ... 9 PERIOD 7

Period 3 ... Period 7 Time Schedule

Period 8 Time Schedule

...

10 PERIOD 8

11 HOLIDAYS

PERIOD 8

HOLIDAYS

Deﬁne Calendar Holidays

Holiday Date 1

DAT MM.DD

New = Unassigned Holiday Date

DAT MM.DD.NN

Holiday Date 30

For example: To enter July 4th holiday press: 07.04.01

operation, refer to Schedule Function section on page 44.

. Display shows Jul 04. For further information on the Schedule function and its

SERVICE

To view and modify conﬁgurations, the password must be entered under the log on subfunction.

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

1 LOG ON AND LOG OFF

PASSWORD

Enter Password/Disable Password Protection

LOGGEDON

Logged On

At this time, conﬁgurations may be modiﬁed. When ﬁnished viewing and/or modifying conﬁgurations, log out as follows:

LOGGEDON

LOG OFF

—

Disable Password Protection

EXIT LOG

Logged Off/Enable Password Protection

2 VERSION

VERSION

Software Information

XXXXXXXX

Version No. of Software (CESRXX)

The next 3 subfunctions provide the ability to modify conﬁgurations. Refer to separate Installation, Start-Up, and Service Instructions

supplied with unit for further information on changing conﬁgurations.

To change a conﬁguration, enter the new conﬁguration and press

while on the correct conﬁguration.

3 FACTORY

FACT CFG

Factory Conﬁguration Codes

CONFIGURATION

XXXXXXXX

Conﬁguration Code 1

Conﬁguration Code 2

Conﬁguration Code 3

Conﬁguration Code 4

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Table 9 — Keypad Directory (cont)

SERVICE (cont)

SUBFUNCTION

KEYPAD ENTRY

DISPLAY

COMMENT

3 FACTORY

CONFIGURATION (cont)

XXXXXXXX

Conﬁguration Code 5

Conﬁguration Code 6

Conﬁguration Code 7

4 FIELD

CONFIGURATION

FLD CFG

ENO X

Adjustable Field Conﬁguration

CCN Element Address

BUS X

CCN Bus Number

BAUD X

FLUID X

UNITS X

DELAY X

NULA X

NULB X

HGB X

CCN Baud Rate

Cooler Fluid Select (water/medium brine)

Display Unit Select (English/Metric)

Delay at Power Up (minutes)

No. Circuit A Unloaders

No. Circuit B Unloaders

Hot Gas Bypass Select (used, not used)

Loading Sequence Select (equal circuit, staged circuit)

Lead/Lag Sequence Type

SEQT X

LEADT X

OPS X

Oil Pressure Switch Select (enable/disable)

Head Pressure Control Type

HEADT X

MM X

(none, air cooled, water cooled)

Motormasterா Select

CSPTYP X

CRTYP X

ERTYP X

OATSEL X

LSTYP X

RAMP X

LOCK X

CPC X

Cooling Set Point Control Select

Cooling Reset Control Select

External Reset Sensor Select

Outdoor-Air Sensor Select

Demand Limit Control Select

Ramp Load Select (enable, disable)

Cooler Pump Interlock Select

Cooler Pump Control Select

REMA X

ALRST X

Remote Alarm Option Select (yes/no)

Allow Local/Stop/CCN Reset of Alarms (yes/no)

To toggle between inputs (Yes/No) Press:

(no) or

(yes)

5 SERVICE

CONFIGURATION

SRV CFG

XXXXXXXX

REFRIG X

TDTYP X

OPS X

Service Conﬁgurations

Conﬁguration Code 8

Conﬁguration Code 9

Refrigerant

Pressure Transducer Select

Oil Transducer Set Point (psig)

Low Pressure Set Point (psig)

Fan Staging Select

LPS X

FANTYP X

SH X

EXV Superheat Set Point (F)

EXV MOP Set Point (F)

Z Multiplier

MOP X

ZM X

LEGEND

**If applicable.

††Not manually resettable.

CCN

EXV

MOP

—

Carrier Comfort Network

Electronic Expansion Valve

Maximum Operating Pressure

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

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Table 9 — Keypad Directory (cont)

HISTORY

SUBFUNCTION

1 RUN TIME

KEYPAD ENTRY

DISPLAY

COMMENT

RUN TIME

HR X

Run Time Information

Total Hrs Unit Has a Comp Operating

Circuit A Run Time

HRA X

HRB X

HA1 X

HA2 X

HA3 X

HA4 X

HB1 X

HB2 X

HB3 X

HB4 X

Circuit B Run Time

Circuit A, Comp A1 Operating Hours

Circuit A, Comp A2 Operating Hours**

Circuit A, Comp A3 Operating Hours**

Circuit A, Comp A4 Operating Hours**

Circuit B, Comp B1 Operating Hours

Circuit B, Comp B2 Operating Hours**

Circuit B, Comp B3 Operating Hours**

Circuit B, Comp B4 Operating Hours**

2 STARTS

STARTS

CY X

Starts Information

Cycles from Stage 0 to Stage 1

Circuit A Starts

CYA X

CYB X

CA1 X

CA2 X

CA3 X

CA4 X

CB1 X

CB2 X

CB3 X

CB4 X

Circuit B Starts

Circuit A, Comp A1 Starts

Circuit A, Comp A2 Starts**

Circuit A, Comp A3 Starts**

Circuit A, Comp A4 Starts**

Circuit B, Comp B1 Starts

Circuit B, Comp B2 Starts**

Circuit B, Comp B3 Starts**

Circuit B, Comp B4 Starts**

3 ALARM/ALERT

HISTORY††

ALRMHIST

ALARM X

Last 10 Alarms/Alerts

Alarm/Alert Description

}

LEGEND

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

CCN

EXV

MOP

—

Carrier Comfort Network

**If applicable.

Electronic Expansion Valve

††Not manually resettable.

Maximum Operating Pressure

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

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Table 9 — Keypad Directory (cont)

SET POINT

To read a set point, go to proper subfunction and read desired set point. To change a set point, enter new set point value, then press

LOCAL/ENABLE-STOP-CCN switch must be in LOCAL/ENABLE or STOP position.

SUBFUNCTION

1 SET POINTS

KEYPAD ENTRY

DISPLAY

COMMENT

SET POINT

CSP1 X

Unit Set Point

Chiller Fluid Set Point 1 (F)

Chiller Fluid Set Point 2 (F)

CSP2 X

HSPA X

Head Pressure Set Point Circuit A (F)

Head Pressure Set Point Circuit B (F)

Cooling Ramp Loading Rate (F)

HSPB X

CRAMP X

2 RESET SET POINTS

RESET

Reset Set Points

CRT1 X

Cooling reset at 20 mA (F)

CRT2N X

CRT2F X

CRT2D X

CRT3N X

CRT3F X

CRT3D X

Reference Temperature at No Reset (F)

Reference Temperature at Full Reset (F)

Total Degrees of Reset (F)

Chiller Fluid ⌬T at No Reset (F)

Chiller Fluid ⌬T at Full Reset (F)

Total Degrees of Reset (F)

3 DEMAND SET POINTS

DEMAND

DLS1 X†

DLS2 X†

DL20 X

Demand Set Points

Demand Switch 1 Set Point (percent)

Demand Switch 2 Set Point (percent)

Demand Limit at 20 mA (percent)

Loadshed Group Number

DLGN X

LSDD X

TIME X

Loadshed Demand (percent)

Minimum Loadshed Time (minutes)

4 DATE AND TIME

DATE.TIME

Date, Time and Day of Week

DOW.HR.MIN

Day 1 = Mon, 2 = Tues. . .7 = Sun

Hours are displayed in 24-hr time. Decimal point serves as colon.

Month.Day.Year. When entering date, enter a decimal

point between entries. Each entry must be two numbers.

MM.DD.YR

LMT X

5 LEAVING CHILLER

FLUID ALERT LIMIT

Leaving Chiller Fluid Alert Limit (F)

LEGEND

*Will read ALARM or ALERT as appropriate.

†Must be conﬁgured.

CCN

EXV

MOP

—

Carrier Comfort Network

**If applicable.

Electronic Expansion Valve

††Not manually resettable.

Maximum Operating Pressure

NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

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STATUS FUNCTION — This function shows the rotating

display, current status of alarm and alert (diagnostic) codes,

capacity stages, operating modes, chilled water set point, all

measured system temperatures and pressures, superheat val-

ues, pressure switch positions, analog inputs, and switch in-

puts. These subfunctions are deﬁned on pages 36 and 37.

To reset alarms/alerts using keypad and display module:

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Reset all alarms/alerts

function disabled

RSAL DSB

RSAL ENB

Reset all alarms/alerts

function enabled

(Rotating Display)

(Modes) — The operating mode codes are dis-

played to indicate the operating status of the unit at a given

time. See Table 10.

(Alarms/Alerts) — Alarms and alerts are messages

that one or more faults have been detected. Each fault is as-

signed a code number which is reported with the alarm or

alert. See Table 10 for code deﬁnitions. The codes indicate

failures that cause the unit to shut down, terminate an option

(such as reset) or result in the use of a default value as set

point.

To enter the MODES subfunction, press

and

press the key to determine if more than one mode ap-

plies. See Example 2 to read current mode with expansion.

Up to 10 codes can be stored at once. To view them

Example 2 — Reading Current Operating Modes

in sequence, press

to enter the alarm/alert dis-

to move to the individual dis-

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

plays and then press

TUE 15:45

LOCAL ON

CLOCK ON

8 MODE

Keypad has not been used for at

least 10 minutes. Rotating summary

display appears on screen

plays. Press

after a code has been displayed. The mean-

ing of the code scrolls across the screen. See Example 1.

COOL 1

Example 1 — Reading Alarm Codes

0 ALARMS

3 MINS

KEYPAD

ENTRY

DISPLAY

COMMENTS

2 MODES

LOCAL ON

8 MODE

There are 2 modes currently in effect

Unit is on by chiller on/off switch

Temperature reset is in effect

RESPONSE

TUE 12:45

LOCAL ON

CLOCK ON

13 MODE

8 MODE

Keypad has not been used for

at least 10 minutes. Alternating

summary display appears on

screen

COOL 1

2 ALARMS

3 MINS

(Stage) — This subfunction displays the capac-

ity stage number. See Tables 4A-4C for compressor loading

sequence. To enter the STAGE subfunction, press

2 ALARMS

RSAL DSB

2 alarms/alerts detected

Reset all alarms/alerts

First alarm/alert code

and press the

Continue pressing

to display the stage number.

for the following information:

ALARM 9

• Number of requested stages.

COOLER LEAVING

FLUID THERMISTOR Explanation of alarm/alert code

FAILURE

• Percent of total unit capacity being utilized.

• Percent of each circuit capacity being utilized.

• Percent of total capacity available.

Second alarm/alert code.

ALARM 42

Cooler freeze protection

COOLER FREEZE

• Percent of capacity available in each circuit.

Explanation of alarm/alert code

PROTECTION

• Demand limit set point in effect (can be any value be-

tween 0% and 100%).

• Status of each compressor relay. When a compressor is

on, the number of that compressor is displayed. If a com-

pressor is off, a 0 is displayed. For example: In a given

circuit, if compressors 1 and 3 are running, and 2 and 4 are

not running, 0301 is displayed for that circuit.

• Load/Unload factor for compressors. This factor is an in-

dication of when a step of capacity is added or subtracted.

Its value can range from slightly less than –1.0 to slightly

more than +1.0. When load/unload factor reaches +1.0, a

compressor is added. When the load/unload factor reaches

–1.0, a compressor is subtracted. If compressor unloaders

are used, at –.6 a compressor is unloaded and at +.6, a

compressor is loaded up.

When a diagnostic (alarm or alert) code is stored in the

display and the machine automatically resets, the code is de-

leted. Codes for safeties which do not automatically reset

are not deleted until the problem is corrected and either the

machine is switched to STOP position, then back to LOCAL/

ENABLE or CCN position, or by using the keypad and dis-

play module.

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Table 10 — Operational and Mode Display Codes

(Set Point) — This subfunction displays leaving

The operating modes are displayed by name or code num-

ber, to indicate the operating status of the unit at a given

time. The modes are:

ﬂuid temperature and leaving chilled ﬂuid set point. If unit

is programmed for dual set point, the chilled ﬂuid set point

currently in effect (either occupied or unoccupied) is

displayed. If reset is in effect, the unit operates to the modi-

ﬁed chilled ﬂuid set point. This means the leaving ﬂuid tem-

perature may not equal the chilled ﬂuid set point. The

modiﬁed chilled ﬂuid set point can also be displayed in the

Status function. To enter the set point subfunction,

CODE

DESCRIPTION

Unit is off. LOCAL/ENABLE-STOP-CCN switch is in

OFF position, or LOCAL/ENABLE-STOP-CCN switch

may be in LOCAL position with external ON/OFF

switch in OFF position.

LOCAL OFF

press

and press

to display the set point fol-

Unit is off due to CCN network command. LOCAL/

ENABLE-STOP-CCN switch is in CCN position.

CCN OFF

lowed by the modiﬁed leaving chilled ﬂuid set point and ac-

tual control temperature.

Unit is off due to internal clock schedule. LOCAL/

ENABLE-STOP-CCN switch is in LOCAL position.

CLOCK OFF

(Temperature) — The temperature subfunction dis-

plays the readings at temperature sensing thermistors.

Unit is on. LOCAL/ENABLE-STOP-CCN switch is in

LOCAL ON LOCAL position. If external ON/OFF switch is used,

it will be in ON position.

To read a temperature, enter

sired temperature using the

order of readouts. This subfunction also displays the satu-

rated refrigerant temperatures corresponding to the suction

and discharge pressures measured by the compressor

transducers.

, then scroll to de-

Unit is on due to CCN command. LOCAL/ENABLE-

CCN ON

STOP-CCN switch is in CCN position.

key. See Table 9 for the

Unit is on due to internal clock schedule or occu-

CLOCK ON pied override function. LOCAL/ENABLE-STOP-

CCN switch is in LOCAL/ENABLE position.

Dual set point is in effect. In this mode, unit contin-

ues to run in unoccupied condition, but leaving ﬂuid

MODE 7

set point is automatically increased to a higher level

(CSP2 set point is in SET function).

(Pressure) — This subfunction displays suction,

discharge, and net oil pressure at lead compressor of each

circuit of unit.

Temperature reset is in effect. In this mode, unit is

using temperature reset to adjust leaving ﬂuid set

point upward, and unit is currently controlling to the

MODE 8

modiﬁed set point. The set point can be modiﬁed based

(Analog Inputs) — This subfunction displays

on return ﬂuid, outdoor-air temperature, or space tem-

perature.

analog inputs, if any. Press

, then press

. The

Demand limit is in effect. This indicates that ca-

pacity of unit is being limited by demand limit control

option. Because of this limitation, unit may not

be able to produce the desired leaving ﬂuid

temperature.

transducer supply voltage, 4-20 mA reset signal can be dis-

played. This is useful for problem diagnosis prior to using

the test function.

MODE 9

Flotronic™ System Manager (FSM) is controlling the

chiller.

(Discrete Inputs) — This subfunction displays sta-

MODE 10

MODE 11

tus (open/closed) of discrete input switch where applicable.

Status of dual set point switch and demand limit switches 1

and 2 can be displayed. This is useful for problem diagnosis

prior to using the test function.

Not applicable.

Ramp load (pulldown) limiting is in effect. In this mode,

the rate at which leaving ﬂuid temperature is dropped

is limited to a predetermined value to prevent com-

pressor overloading. See CRAMP set point in the

SET function in Table 9. The pulldown limit can be

modiﬁed, if desired, to any rate from .2 F to 2 F

(.1° to 1° C)/minute.

MODE 12

MODE 13

(Outputs) — This function displays on/off sta-

tus of alarm relay, all fan relays, and chilled water pump

relay. It also displays on/off status of compressor unloaders

(if used). The position of each EXV (in percent open) can be

displayed.

Timed override is in effect. This is a 1 to 4 hour tem-

porary override of the programmed schedule, forc-

ing unit to occupied mode. Override can be imple-

mented with unit under LOCAL/ENABLE or CCN

control. Override expires after each use.

TEST FUNCTION — The test function operates the diag-

nostic program. To initiate test function, the LOCAL/

ENABLE-STOP-CCN switch must be in STOP position.

Low cooler suction protection is in effect. In this mode,

circuit capacity is not allowed to increase if cooler

saturated suction temperature is 20° F (11° C) for

ﬂuid or 30° F (16° C) for brine or more below leaving

ﬂuid temperature, and saturated suction tempera-

ture is less than 32 F (0° C). If these conditions per-

sist beyond 10 minutes, circuit is shut down and fault

code 44 or 45 is displayed.

To reach a particular test, press its subfunction number,

MODE 14

then scroll to desired test by pressing

. Press

to terminate or exit a

key after a test has started advances

start a test. Press

test. Pressing the

MODE 15

MODE 16

MODE 17

MODE 18

Water System Manager is controlling the chiller.

Slow change override is in effect.

system to next test, whether current test is operating or has

timed out. Once in the next step, you may start

X minute off-to-on delay is in effect.

Low suction superheat protection is in effect.

test by pressing

or advance past it by pressing

CCN — Carrier Comfort Network

While the unit is in test, you may leave test function and

access another display or function by pressing appropriate

keys. However, a component that is operating when an-

other function is accessed remains operating. You must

re-enter test function and press

to shut down the com-

ponent. Components with a timed operating limit time out

normally even if another function is accessed.

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SET POINT FUNCTION — Set points are entered through

the keypad. Set points can be changed within the upper and

lower limits, which are ﬁxed. The ranges are listed below.

Keypad entry

allows the operator to make the

following checks by using

• LID display check. Proper display is 8.8.8.8.8.8.8.8.

• Operation of alarm relay.

Chilled Fluid Set Point

Water:

38 to 86 F (3.3 to 30 C)

Medium Brine:

14 to 86 F (–10 to 30 C)

• Operation of condenser fans.

• Operation of chilled ﬂuid pump.

• Operation of liquid line solenoids.

• Operation of the hot gas bypass relays.

• Operation of EXVs. To drive EXV fully open, enter

Pulldown Set Point

0.2 to 2.0 F (0.11 to 1.1 C)/min.

(100% open). To drive EXV fully closed, en-

ter

(0% open).

Reset Set Points

Maximum Reset Range:

• Operation of each remote alarm.

• Operation of Motormaster௡ signals.

–30° to 30° F (–17° to 17° C)

External Temperature Reset –40 to 240 F

(–40 to 118 C)

Chiller Fluid ⌬T: 0° to 15° F

(0° to 8° C)

External Signal Reset 4 to 20 mA

Keypad entry

compressor unloader operational tests.

accesses the compressor and

During compressor operational tests, compressor starts

and runs for 10 seconds. Compressor service valves must

be open. Energize crankcase heaters 24 hours prior to

performing compressor tests.

Demand Limit Set Points

Switch Input:

Step 1 — 0 to 100% Capacity Reduction

Step 2 — 0 to 100% Capacity Reduction

External Signal:

Maximum Demand Limit 4 to 20 mA

Minimum Demand Limit 4 to 20 mA

Since test function checks only certain outputs, it is good

practice to also check all inputs and outputs accessible

through the status function. These are located at

Loadshed Demand Delta: 0 to 60%

, and (see Table 9). If keypad is not used

for 10 minutes, unit automatically leaves test function and

resumes rotating display. See Example 3.

Maximum Loadshed Time: 0 to 120 min.

Set points are grouped in subfunctions as follows:

Subfunction displays chiller ﬂuid set points.

Example 3 — Using Test Function

a. The ﬁrst value shown is the occupied chilled ﬂuid set

point.

KEYPAD DISPLAY

COMMENTS

ENTRY RESPONSE

b. The next value displayed depends on how the sched-

ule function has been programmed. (See pages 44-

47.) If dual set point has been selected, the next set

COMP

Factory/ﬁeld test of compressors

subfunction of test function

CPA 1 OFF Circuit A, Compressor 1A test

point after

has been pressed is the second chilled

CPA 1 ON

Pressing ENTR starts the test:

when the compressor should be running

the display shows CPA1 on

ﬂuid set point. If single set point or inactive sched-

ule has been selected in the schedule function,

CPA 1 OFF If the test is allowed to time out (10 sec-

onds) the display will show CPA1 off

then when

is pressed, the display shows the

head pressure set points, one for each circuit. These

are utilized only if the set point controlled method of

CPA 2 OFF Pressing the down arrow key advances the

system to Circuit A, compressor 2 test

head pressure control is selected in

NOTE: Once a compressor has been run using the

it is not allowed to run again for 30 seconds.

function,

c. The ﬁnal value displayed when the

is pressed

is the cooling ramp loading rate. This is the maximum

rate at which the leaving chilled ﬂuid is allowed to

drop, and can be ﬁeld set from 0.2 to 2.0 F (.11° to

1.1° C)/minute. This value is not displayed unless the

function is enabled (see Adjustable Field Conﬁgura-

tions on page 44).

accesses the transducer calibration subfunction.

All transducers must be calibrated in order for the unit to

operate. Refer to Pressure Transducers section on page 60

for calibration procedure.

HISTORY FUNCTION — Pressing

plays total unit run time, total run time for each circuit, and

total run time for each compressor.

and

dis-

Reading and Changing Set Points — Example 4 shows how

to read and change the chilled ﬂuid set point. Other set points

can be changed by following the same procedure. Refer to

Table 9 for the sequence of display of set points in each sub-

function.

Pressing

total starts for each circuit, and total starts for each com-

pressor. Pressing and displays the last 10 alarms

along with a description of each alarm.

and

displays total unit starts, the

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Example 4 — Reading and Changing

Chilled Fluid Set Point

conﬁguration. Select one of the 4 choices for type of reset:

Return Fluid Reset, External Temperature Reset, 4-20 mA

External Signal Reset, or 4-20 mA Internal Signal Reset.

If dual set point control is enabled (see Field Wiring sec-

tion on page 69), the amount of reset is applied to whichever

set point is in effect at the time.

Examples 5A-5C demonstrate how to activate reset. Ex-

ample 6 demonstrates how to change the type of reset. As-

sume that reset is to be based on return ﬂuid temperature,

the desired reset range is to be 0° to 10° F (0° to 5.5° C) and

full load is a 10° F (5.5° C) drop across the cooler. See

Fig. 5.

Activating reset based on external temperature or

4-20 mA signal is done the same way, except the reference

set point range is –40° to 240° F (–40° to 115° C), or 4 to

20 mA depending on which method was selected at the ﬁeld

conﬁguration step.

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

SET POINT

CSP1 44.0

System set points

Present occupied chilled ﬂuid

set point is 44.0 F

CSP1 42.0

Press the

Display shows new occupied

chilled ﬂuid set point is 42.0 F

Present unoccupied chilled ﬂuid

set point is 44.0 F

CSP2 44.0

CSP2 50.0

Press the

. Display

shows new unoccupied chilled

ﬂuid set point is 50.0 F

RESET

Displays the maximum reset

set point. The minimum and

maximum reference reset

set points can also be displayed.

These set points are not

accessible when reset type has

been conﬁgured for NONE in

the service function.

Example 5A — External Reset

In this example, the unit set point is reset from full load

at 90 F (32 C) to a maximum reset value of 10 F (5.5 C) at

20 F (–6.7 C) outdoor ambient.

NOTE: All temperatures given in this example are in F.

Subfunction displays temperature reset set points.

KEYPAD

ENTRY

DISPLAY

COMMENTS

RESPONSE

Temperature Reset Based on Return Fluid Temperature —

The control system is capable of providing leaving ﬂuid tem-

perature reset based on return ﬂuid temperature. Because the

temperature difference between leaving and return tempera-

ture is a measure of the building load, return ﬂuid tempera-

ture reset is essentially an average building load reset method.

Under normal operation, the chiller maintains a constant

leaving ﬂuid temperature approximately equal to chilled fluid

set point. As building load drops from 100% down to 0%,

entering cooler ﬂuid temperature drops in proportion to load.

Thus, temperature drop across the cooler drops from a typi-

cal 10 F (5.5 C) at full load to a theoretical 0° F (0° C) at no

load. See Fig. 5.

At partial load, leaving chilled ﬂuid temperature may be

lower than required. If this is allowed to increase (reset), the

efficiency of the chiller increases. Amount of reset can be

deﬁned as a function of cooler temperature drop, as shown

in Fig. 5. This is a simple linear function that requires

3 pieces of input data for the set function that will vary de-

pending on measurement method used as follows (see

Table 11):

FLD CFG

CRTYP 0

CRTYP 2

ERTYP 0

ERTYP 1

RESET

Scroll past to reset type

External reset selected

Scroll past to space

thermistor sensor selected

OAT selected

Temperature for no

reset is 0

CRT2N 0

CRT2N 90

CRT2F 0

CRT2F 20

CRT2D 0

CRT2D 10

Temperature for no

reset is 90

Temperature for maximum

reset is 0

Temperature for maximum

reset is 20

Maximum reset is 0

Maximum reset is 10

NOTE: Reset set points are not accessible unless the reset

function is enabled ﬁrst. This is done as a ﬁeld

Table 11 — Reset Amounts

MEASUREMENT METHOD

OAT/Occupied Space

or Internal/External

INPUT DATA DESCRIPTION

4-20 mA

Return Water

Variable

Limits (F)

Variable

Limits (F)

Variable

Limits (F)

Maximum Reset Amount — Allowable range for

maximum amount which LWT is to be reset.

CRT1

—

–30 to 30

CRT2D

–30 to 30

CRT3D

–30 to 30

Maximum Reset Reference — Temperature at

which maximum reset occurs.

—

CRT2F

CRT2N

–40 to 240

CRT3F

CRT3N

0 to 15

Minimum Reset Reference — Temperature at

which no reset occurs.

—

LEGEND

OAT

LWT

—

Outdoor-Air Temperature

Leaving Fluid Temperature

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Example 5B — 4 to 20 mA and Internally or

Externally Powered Reset

In this example, the unit set point is reset from full load

at 4 mA to a maximum reset value of 10 F (5.5 C) at

20 mA. Internally powered 4 to 20 mA option is used in this

example.

Temperature Reset Based on External Temperature — If de-

sired, temperature reset can be based on an external tem-

perature, such as space or outdoor-air temperature. This re-

quires a thermistor (T10, Part No. 30GB660002) located in

the space or outdoor air and wired to terminals as follows

(also see Field Wiring section on page 69 and Fig. 6):

NOTE: To use externally powered reset, when CRTYP

4 in/4 out Module — J7-15 and J7-16.

appears, press

display. The remainder of the information in the fol-

lowing example applies to either type of reset.

so CRTYP 4 appears in the

At the ﬁeld conﬁguration step, enter set points as de-

scribed in Examples 5A-5C on pages 39 and 40. Then

select external temperature reset by entering

CRTYP 0 appears. See Fig. 7.

when

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Temperature Reset Based on 4-20 mA Signal— If desired,

temperature reset can be based on a 4-20 mA signal. For

proper connections, refer to Field Wiring section on

page 69 and Fig. 8.

FLD CFG

CRTYP 0

CRTYP 1

RESET

Scroll past to reset type

Internally powered reset

selected

At the ﬁeld conﬁguration step, select 4-20 mA reset by

entering

(internally powered) or

(externally pow-

ered) when CRTYP 0 appears. Then enter set points as de-

scribed previously in Examples 5A-C. See Fig. 8.

CRT1 0

Reset at 20 mA is 0

Reset at 20 mA is 10

CRT1 10

Subfunction displays demand limit set points.

Example 5C — Using Return Fluid

Temperature Reset

Demand Limit, 2-Stage Switch Control — This control has

been designed to accept demand limit signals from a build-

ing load shedding control. The demand limit function pro-

vides for 2 capacity steps. The keypad is used to set the 2

demand limit set points, which range from 100 to 0% of ca-

pacity. Capacity steps are controlled by 2 ﬁeld-supplied re-

lay contacts connected to the designated chiller terminals.

(See Field Wiring section on page 69 and Fig. 7.)

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Field conﬁguration

subfunction of

service function

FLD CFG

CSPTYP X

CRTYP 0

CRTYP 3

RESET

Scroll past single/dual

Display shows no reset

type has been selected

Return ﬂuid temperature

is selected and activated

Reset set points

Fig. 5 — Cooling Return Fluid Reset

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Fig. 6 — Cooling External Temperature Reset

LEGEND

COMM

PWR

—

Communications Bus

Power

Switch

NOTE: For speciﬁc connection points,

see Fig. 25 - 29.

Fig. 7 — 4 IN/4 OUT Options Module Wiring for Reset, Demand Limit, and Dual Set Point

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Fig. 8 — 4-20 mA Cooling Temperature Reset

Example 6 — Changing Reset Type

Table 12 — Service Functions

To change type of reset, ﬁrst log on as shown in

Table 12. Also refer to Set Point Function section, page 38,

for information on entering reset set points using reset

feature.

To view and modify conﬁgurations, the password must be

entered under the log on subfunction.

SUB-

KEYPAD

ENTRY

DISPLAY

COMMENT

FUNCTION

Enter Password/

Disable Password

KEYPAD

ENTRY

DISPLAY

RESPONSE

1 Log On

PASSWORD

COMMENTS

LOGGEDON Logged On

Field conﬁguration

subfunction of

FLD CFG

service function

NOTE: Conﬁgurations may be modiﬁed at this time. When

ﬁnished viewing and/or modifying conﬁgurations, log out as

follows:

Scroll past single cooling

set point

CSPTYP 0

CRTYP 0

CRTYP 1

No reset has been

selected

LOGGEDON

LOG OFF

—

Internally powered 4-20 mA

signal reset is selected

Disable Password

Protection

Space or outdoor-air

temperature reset is

selected

Logged Off/

Enable Password

Protection

CRTYP 2

EXIT LOG

Return ﬂuid temperature

reset is selected

CRTYP 3

CRTYP 4

CRTYP 0

2 Version

Software

Information

VERSION

Externally powered 4-20 mA

signal reset is selected

Version No.

of Software

XXXXXXXX

Reset is deactivated

Demand Limit, 4 to 20 mA Signal — The controls can also

accept a 4 to 20 mA signal for load shedding. Input for the

signal are terminals shown below:

Externally powered

Positive lead to J7-5 - 4 In/4 Out Module

Negative lead to J7-6 - 4 In/4 Out Module

Internally powered

Positive lead to J7-6 - 4 In/4 Out Module

Negative lead to J7-7 - 4 In/4 Out Module

To use Demand Limit, ﬁrst enable loadshed, then enter

demand limit set points. See Example 7A. Closing the ﬁrst

stage demand limit contact puts unit on the ﬁrst demand limit

level, that is, the unit does not exceed the percentage of ca-

pacity entered as demand limit stage 1. Closing contacts on

second-stage demand limit relay prevents unit from exceed-

ing capacity entered as demand limit stage 2. The demand

limit stage that is set to the lowest demand takes priority if

both demand limit inputs are closed.

The demand limit function must be enabled in order to

function and may be turned off when its operation is not de-

sired. The demand limit relays can, in off condition, remain

connected without affecting machine operation.

See Field Wiring section on page 69 and Fig. 7.

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the loadshed demand delta, which deﬁnes the percent of the

load to be removed when a loadshed command is in effect.

The third set point is maximum loadshed time, which de-

ﬁnes the maximum length of time that a loadshed condition

is allowed to exist. The allowable range for this entry is zero

to 120 minutes.

At ﬁeld conﬁguration step, select 4 to 20 mA loadshed

by entering (internally powered) or (externally pow-

ered) when the LSTYP 0 display appears. See Example 7B.

Then enter set points as follows. In this example, set points

are coordinates of the demand limit curve shown in Fig. 9.

Example 7A — Using Demand Limit

(First Log On as Shown in Table 12)

Subfunction displays date, time, and day of the week.

Reading and Changing Time Display — Time is entered and

displayed in 24-hour time. The day of the week is entered as

a number.

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

1 = Mon, 2 = Tue, 7 = Sun, etc.

Field conﬁguration sub-

FLD CFG

LSTYP 0

LSTYP 1

function of service function

Key is used as the colon when entering time. See

Example 8.

Loadshed is not enabled

Loadshed is now enabled

for 2-stage switch control

subfunction accesses the leaving chiller ﬂuid alert

Demand Limit set points

subfunction of set point

function

limit (LMT) option. The value to be entered here is the num-

ber of degrees above the control set point at which an alert

should be generated. For example, if the control set point is

44 F, and an alert is desired (alert 70) if the ﬂuid temperature

reaches 50 F, then enter 6 for this set point. The allowable

range for this entry is between 2 and 30 (F).

DEMAND

Loadshed 1 currently set

at 80%

DLS1 80

DLS1 60

DLS2 50

DLS2 40

Loadshed reset to 60%

Loadshed 2 currently set

at 50%

SERVICE FUNCTION — This function allows the techni-

cian to view and input conﬁguration data. Factory conﬁgu-

ration data, ﬁeld conﬁguration data, and service conﬁgura-

tion data may be viewed or entered through the keypad and

display module. See Table 9 for a complete listing of con-

ﬁgurable items. Whenever a processor module is replaced in

the ﬁeld, the complete list of conﬁguration codes must be

entered.

Loadshed 2 reset to 40%

To Disable Demand Limit:

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Logging On/Logging Off — The service function is pass-

word protected. Therefore, to gain entry to this function,

Field conﬁguration sub-

FLD CFG

ERTYP 0

LSTYP 1

LSTYP 0

function of service function

Scroll past other elements

in the subfunction

this password must be entered. Pressing

allows the technician to view, change, or enter conﬁguration

codes. To log off, perform the following keystrokes:

Loadshed is enabled for

2-stage switch control

Loadshed is now disabled

. The service function is once again password

protected.

NOTES:

1. Select 2 for internally powered 4 to 20 mA signal load limiting.

2. Select 3 for Carrier Comfort Network loadshed.

3. Select 4 for externally powered 4 to 20 mA signal load limiting.

Software Information —

displays the version

number of the software that resides in the processor

module. The

rized in Table 12.

and

subfunctions are summa-

Example 7B — Using Demand Limit (4-20 mA)

(First Log On As Shown in Table 12)

KEYPAD

ENTRY

DISPLAY

Example 8 — Setting Time of Day and

Day of Week

COMMENTS

RESPONSE

Field conﬁguration subfunction

of service function

FLD CFG

ERTYP 0

LSTYP 0

KEYPAD

ENTRY

DISPLAY

RESPONSE

COMMENTS

Scroll past other elements in

the subfunction

Time display sub-

function of set point

function

TIME

Loadshed is not enabled

Loadshed is now enabled

for 4-20 mA internally-powered

signal control

Current setting is

Monday, 4:00 p.m.

MON 16.00

LSTYP 2

New setting of

Tuesday, 1:05 p.m.

is entered

DEMAND

DL20 100

DL20 90

Demand Limit set points

TUE 13.05

JAN 01 90

APR 15 90

and displayed

Maximum demand limit is 100%

Maximum demand limit is 90%

Current date is

Jan. 1, 1990

New setting

April 15, 1990

is entered

Scrolling past the 4 to 20 mA demand limit set point brings

up the loadshed set points. The loadshed feature is activated

by a redline alert and loadshed commands from the CCN

loadshed option. The ﬁrst set point is the group number, es-

tablished by the CCN system designer. The second option is

and displayed

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Fig. 9 — 4-20 mA Demand Limiting

Factory Conﬁguration Codes —

allows entry into

replaced in the ﬁeld, the 2 groups of conﬁguration codes must

be entered through the keypad and display module. The

2 groups of conﬁguration codes (groups 8 and 9) that apply

to the unit being serviced can be found on a label diagram

inside the control box cover. See Table 13 for keystroke in-

formation to enter conﬁguration codes 8 and 9. The remain-

ing items in this subfunction are read-only data provided to

assist in service evaluations.

the factory conﬁguration subfunction. Under this subfunc-

tion, there are 7 groups of conﬁguration codes that are down-

loaded at the factory. Each group is made up of 8 digits. If

processor module is replaced in the ﬁeld, these 7 groups of

conﬁguration codes must be entered through the keypad

and display module. Factory conﬁguration codes (groups 1

through 7) that apply to the particular Flotronic™ II chiller

being serviced are found on a label diagram located inside

the control box cover. See Table 13 for a summary of factory

conﬁguration subfunction keystrokes.

SCHEDULE FUNCTION — This function provides a means

to automatically switch chiller from an occupied mode to an

unoccupied mode. When using schedule function, chilled fluid

pump relay must be used to switch chilled ﬂuid pump on

and off. Connections for chilled ﬂuid pump relay are: TB3-3

and TB3-4. The chilled ﬂuid pump relay starts chilled ﬂuid

pump but compressors do not run until remote chilled ﬂuid

pump interlock contacts are between TB6-1 and TB6-2 are

closed and leaving chilled ﬂuid temperature is above set point.

If a remote chilled ﬂuid pump interlock is not used, the ﬁrst

compressor starts (upon a call for cooling) approximately

one minute after chilled ﬂuid pump is turned on.

The unit can be programmed for inactive, single set point,

or dual set point operation.

When unit is conﬁgured for inactive, chilled ﬂuid pump

relay remains energized continuously but is not used since

chiller is usually controlled by remote chilled ﬂuid pump in-

terlock contacts.

Adjustable Field Conﬁgurations — After logging on, press

to enter subfunction. The subfunction allows opera-

tion of the chiller to be customized to meet the particular

needs of the application. The chiller comes from the factory

preconﬁgured to meet the needs of most applications. Each

item should be checked to determine which conﬁguration

alternative best meets the needs of a particular application.

See Table 14 for factory loaded conﬁguration codes and al-

ternative conﬁgurations.

If processor module is replaced, the replacement module

is preloaded with factory default conﬁguration codes. Each

conﬁguration code must be checked and, if necessary, re-

conﬁgured to meet needs of the application. See Table 14 for

pre-loaded service replacement conﬁguration codes.

When unit is conﬁgured for single set point operation, chilled

ﬂuid pump relay is energized whenever chiller is in occu-

pied mode regardless of whether chiller is running. When

chiller is in unoccupied mode, chilled ﬂuid pump relay is

not energized.

Service Conﬁguration Codes — Press

to enter the

service conﬁguration subfunction. The ﬁrst 2 items under this

subfunction are 2 groups (8 digits each) of conﬁguration codes

that are downloaded at the factory. If processor module is

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Table 13 — Factory Conﬁguration Keystrokes

Table 14 — Adjustable Field Conﬁgurations

To change a conﬁguration enter the new conﬁguration

FACTORY

CONFIGURATION

CODE

SERVICE

REPLACEMENT

CODE

FIELD CONFIGURATION

ITEM AND CODES

and press

while on the correct conﬁguration.

CCN element address

(Entered by CCN Technician)

001

SUB-

FUNCTION

KEYPAD

ENTRY

DISPLAY

COMMENTS

CCN Bus Number

(Entered by CCN Technician)

000

FACTORY

CONFIGURATION

CODES

CCN Baud Rate

9600

3 FACTORY

CFG

(Entered by CCN Technician)

FACT CFG

Cooler Fluid Select

1 = Water (38 to 70 F

[3.3 to 21 C] Set Point)

2 = Medium Brine (15 to 70 F

[–9 to 21 C] Set Point)

1 = Standard Models

2 = Brine Models

Conﬁguration

Code 1

XXXXXXXX

Conﬁguration

Code 2

Display Unit Select

0 = English

1 = Metric SI

Conﬁguration

Code 3

Delay at Power Up

No. Circuit A Unloaders

0 = No Unloaders

1 = One Unloader

2 = Two Unloaders

Conﬁguration

Code 4

0 = 30GN190-210*

1 = 30GN040-170*

Conﬁguration

Code 5

No. Circuit B Unloaders

0 = No Unloaders

1 = One Unloader

2 = Two Unloaders

0 = 30GN040-070,

190-210*

1 = 30GN080-170*

Conﬁguration

Code 6

XXXXXXXX

Hot Gas Bypass Select

0 = No Valve

Conﬁguration

Code 7

Loading Sequence Select

1 = Equal Circuit Loading

2 = Staged Circuit Loading

SERVICE

CONFIGURATION

CODES

5 SERVICE

CFG

SRV CFG

Lead/Lag Sequence Select

1 = Automatic

2 = Manual, Circuit A Leads

3 = Manual, Circuit B Leads

Conﬁguration

Code 8

XXXXXXXX

REFRIG X

TDTYPE X

OPS X

Oil Pressure Switch Select

0 = Not Used

1 = Air Cooled

Conﬁguration

Code 9

Head Pressure Control Type

0 = Not Used

1 = Air Cooled

Refrigerant Type

Head Pressure Control Method

1 = EXV Controlled

2 = Set Point Control for

Both Circuits

3 = Set Point Control for

Circuit A; EXV Control

for Circuit B

4 = Set Point Control for

Circuit B; EXV Control

for Circuit A

Pressure Transducer Select

Oil Pressure Set Point

Low Pressure Set Point

Fan Staging Select

EXV Superheat Set Point

EXV MOP Superheat

Z Multiplier

2 = 040,045

Brine Units

LPS X

FANTYP X

SH X

Motormasterா Select

0 = None

2 = Indirect Control

Cooling Set Point

Control Select

0 = Single Set Point Control

1 = External Switch

Controlled Set Point

2 = Clock Controlled

Set Point

MOP X

ZM X

Cooling Reset Control Select

0 = No Reset

LEGEND

MOP

EXV

—

Maximum Operating Pressure

Electronic Expansion Valve

1 = 4-20 mA, Internally Powered

2 = External Temperature

Reset

3 = Return Fluid Reset

4 = 4-20 mA, Externally Powered

External Reset Sensor Select

0 = Thermistor Connected to

Options Module

When unit is conﬁgured for dual set point, chilled liquid

pump relay is energized continuously, in both occupied and

unoccupied modes. Occupied mode places occupied chilled

water set point into effect; unoccupied mode places unoc-

cupied chilled water set point into effect.

1 = Obtained Through CCN

Outdoor-Air Sensor Select

0 = Not Selected

1 = Selected

Demand Limit Control Select

0 = No Demand Limiting

1 = Two External Switch Inputs

2 = Internal 4-20 mA Input

3 = CCN Loadshed

Scheduling —

is used to override any current sched-

ule in effect (for 0-4 hours).

is used to activate a

4 = External 4-20 mA Input

Ramp Load Select

(Pulldown Control)

0 = Disabled

clock for the scheduling function.

are used

to program schedules for speciﬁc occupied and unoccupied

periods.

1 = Enabled

Cooler Pump Interlock Select

0 = No Interlock

1 = With Interlock

The schedule consists of from one to 8 occupied time pe-

riods, set by the operator. These time periods can be ﬂagged

to be in effect or not in effect on each day of the week. The

day begins at 00.00 and ends at 24.00. The machine is in

unoccupied mode unless a scheduled time period is in effect.

If an occupied period is to extend past midnight, it must be

programmed in the following manner: occupied period must

end at 24:00 hours (midnight); a new occupied period must

be programmed to begin at 00:00 hours.

Cooler Pump Control Select

0 = Not Controlled

1 = ON/OFF Controlled

Remote Alarm Option Select

0 = Not Selected

1 = Selected

Local/Enable-Stop-CCN

Switch Usage†

0 = Not Allowed

1 = Allowed

LEGEND

CCN

EXV

—

Carrier Comfort Network

Electronic Expansion Valve

*And associated modular units.

†For reset of alarms.

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NOTE: This is true only if the occupied period starts at 00:00

(midnight). If the occupied period starts at a time other than

midnight, then the occupied period must end at 00:00 hours

(midnight) and new occupied period must be programmed

to start at 00:00 in order for the chiller to stay in the occu-

pied mode past midnight.

The time schedule can be overridden to keep unit in oc-

cupied mode for one, 2, 3, or 4 hours on a one-time basis.

See Example 9.

Example 9 — Using the Schedule Function (cont)

KEYPAD

ENTRY

DISPLAY

COMMENT

PROGRAMMING PERIOD 2:

PERIOD 2 Deﬁne schedule period 2

OCC 00.00 Start of occupied time

Occupied time will start

OCC 7.00

at 7:00 a.m.

All subfunctions of schedule function are password

Start of unoccupied time

(end of period). For this

UNO 00.00

protected except the override subfunction,

word entry into subfunctions through

. Pass-

example, period 2 should

end at 18:00 (6:00 p.m.)

Period 2 ends at 18:00

UNO 18.00

(6:00 p.m.)

is done through service function. See page 43, logging on/

logging off.

Monday is now ﬂagged no

for period 2. To put period 2

MON NO

Figure 10 shows a schedule for an office building with the

chiller operating on a single set point schedule. The sched-

ule is based on building occupancy with a 3-hour off-peak

cool-down period from midnight to 3 a.m. following the week-

end shutdown. To learn how this sample schedule would be

programmed, see Example 9.

NOTE: This schedule was designed to illustrate the pro-

gramming of the schedule function and is not intended as a

recommended schedule for chiller operation.

into effect on Monday,

Monday must be ﬂagged yes

Monday is now ﬂagged for

MON YES

period 2 to be in effect

Tuesay is now ﬂagged no

for period 2. To put period 2

into effect on Tuesday,

Tuesday must be ﬂagged

yes

TUE NO

Tuesday is now ﬂagged for

period 2 to be in effect

TUE YES

For this example, period 2

is to be in effect only on

Monday and Tuesday.

All other days must be

checked to be sure that

they are ﬂagged no. If

a day is ﬂagged yes,

change to no

Example 9 — Using the Schedule Function

WED YES

WED NO

KEYPAD

ENTRY

DISPLAY

COMMENT

No scheduled override

in effect

OVRD 0

OVRD 3

OVRD 0

CLOCK 0

CLOCK 1

Wednesday is now ﬂagged

no for period 2

3 hours override in effect

Override cancelled

Deﬁne schedule

period 3

PERIOD 3

OCC 00.00

OCC 7.00

Start of occupied

time

Schedule function is inactive

Occupied time will start

at 7:00 a.m.

Schedule function is enabled

through local unit clock

Start of unoccupied time

(end of period 3). For this

example, period 3 should

end at 21:30 (9:30 p.m.)

PROGRAMMING PERIOD 1:

PERIOD 1

UNO 00.00

Deﬁne schedule period 1.

Start of occupied time

Period 3 ends at 21:30

(9:30 p.m.)

UNO 21.30

MON NO

For this example, ﬁrst

period should start here

(at midnight) so no entry

is needed

OCC 00.00

Check to be sure that

Monday and Tuesday are

ﬂagged no for period 3

Start of unoccupied time

(end of period). For this

example, period 1 should

end at 3:00 a.m.

TUE NO

WED NO

WED YES

THUR NO

FRI NO

UNO 00.00

UNO 3.00

Wednesday is ﬂagged

no, change to yes

Period 1 ends at 3:00 a.m.

Wednesday is now

ﬂagged yes for period 3

Monday is now ﬂagged no

for period 1. To put period 1

into effect on Monday,

Monday must be ﬂagged

yes

Check to be sure that all

other days are ﬂagged no

MON NO

Monday is now ﬂagged for

period 1 to be in effect

MON YES

SAT NO

SUN NO

For this example, period 1

is to be in effect on Monday

only. All other days must be

checked to be sure that they

are ﬂagged no. If any day is

ﬂagged yes, change to no

TUE YES

TUE NO

CCN

—

Carrier Comfort Network

Tuesday is now ﬂagged

no for period 1

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Periods 4 and 5 can be programmed in the same manner,

ﬂagging Thursday and Friday yes for period 4 and Saturday

yes for period 5. For this example, periods 6, 7, and 8

are not used: they should be programmed OCC 00.00,

UNO 00.00.

NOTE: When a day is ﬂagged yes for 2 overlapping periods,

occupied time will take precedence over unoccupied time.

Occupied times can overlap in the schedule with no

consequence.

To extend an occupied mode beyond its normal termina-

tion for a one-time schedule override, program as shown

below:

Override is set for 0. Enter

OVRD 0

OVRD 3

the number of hours of

override desired

Unit will now remain in

occupied mode for

an additional 3 hours

Holiday Schedule — Press

to schedule up to

30 holiday periods. All holidays are entered with numerical

values. First, the month (01 to 12), then the day (01 to 31),

then the duration of the holiday period in days.

Examples: July 04 is 07.04.01.

Dec 25 - 26 is 12.25.02

If any of the 30 holiday periods are not used, the display

shows NEW.

See Example 10.

Fig. 10 — Sample Time Schedule

TROUBLESHOOTING

The Flotronic™ II control has many features to aid the

technicians in troubleshooting a Flotronic II Chiller. By us-

ing the keypad and display module and the status function,

actual operating conditions of the chiller are displayed while

unit is running. Test function allows proper operation of com-

pressors, compressor unloaders, fans, EXVs and other com-

ponents to be checked while chiller is stopped. Service func-

tion displays how conﬁgurable items are conﬁgured. If an

operating fault is detected, an alarm is generated and an

Example 10 — Holiday Schedule Function

ENTER

DISPLAY

HOLIDAY

JAN01 02 (Includes Jan 1st

and 2nd)

APR17 01 (Includes April 17th)

MAY21 01(Includes May 21st)

JUL03 01 (Includes July 3rd)

JUL04 01 (Includes July 4th)

SEP07 01 (Includes Sep. 7th)

alarm code(s) is displayed under the subfunction

along with an explanation of the fault. Up to 10 current alarm

codes are stored under this subfunction. For checking spe-

ciﬁc items, see Table 9.

Checking Display Codes — To determine how ma-

chine has been programmed to operate, check diagnostic

NOV26 02 (Includes Nov. 26th

and 27th)

information (

) and operating mode displays (

If no display appears, follow procedures in Control Modules

section on page 63. If display is working, continue as

follows:

DEC24 02 (Includes Dec. 24th

and 25th)

DEC30 02 (Includes Dec. 30th

and 31st)

1. Note all alarm codes displayed,

2. Note all operating mode codes displayed,

3. Note leaving chilled water temperature set point in ef-

fect and current leaving water temperature,

NEW

MAY25 01 (Includes May 25th)

NEW

If machine is running, compare the ‘‘in effect’’ leaving

water temperature set point with current water tempera-

ture. Remember, if reset is in effect, the values may be

different because machine is operating to the modiﬁed chilled

water set point. If current temperature is equal to set point,

but set point is not the one desired, remember that if dual

set point has been selected in the schedule function, there

are 2 set points to which the machine can be operating.

Check the programming of schedule function to see if oc-

cupied or unoccupied set point should be in effect.

NEW

NEW (30TH HOLIDAY)

NEW indicates a holiday that has not been assigned yet.

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Unit Shutoff — To shut unit off, move LOCAL/ENABLE-

STOP-CCN switch to STOP position. Any refrigeration cir-

cuit operating at this time continues to complete the pum-

pout cycle. Lag compressors stop immediately, and lead

compressors run to complete pumpout.

If stoppage occurs more than once as a result of any of

the above safety devices, determine and correct the cause

before attempting another restart.

Complete Unit Stoppage — Complete unit stoppage

Restart Procedure — After cause for stoppage has been

corrected, restart is either automatic or manual, depending

on fault. Manual reset requires that LOCAL/ENABLE-

STOP-CCN switch be moved to STOP position, then back

to original operating position. Some typical fault conditions

are described in Table 15. For a complete list of fault con-

ditions, codes, and reset type, see Table 16.

can be caused by any of the following conditions:

1. Cooling load satisﬁed

2. Remote on/off contacts open

3. Programmed schedule

4. Emergency stop command from CCN

5. General power failure

6. Blown fuse in control power feed disconnect

7. Open control circuit fuse

8. LOCAL/ENABLE-STOP-CCN switch moved to STOP

position

Table 15 — Typical Stoppage Faults and Reset Types

Chilled Fluid, Low Flow

Manual reset

Chilled Fluid, Low Temperature

Auto reset ﬁrst time, manual

if repeated in same day

9. Freeze protection trip

10. Low ﬂow protection trip

11. Open contacts in chilled water ﬂow switch (optional)

Chilled Fluid Pump Interlock

Control Circuit Fuse Blown

High-Pressure Switch Open

Low Refrigerant Pressure

Low Oil Pressure

Manual reset

Unit restarts automatically when

power is restored

Manual reset

12. Open contacts in any auxiliary interlock. Terminals that

are jumpered from factory are in series with control switch.

Opening the circuit between these terminals places unit

in stop mode, similar to moving the control switch to

STOP position. Unit cannot start if these contacts are

open. If they open while unit is running, unit pumps down

and stops.

13. Cooler entering or leaving ﬂuid thermistor failure

14. Low transducer supply voltage

15. Loss of communications between processor module and

other control modules

Auto reset ﬁrst time, then

manual if within same day

Manual reset

Discharge Gas Thermostat Open Manual reset

POWER FAILURE EXTERNAL TO THE UNIT — Unit

restarts automatically when power is restored.

Alarms and Alerts — These are warnings of abnormal

or fault conditions, and may cause either one circuit or the

whole unit to shut down. They are assigned code numbers as

described below. These code numbers are displayed

16. Low refrigerant pressure

17. Off-to-on delay is in effect.

on the HSIO when the

subfunction is entered. A

fault that affects one one circuit of the chiller will generate

an alert, and a fault that affects the entire unit will generate

an alarm.

Following is a detailed description of each alarm and alert

code error and possible cause. Manual reset is accomplished

by moving LOCAL/ENABLE-STOP-CCN Switch to STOP

position, then back to LOCAL or CCN position. See

Table 16 for listing of each alarm and alert code.

Single Circuit Stoppage — Single circuit stoppage

can be caused by the following:

1. Low oil pressure in lead compressor

2. Open contacts in lead compressor high-pressure switch

3. Low refrigerant pressure

4. Thermistor failure

5. Transducer failure

Code 0

No alarms or alerts exist

Codes 1 - 8 Compressor failure

6. Ground fault in lead compressor indicator (indicator is

ﬁeld-supplied on 040-060, 070 [60 Hz], and 080-110 and

associated modular units)

7. High suction superheat

8. Low suction superheat

9. Lead compressor circuit breaker trip. Stoppage of one

circuit by a safety device action does not affect other

circuit. When a safety device trips on a lead compres-

sor, circuit is shut down immediately and EXV closes.

If DSIO-LV or -EXV relay module control relay feedback

switch or signal is sensed as open during operation of a com-

pressor, microprocessor detects this and stops compressor,

energizes alert light, and displays a code of 1, 2, 3, 4, 5, 6,

7, or 8 depending on the compressor. Compressor locks off;

to reset, use manual reset method.

If lead compressor in a circuit shuts down, the other com-

pressors in the circuit stop and lock off. Only the alert mode

for lead compressor is displayed.

The microprocessor is also programmed to indicate com-

pressor failure if feedback terminal on DSIO-LV or -EXV J3

terminal strip receives voltage when compressor is not sup-

posed to be on.

10. Ground fault for any circuit compressor (130-210 and

associated modular units).

Lag Compressor Stoppage — Lag compressor stop-

page can be caused by the following:

1. Open contacts in high-pressure switch

2. Compressor ground fault (indicator is ﬁeld-supplied on

040-060, 070 [60 Hz], and 080-110 and associated modu-

lar units)

NOTE: It takes 5 seconds for the control to generate the alarm

code and lock out the compressor(s) on compressor failure

code(s) 1 through 8.

3. Compressor circuit breaker trip

4. Not required to run to meet cooling load requirement

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Table 16 — Alarm and Alert Codes

ALARM

ACTION TAKEN

BY CONTROL

CIRCUIT

RESET

DISPLAY

DESCRIPTION

No Alarms or Alerts Exist

PUMPDOWN METHOD

PROBABLE CAUSE

ALERT

—

Compressor A1 failure

Circuit A shut down

Manual High-pressure switch trip, or wiring

error.

2, 3, 4

Compressor A2, A3, A4 failure

Compressor B1 failure

Compressor shut down

Circuit B shut down

Compressor shut down

Unit shut down

Yes

Manual CPCS Ground Fault Protection

Alert

Manual

Auto.

6, 7, 8

Compressor B2, B3, B4 failure

Leaving ﬂuid thermistor failure

Entering ﬂuid thermistor failure

Compressor A1 sensor failure

Compressor B1 sensor failure

Reset thermistor failure

Yes

Alarm

Alert

Unit shut down

Auto.

Thermistor or transducer failure

or wiring error.

Circuit A shut down

Circuit B shut down

Normal set point used

Auto.

Discharge pressure transducer failure, circuit A Circuit A shut down

Discharge pressure transducer failure, circuit B Circuit B shut down

Yes

Suction pressure transducer failure, circuit A

Suction pressure transducer failure, circuit B

Oil pressure transducer failure, circuit A

Oil pressure transducer failure, circuit B

Transducer supply voltage low

Circuit A shut down

Circuit B shut down

Circuit A shut down

Circuit B shut down

Unit shut down

Auto.

Alert

Transducer failure or wiring error.

Auto.

Unit voltage low or PS1 faulty.

Alarm

Alert

LOCAL/ENABLE-STOP-CCN

Unit shut down

Manual Switch failure or wiring error.

4-20 mA reset input failure

Normal set point used

Demand limit ignored

Unit shut down

Auto.

4-20 mA demand limit failure

Loss of communication with DSIO-LV

Auto.

Wiring error or faulty module

or improper address code.

Alarm

Loss of communication with DSIO-EXV

Unit shut down

Yes

—

Auto.

—

Loss of communication with 4 In/4 Out module Unit shut down

—

Not used

—

Low refrigerant pressure circuit A

Circuit A shut down

Low refrigerant charge, plugged ﬁlter

drier, faulty expansion valve.

Alert

Low refrigerant pressure circuit B

Failure to pump out circuit A

Failure to pump out circuit B

Low oil pressure circuit A

Circuit B shut down

Circuit A shut down

Circuit B shut down

Circuit A shut down

Low refrigerant charge, plugged ﬁlter

drier, faulty expansion valve.

Manual Faulty expansion valve, transducer,

or thermistor.

Alert

Manual Faulty expansion valve, transducer,

or thermistor.

Manual Low oil level, circuit breaker trip,

faulty expansion valve, crankcase

heater, or pressure transducer.

Low oil pressure circuit B

Circuit B shut down

Manual Low oil level, circuit breaker trip,

faulty expansion valve, crankcase

heater, or pressure transducer.

Cooler freeze protection

Low cooler ﬂuid ﬂow

Unit shut down

Low ﬂuid ﬂow or faulty thermistor.

Alarm

Alert

Manual Chilled ﬂuid pump failure

or faulty thermistor.

Low suction temperature circuit A

Low suction temperature circuit B

High suction superheat circuit A

High suction superheat circuit B

Circuit A shut down

after 10 minutes

Manual Faulty expansion valve or thermistor.

Circuit B shut down

after 10 minutes

Manual Faulty expansion valve or thermistor.

Circuit A shut down

Yes

Manual Low charge, faulty expansion valve or

thermistor, or plugged ﬁlter drier.

Alert

Circuit B shut down

Manual Low charge, faulty expansion valve or

thermistor, or plugged ﬁlter drier.

Low suction superheat circuit A

Low suction superheat circuit B

Illegal conﬁguration

Circuit A shut down

Circuit B shut down

Unit cannot start

Yes

—

Manual Faulty EXV or thermistor.

Manual Conﬁguration error.

Alarm Initial conﬁguration required

Emergency stop by CCN command

Cooler pump interlock failure

Unit cannot start

—

Manual Conﬁguration omitted.

Unit shut down

Yes

—

CCN

Network command.

Unit shut down

Manual Failure of cooler pump or controls

Manual Failure of cooler pump relay or interlock

Alarm Cooler pump interlock failure

Cooler pump interlock failure

Unit shut down

Cooler pump shut down

WSM forces removed

Circuit cannot start

Alert

WSM communication failure

—

Auto.

Wiring fault or module failure

Transducer not calibrated

Calibration required for discharge pressure

transducer, circuit A

—

Calibration required for discharge pressure

transducer, circuit B

Circuit cannot start

—

Auto.

Calibration required for suction pressure

transducer, circuit A

Alert

Calibration required for suction pressure

transducer, circuit B

Calibration required for oil pressure

transducer, circuit A

Calibration required for oil pressure

transducer, circuit B

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Table 16 — Alarm and Alert Codes (cont)

ALARM

ACTION TAKEN

BY CONTROL

CIRCUIT

PUMPDOWN

RESET

METHOD

DISPLAY

DESCRIPTION

PROBABLE CAUSE

Check individual alarms

ALERT

Alarm

Alert

Complete unit shutdown

Alarm only

—

Auto.

Loss of charge, circuit A

Loss of charge, circuit B

Circuit cannot start

—

Auto.

Refrigerant leak or transducer

failure

Alarm

—

FSM communication loss

FSM forces removed

Unit cannot start

—

Auto.

—

Wiring faulty or module failure

Incorrect date code entered

—

Transducer calibration date code failure

Not used

68,69

Alert

High leaving chilled ﬂuid temperature

Alarm only

Auto.

Building load greater than unit capacity,

low water/brine ﬂow, or compressor

fault. Check for other alarms or alerts.

LEGEND

*Reset automatic ﬁrst time, manual if repeated same day.

CPCS

—

Compressor Protection Control Module

Flotronic™ System Manager

Power Supply

FSM

WSM

Water System Manager

Possible causes of failure:

Compressor Alarm/Alert Circuit — For compres-

sor A1 circuit, processor closes contacts between J4 termi-

nals 2 and 3 to start compressor. See Fig. 11A-11C. Safeties

shown to left of J4 must be closed in order for power to

reach compressor control relay, and the feedback input ter-

minals on J3.

Failure of power to terminal 1 on J3, when contacts be-

tween 2 and 3 on J4 should be closed, causes a code 1 alert.

Terminal 2 on J3 is the other leg of the compressor A1

feedback channel. It is connected to the 24-v common.

1. High-Pressure Switch Open — High-pressure switch for

each compressor is wired in series with 24-v power that

energizes compressor control relay. If high-pressure switch

opens during operation, compressor stops. This is

detected by microprocessor through the feedback

terminals.

2. DSIO-LV or DSIO-EXV Module Failure — If a DSIO-LV

relay module relay fails open or closed, microprocessor

detects this, locks compressor off, and indicates an

error.

3. Wiring Errors — If a wiring error exists causing CPCS,

CR, or feedback switch to not function properly, micro-

processor indicates an error.

4. Processor (PSIO) Failure — If hardware that monitors

feedback switch fails, or processor fails to energize relay

module relay to on, an error may be indicated.

NOTE: Similar connections for each compressor can be fol-

lowed on the unit wiring diagrams located on the unit.

Code 9

Leaving ﬂuid thermistor failure (alarm)

Code 10 Entering ﬂuid thermistor failure (alarm)

If temperature measured by these thermistors is outside

range of –40 to 240 F (–40 to 116 C), unit shuts down after

going through a normal pumpout. Reset is automatic if tem-

perature returns to the acceptable range, and unit start-up fol-

lows normal sequence. The cause of the fault is usually a

bad thermistor, wiring error, or loose connection.

NOTE: The control does not detect circuit breaker fail-

ures. If a circuit breaker trips on lead compressor in a

circuit, a low oil pressure failure is indicated. On the other

compressors, no failure is indicated.

Code 19

Code 20

Compressor A1 suction sensor failure (alert)

Compressor B1 suction sensor failure (alert)

5. Ground Fault Module on 130-210 and associated modu-

lar units (CGFA or CGFB) Open — Module contacts are

in lead compressor circuits, but ground fault could be in

any compressor in affected circuit.

On units with thermistors, if temperature measured by these

thermistors is outside the range of –40 to 240 F (–40 to

116 C), affected circuit shuts down after going through a nor-

mal pumpout. Other circuit continues to run. Reset is auto-

matic if temperature returns to the acceptable range, and cir-

cuit start-up follows normal sequence. The cause of this fault

is usually a bad thermistor, wiring error, or loose

connection.

On units with transducers, if the saturated suction tem-

perature is greater than the leaving ﬂuid temperature plus

10° F (5.5 C) for more than 5 minutes, the affected circuit

shuts down (after going through normal pumpout). The reset

is automatic if the saturated suction temperature returns to

the acceptable range and start-up follows the normal se-

quence. The cause of this fault is usually a bad transducer,

a wiring error, or a loose connection.

Ground fault of any 040-110 and associated modular unit

compressor (ﬁeld-supplied accessory on 040-060 and 070,

60 Hz units; standard on 070, 50 Hz and 80-110 and as-

sociated modular units) will cause a trip.

6. Checkout Procedure — Shut off main power to unit. Turn

on control power, then step through subfunc-

tion

to proper compressor number (i.e., failure

code 5 is compressor B1). Next, energize the step. If step

works correctly, then failure code is caused by:

• HPS (high-pressure switch) open

• Misplaced feedback wire from J4 and J5 terminals

• Ground wire and 24-v feeds reversed on one or more

points on J3

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LEGEND

—

Contactor

Circuit Breaker

COM, COMM

CPCS

Communications Bus

Compressor Protection

Control Module

—

Compressor Contactor Relay

Discharge Gas Thermostat (Optional)

Relay Module (Low Voltage)

High-Pressure Switch

Low Voltage

DGT

DSIO

HPS

Normally Closed

Normally Open

Plug

PWR

SNB

Power

Snubber

Terminal Block

TRAN

Transformer

Unloader

Fig. 11A — 24-V Safety Circuit Wiring (040-070)

Code 21 Reset thermistor failure (applies only to installa-

Code 27 Compressor B1 oil pressure transducer failure (alert)

tions having external temperature reset) (alert)

If output voltage of any of these transducers is greater than

5 v, affected circuit shuts down without going through pum-

pout process (Alerts 24-27). Other circuit continues to run.

Reset is automatic if output voltage returns to the acceptable

range, and circuit start-up follows normal sequence. The cause

of this fault is usually a bad transducer or a wiring error.

If temperature measured by this thermistor is outside range

of –40 to 240 F (–40 to 116 C), reset function is disabled and

unit controls to normal set point. If temperature returns to

the acceptable range, reset function is automatically en-

abled. The cause of this fault is usually a bad thermistor,

wiring error, or loose connection.

Code 28

Low transducer supply voltage (alarm)

Code 22 Compressor A1 discharge pressure

If transducer supply voltage is less than 4.5 v or greater

than 5.5 v, unit shuts down without going through pumpout

process. Reset is automatic if supply voltage returns to the

acceptable range, and circuit start-up follows normal se-

quence. The cause of this fault is usually a faulty trans-

former or primary voltage is out of range.

transducer failure (alert)

Code 23 Compressor B1 discharge pressure

transducer failure (alert)

Code 24 Compressor A1 suction pressure transducer

failure (alert)

Code 25 Compressor B1 suction pressure transducer

failure (alert)

Code 26 CompressorA1 oil pressure transducer failure (alert)

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LEGEND

—

Contactor

Circuit Breaker

COMM

CPCS

DGT

DSIO

HPS

Communications Bus

Compressor Protection Control Module

Discharge Gas Thermostat (Optional)

Relay Module (Low Voltage)

High-Pressure Switch

Low Voltage

*And associated modular units.

Plug

PWR

Power

Terminal Block

TRAN

Transformer

Unloader

Fig. 11B — 24-V Safety Circuit Wiring (080-110 and Associated Modular Units)

The voltage supplied to the processor is polarized. When

checking for proper voltage supply, be sure to consider this

polarity. If voltage appears to be within acceptable toler-

ance, check to be sure the transformer supplying PS1 is not

grounded. Grounding the supply transformer can result in

serious damage to the control system.

Loss of communication can be attributed to a grounded

transformer with a secondary voltage of 21 vac supplying

the PSIO, DSIO-LV, or 4 IN/4 OUT modules; the 12.5-vac

transformer supplying the DSIO-EXV module; or the

24-vac transformer supplying PS1 for the transformers.These

transformers should not be grounded, or serious damage to

controls can result. Check to be sure the transformers are

not grounded.

Code 29 LOCAL/ENABLE-STOP-CCN Switch Failure

(switch resistances out of range) (alarm)

NOTE: If a blank PSIO module is downloaded without be-

ing connected to the modules DSIO, this alarm is

energized.

Code 34 Loss of communication with 4 In/4 Out module

(alarm)

This fault occurs due to the failure of the switch or due to

a wiring error.

Code 30 Reset input failure (4 to 20 mA) (alert)

Code 31 Demand limit input failure (4 to 20 mA) (alert)

These codes apply only if unit is conﬁgured for these func-

tions. If 4 to 20 mA signal is less than 4 or more than

20 mA, reset or demand limit function is disabled and unit

functions normally. If mA signal returns to the acceptable

range, function is automatically enabled.

Code 32 Loss of communication with compressor

relay module (DISO-LV) (alarm)

Code 33 Loss of communication with EXV relay

module (DSIO-EXV) (alarm)

This applies only if one or more of the following options

are used:

• external temperature reset

• 4 to 20 mA temperature reset

• external switch controlled dual set point

• switch controlled demand limit

• 4 to 20 mA demand limit

• hot gas bypass

If communication is lost with 4 IN/4 OUT module, the

unit shuts off automatically, after ﬁnishing pumpout. Reset

of alarm is automatic when communication is restored. Start-up

after alarm is remedied follows a normal sequence. Probable

cause of condition is a faulty or improperly connected plug,

wiring error, or faulty module.

If communication is lost with either of these modules, unit

shuts down without pumpout. This alarm resets automati-

cally when communication is restored. The unit starts up nor-

mally after alarm condition is reset. Probable cause of con-

dition is a faulty or improperly connected plug, wiring error,

or faulty module.

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LEGEND

—

Circuit Breaker

CGF

COMM

Ground Fault Module

Communications Bus

Compressor Contactor Relay

Relay Module (Low Voltage)

High-Pressure Switch

Low Voltage

DSIO

HPS

*And associated modular units.

Plug

SNB

Snubber

Terminal Block

TRAN

Transformer

Unloader

Fig. 11C — 24-V Safety Circuit Wiring (130-210 and Associated Modular Units)

Loss of communication can be attributed to a grounded

transformer with a secondary voltage of 21 vac supplying

the PSIO, DSIO-LV, or 4 IN/4 OUT; the 12.5-vac trans-

former supplying the DSIO-EXV module, or the 24-vac trans-

former supplying PS1 for the transformers.These transformers

should not be grounded, or serious damage to controls can

result. Check to be sure the transformers are not grounded.

Possible causes of fault are low refrigerant charge, faulty

EXV, plugged ﬁlter drier, or faulty transducer.

Code 38 Failure to pump out, Circuit A (alert)

Code 39 Failure to pump out, Circuit B (alert)

The pumpout process is terminated when saturated suc-

tion temperature is 10° F (5.6° C) below temperature at be-

ginning of pumpout, or 10° F (5.6° C) below leaving water

temperature or reaches a saturated suction temperature of

–15 F (–26 C). If appropriate saturated suction temperature

is not met within 3 minutes (on 2 consecutive tries), circuit

shuts down without pumpout. Reset is manual with LOCAL/

ENABLE-STOP-CCN switch, and start-up follows normal

sequence.

Code 36 Low refrigerant pressure, Circuit A (alert)

Code 37 Low refrigerant pressure, Circuit B (alert)

If suction pressure transducer senses a pressure below set

point for more than 5 minutes at start-up or more than

2 minutes during normal operation, affected circuit shuts down

without going through the pumpout process. Reset is auto-

matic when pressure reaches 10 psig above set point if there

have been no previous occurrences of this fault on the same

day. If this is a repeat occurrence on same day, then reset is

manual, with LOCAL/ENABLE-STOP-CCN switch. Fac-

tory conﬁgured set point is 27 psig for standard chillers and

12 psig for brine chillers.

Possible causes for this alarm are a bad thermistor or trans-

ducer or a faulty expansion valve.

Code 40 Low oil pressure, Circuit A (alert)

Code 41 Low oil pressure, Circuit B (alert)

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If oil pressure differential is less than set point for more

than 2 minutes at start-up, or more than one minute during

normal operation, affected circuit shuts down without going

through pumpout process. Reset is manual with LOCAL/

ENABLE-STOP-CCN switch, and start-up follows normal

sequence. Factory conﬁgured differential oil pressure is

6 psig.

Possible causes of fault are faulty compressor, expansion

valve, crankcase heater or transducer, refrigerant over-

charge, insufficient oil charge, or tripped circuit breaker.

Code 50 Illegal conﬁguration (alarm)

This fault indicates a conﬁguration error. Unit is not al-

lowed to start. Check all conﬁguration data and set points

and correct any errors.

Code 51 Initial conﬁguration required (alarm)

This fault indicates factory conﬁguration has not been done,

and unit is not allowed to start. Refer to unit wiring

label diagrams for factory conﬁguration codes. There are

9 groups of 8-digit numbers that must be entered. The ﬁrst

7 groups must be entered under

subfunction. Groups

Code 42 Cooler freeze protection (alarm)

8 and 9 must be entered under

subfunction.

If cooler entering or leaving water temperature is below

34° F (1.1° C) for water or more than 8° F (4.4° C) below

set point for brine, unit shuts down without pumpout. Chilled

water pump continues to run if controlled by chiller con-

trols. Reset is automatic when leaving ﬂuid temperature reaches

6° F (3° C) above set point, providing there has been no prior

occurrence of this fault the same day. If fault has occurred

previously the same day, reset is manual with LOCAL/

ENABLE-STOP-CCN switch.

Enter each group, then press the

key. Press the

down arrow

after each group to bring up the next

empty screen. Unit should start after factory and ﬁeld con-

ﬁgurations are correctly entered.

The usual cause of this fault is replacement of the pro-

cessor module. Refer to instructions accompanying the re-

placement module.

Possible causes of fault are low ﬂuid ﬂow or faulty

thermistor.

Code 52 Emergency stop by CCN command (alarm).

Unit shuts down immediately without pumpout when this

command is received, and goes through normal start-up when

command is cancelled.

Code 43 Low ﬂuid ﬂow (alarm)

If any compressors are operating and entering ﬂuid tem-

perature is 3° F (1.7° C) or more below leaving ﬂuid tem-

perature for more than one minute, unit shuts down without

pumpout. Chilled ﬂuid pump also shuts down. Reset is manual

with LOCAL/ENABLE-STOP-CCN switch, and start-up fol-

lows normal sequence.

This is a suitable method for sensing low ﬂuid ﬂow be-

cause entering ﬂuid thermistor is in the cooler shell and re-

sponds more quickly to compressor operation than the leav-

ing ﬂuid thermistor in the leaving water nozzle. Possible causes

of fault are faulty chilled ﬂuid pump, control or thermistor.

Code 53 Cooler pump interlock failure — Contacts fail to

close at start-up (alarm)

If the unit is conﬁgured for cooler pump control and cooler

pump interlock, and the interlock fails to close within one

minute of starting the cooler pump, the unit is shut down

without pumpout. The cooler pump is also shut down. Reset

is manual with the LOCAL/ENABLE-STOP-CCN switch,

and start-up follows the normal sequence.

Possible causes are:

Code 44 Low cooler suction temperature, Circuit A (alert)

Code 45 Low cooler suction temperature, Circuit B (alert)

1. Interlock switch fails to close within one minute after chilled

water pump starts

If saturated suction temperature is less than 32 F (0°C)

and is 20° F (11° C) for water or 30° F (16° C) for brine or

more below leaving ﬂuid temperature, mode 14 is dis-

played. Unit continues to run, but additional compressors are

not allowed to start. If condition persists for more than

10 minutes, fault code is displayed, and unit shuts down with-

out pumpout. Reset is manual with LOCAL/ENABLE-STOP-

CCN switch, and start-up follows normal sequence.

Possible causes of fault are low refrigerant charge, plugged

ﬁlter drier, or a faulty expansion valve or thermistor.

Code 46 High suction superheat, Circuit A (alert)

Code 47 High suction superheat, Circuit B (alert)

If expansion valve is fully open, suction superheat is greater

than 75 F (42 C), and saturated evaporator temperature is

less than MOP (maximum operating pressure) for more than

5 minutes, unit shuts down after normal pumpout process.

Reset is manual with LOCAL/ENABLE-STOP-CCN switch,

and start-up follows normal sequence.

Possible causes of fault are low refrigerant charge, plugged

ﬁlter drier, or a faulty expansion valve or thermistor.

Code 48 Low suction superheat, Circuit A (alert)

Code 49 Low suction superheat, Circuit B (alert)

2. Interlock switch opens during unit operation

3. Interlock voltage is detected, but unit is not conﬁgured

for interlock

4. Interlock voltage is outside its valid range

If any of these conditions occur, all compressors are dis-

abled and, if running, shutdown occurs without pumpout.

Chilled ﬂuid pump also shuts down. Reset is manual, with

LOCAL/ENABLE-STOP-CCN switch. Most probable cause

of this fault is shutdown or failure of chilled ﬂuid pump to

start. Other possibilities are improper conﬁguration or wir-

ing errors.

Code 54 Cooler pump interlock failure — Contacts open

during normal operation (alarm)

If the unit is conﬁgured for cooler pump control and cooler

pump interlock, and the interlock opens during normal op-

eration, the unit is shut down without pumpout. The cooler

pump is also shut down. Reset is manual with the LOCAL/

ENABLE-STOP-CCN switch, and startup follows the nor-

mal sequence.

Possible causes are:

1. Interlock switch fails to close within one minute after chilled

water pump starts

If EXV is at minimum position, suction superheat is less

than 10° F (5.5° C) or saturated evaporator temperature is

greater than MOP (maximum operating pressure) for more

than 5 minutes, affected circuit shuts down after going through

pumpout process. Reset is manual with LOCAL/ENABLE-

STOP-CCN switch, and start-up follows normal sequence.

2. Interlock switch opens during unit operation

3. Interlock voltage is detected, but unit is not conﬁgured

for interlock

4. Interlock voltage is outside its valid range

If any of these conditions occur, all compressors are dis-

abled and, if running, shutdown occurs without pumpout.

Chilled ﬂuid pump also shuts down. Reset is manual, with

Possible causes of fault are faulty expansion valve or

thermistor.

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LOCAL/ENABLE-STOP-CCN switch. Most probable cause

of this fault is shutdown or failure of chilled ﬂuid pump to

start. Other possibilities are improper conﬁguration or wir-

ing errors.

15 psig. This alarm does not function in units using different

part number transducers for suction and discharge pressure,

since the discharge transducer in that application does not

function below 20 psig.

Code 55 Cooler pump interlock failure — Contacts closed

Code 66 Flotronic™ System Manager loss of communi-

when pump is off (alarm)

cations (alarm)

If the unit is conﬁgured for cooler pump control and cooler

pump interlock, and the interlock is closed when the cooler

pump relay is off, the cooler pump shall be shut down and

the unit prevented from starting. Reset is manual with the

LOCAL/ENABLE-STOP-CCN switch.

Possible causes are:

1. Interlock switch fails to close within one minute after chilled

water pump starts

If the FSM has established communication with the con-

trol, and the communication is subsequently lost for more

than 20 seconds, the control will remove all forces on the

chiller variables. Control of the unit will revert to stand-

alone basis, and reset is automatic upon re-establishment of

communication.

Code 67 Transducer calibration failure due to incorrect date

code (alarm)

This applies to units having pressure transducers with the

same part number for both suction and discharge pressures.

If the transducer calibration is attempted and the factory de-

fault date code (Jan. 1, 1980) is in the date variable, then the

unit will not start. Reset is automatic when the proper date

code is entered upon calibration.

2. Interlock switch opens during unit operation

3. Interlock voltage is detected, but unit is not conﬁgured

for interlock

4. Interlock voltage is outside its valid range

If any of these conditions occur, all compressors are dis-

abled and, if running, shutdown occurs without pumpout.

Chilled ﬂuid pump also shuts down. Reset is manual, with

LOCAL/ENABLE-STOP-CCN switch. Most probable cause

of this fault is shutdown or failure of chilled ﬂuid pump to

start. Other possibilities are improper conﬁguration or wir-

ing errors.

Code 70 High leaving chilled ﬂuid temperature (alert)

If the leaving chilled ﬂuid temperature is rising and is

higher than the limit established in the

subfunction

and the unit is at full capacity then alert 70 will be activated.

The unit will continue to function normally, and reset will

be automatic upon leaving chilled ﬂuid temperature drop-

ping to 5° F below the limit or less than control

set point.

Code 56 Water System Manager (WSM) communication

failure (alert)

If the WSM has previously established communications

with the control and the WSM is not disabled and has not

communicated with the control within the last 5 minutes, the

control will remove all WSM forces from the chillers vari-

ables. The chiller will continue to operate on a stand-alone

basis. Reset is automatic when the WSM re-establishes com-

munication with the unit.

Code 57 Calibration required for discharge pressure trans-

ducer, circuit A (alert)

Code 58 Calibration required for discharge pressure trans-

ducer, circuit B (alert)

If the discharge pressure transducer has not been success-

fully calibrated, the circuit will not start. Reset is automatic

upon successful calibration of the transducer.

Code 59 Calibration required for suction pressure trans-

ducer, circuit A (alert)

Code 60 Calibration required for suction pressure trans-

ducer, circuit B (alert

Electronic Expansion Valve (EXV)

NOTE: This applies to all units except 30GN040 and 045

with optional brine. The 040 and 045 units with optional brine

have TXVs.

EXV OPERATION — These valves control the ﬂow of liq-

uid refrigerant into the cooler. They are operated by the pro-

cessor to maintain a speciﬁed superheat at lead compressor

entering gas thermistor (located between compressor motor

and cylinders). There is one EXV per circuit. See

Fig. 12.

High-pressure liquid refrigerant enters valve through bot-

tom. A series of calibrated slots are located in side of oriﬁce

assembly. As refrigerant passes through oriﬁce, pressure drops

and refrigerant changes to a 2-phase condition (liquid and

If the suction pressure transducer has not been success-

fully calibrated, the circuit will not start. Reset is automatic

upon successful calibration of the transducer.

Code 61 Calibration required for oil pressure transducer,

circuit A (alert)

Code 62 Calibration required for oil pressure transducer,

circuit B (alert)

If the oil pressure transducer has not been successfully

calibrated, the circuit will not start. Reset is automatic upon

successful calibration of the transducer.

Code 63 Complete unit shutdown due to failure (alarm)

This alarm alerts the user that the unit is totally shut down

due to one or more fault conditions. Reset is automatic when

all alarms causing complete unit shutdown are reset.

Code 64 Loss of charge, circuit A (alert)

Code 65 Loss of charge, circuit B (alert)

If the unit uses suction and discharge transducers with the

same part number, and the discharge pressure is below

10 psig when the unit is shut down, the circuit will not start.

Reset is automatic when the discharge pressure rises above

Fig. 12 — Electronic Expansion Valve (EXV)

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vapor). To control refrigerant ﬂow for different operating con-

ditions, sleeve moves up and down over oriﬁce, thereby chang-

ing oriﬁce size. Sleeve is moved by a linear stepper motor.

Stepper motor moves in increments and is controlled di-

rectly by the processor module. As stepper motor rotates,

motion is transferred into linear movement by lead screw.

Through stepper motor and lead screws, 1500 discrete steps

of motion are obtained. The large number of steps and long

stroke result in very accurate control of refrigerant ﬂow.

The

subfunction shows EXV valve position as

a percent of full open. Position should change constantly while

unit operates. If a valve stops moving for any reason (me-

chanical or electrical) other than a processor or thermistor

failure, the processor continues to attempt to open or close

the valve to correct the superheat. Once the calculated valve

position reaches 120 (fully closed) or 1500 (fully open), it

remains there. If EXV position reading remains at 120 or

1500, and the thermistors and pressure transducers are read-

ing correctly, the EXV is not moving. Follow EXV checkout

procedure below to determine cause.

EXV

—

Electronic Expansion Valve

Fig. 13 — EXV Cable Connections to EXV Driver

Module, DSIO (EXV)

The EXV is also used to limit cooler suction temperature

to 50 F (10 C). This makes it possible for chiller to start at

higher cooler ﬂuid temperatures without overloading com-

pressor. This is commonly referred to as MOP (maximum

operating pressure), and serves as a load limiting device to

prevent compressor motor overloading. This MOP or load

limiting feature enables the 30G Flotronic™ II chillers to

operate with up to 95 F (35 C) entering ﬂuid temperatures

during start-up and subsequent pull-down.

Control of valve is by microprocessor. A thermistor and

a pressure transducer located in lead compressor are used

to determine superheat. The thermistor measures tem-

perature of the superheated gas entering the compressor

cylinders. The pressure transducer measures refrigerant

pressure in the suction manifold. The microprocessor con-

verts pressure reading to a saturation temperature. The

difference between temperature of superheated gas and

saturation temperature is the superheat.

Because the EXVs are controlled by the processor mod-

ule, it is possible to track valve position. During initial

start-up, EXV is fully closed. After start-up, valve posi-

tion is tracked by processor by constantly observing amount

of valve movement.

The processor keeps track of EXV position by counting

the number of open and closed steps it has sent to each

valve. It has no direct physical feedback of valve posi-

tion. Whenever unit is switched from STOP to RUN po-

sition, both valves are initialized, allowing the processor

to send enough closing pulses to the valve to move it from

fully open to fully closed, then reset the position counter

to zero.

CHECKOUT PROCEDURE — Follow steps below to di-

agnose and correct EXV problems.

1. Check EXV driver outputs. Check EXV output signals at

appropriate terminals on EXV driver module (see

Fig. 13) as follows:

Connect positive test lead to terminal 1 on EXV driver.

Set meter for approximately 20 vdc. Enter outputs

subfunction of test function by pressing

advance to EXVA test by pressing

, then

10 times. Press

. The driver should drive the circuit A

EXV fully open. During next several seconds connect nega-

tive test lead to pins 2, 3, 4, and 5 in succession. Voltage

should rise and fall at each pin. If it remains constant at

a voltage or at zero v, remove connector to valve and

recheck.

4. The EXV test can be used to drive EXV to any desired

position. When EXV opens, the metering slots begin to

provide enough refrigerant for operation at step 120. This

is fully closed position when circuit is operating. The fully

open position is 1500 steps.

Press

to close circuit A EXV. If a problem still

exists, replace EXV driver module. If voltage reading is

correct, expansion valve should be checked. Next, test

EXVB. Connect positive test lead to pin 7 and the nega-

tive test lead to pin 8, 9, 10, and 11 in succession during

EXVB test.

5. Check thermistors and pressure transducers that control

EXV. Check thermistors and pressure transducers that con-

trol processor output voltage pulses to EXVs. See Fig. 14

for locations.

Circuit A — Thermistor T7, Suction Pressure Transducer

2. Check EXV wiring. Check wiring to electronic expan-

sion valves from terminal strip on EXV driver. See

Fig. 13.

SPTA

Circuit B — Thermistor T8, Suction Pressure Transducer

SPTB

a. Check color coding and wire connections. Make sure

they are connected to correct terminals at driver and

EXV plug connections.

b. Check for continuity and tight connection at all pin

terminals.

a. Use temperature subfunction of the status function

(

) to determine if thermistors are reading

correctly.

b. Check thermistor calibration at known temperature by

measuring actual resistance and comparing value mea-

sured with values listed in Tables 17 and 18.

c. Check plug connections at driver and at EXVs to be

sure EXV cables are not crossed.

c. Make sure thermistor leads are connected to proper

pin terminals at J7 terminal strip on processor module

and that thermistor probes are located in proper posi-

tion in refrigerant circuit. See Fig. 15 and 16.

3. Check resistance of EXV motor windings. Remove plug

at J4 terminal strip and check resistance between com-

mon lead (red wire, terminal D) and remaining leads, A,

B, C, and E (see Fig. 13). Resistance should be

25 ohms Ϯ 2 ohms.

d. Use the pressure subfunction of the Status function

(

) to determine if pressure transducers are

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reading correctly. Connect a calibrated gage to lead

compressor suction or discharge pressure connection

to check transducer reading.

Other possible causes of improper refrigerant ﬂow con-

trol could be restrictions in liquid line. Check for plugged

ﬁlter drier(s) or restricted metering slots in the EXV. For-

mation of ice or frost on lower body of electronic ex-

pansion valve is one symptom of restricted metering slots.

However, frost or ice formation is normally expected when

leaving ﬂuid temperature from the cooler is below 40 F.

Clean or replace valve if necessary.

NOTE: Frosting of valve is normal during compressor

test steps and at initial start-up. Frost should dissipate af-

ter 5 to 10 minutes operation in 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.

e. Make sure transducer leads are properly connected in

junction box and at processor board. Check trans-

former 5 output. Check voltage transducer 5 vdc

Ϯ .2 v.

When above checks have been completed, check ac-

tual operation of EXV by using procedures outlined in

this step.

6. Check operation of EXV.

a. Close liquid line service valve of circuit to be checked,

and run through the test step (

) for lead com-

pressor in that circuit to pump down low side of sys-

tem. Repeat test step 3 times to ensure all refrigerant

has been pumped from low side.

NOTE: Be sure to allow compressors to run for the

full pumpout period.

Thermostatic Expansion Valve (TXV) — Refer to

base unit Installation Instructions for TXV information

(30GN040,045 with optional brine only).

Thermistors — All thermistors are identical in their tem-

perature vs. resistance performance. Resistance at various tem-

peratures are listed in Tables 17 and 18.

b. Turn off compressor circuit breaker(s). Close com-

pressor discharge service valves and remove any re-

maining refrigerant from low side of system.

c. Remove screws holding top cover of EXV. Carefully

remove top cover. If EXV plug was disconnected dur-

ing this process, reconnect it after cover is removed.

LOCATION — General location of thermistor sensors are

shown in Fig. 14.

Cooler Leaving Fluid Thermistor (T1) — T1 is located in

leaving ﬂuid nozzle. The probe is immersed directly in the

ﬂuid. All thermistor connections are made through a ⁄4-in.

coupling. See Fig. 16. Actual location is shown in Fig. 14

and 15.

When removing top cover, be careful to avoid dam-

aging motor leads.

Cooler Entering Fluid Thermistor (T2) — T2 is located in

cooler shell in ﬁrst baffle space near tube bundle. Thermistor

d. Enter appropriate EXV test step for EXVA or

EXVB in the outputs subfunction of the test function

connection is made through a ⁄4-in. coupling. See Fig. 16.

Actual location is shown in Fig. 14 and 15.

Compressor Suction Gas Temperature Thermistors (T7 and

T8) — T7 and T8 are located in lead compressor in each

circuit in suction passage between motor and cylinders, above

oil pump. They are well-type thermistors. See Fig. 14

and 15.

(

). Press

to initiate test. With

cover lifted off EXV valve body, observe operation of

valve motor and lead screw. The motor should turn

counterclockwise, and the lead screw should move up

out of motor hub until valve is fully open. Lead screw

movement should be smooth and uniform from

fully closed to fully open position. Press

check open to closed operation.

THERMISTOR REPLACEMENT (T1, T2, T7, T8)

If valve is properly connected to processor and receiv-

ing correct signals, yet does not operate as described

above, valve should be replaced.

Thermistors are installed directly in ﬂuid Relieve all pres-

sure using standard practices or drain ﬂuid before re-

moving.

Operation of EXV valve can also be checked without

removing top cover. This method depends on opera-

tor’s skill in determining whether or not valve is mov-

ing. To use this method, initiate EXV test and open

valve. Immediately grasp EXV valve body. As valve

drives open, a soft, smooth pulse is felt for approxi-

mately 26 seconds as valve travels from fully closed

to fully open. When valve reaches end of its opening

stroke, a hard pulse is felt momentarily. Drive valve

closed and a soft, smooth pulse is felt for the 52 sec-

onds necessary for valve to travel from fully open to

fully closed. When valve reaches end of its stroke, a

hard pulse is again felt as valve overdrives by 50 steps.

Valve should be driven through at least 2 complete cycles

to be sure it is operating properly. If a hard pulse is

felt for the 26-second duration, valve is not moving

and should be replaced.

Proceed as follows (see Fig. 16):

To replace thermistor sensor T2:

1. Remove and discard original thermistor and coupling.

IMPORTANT: Do not disassemble new coupling.

Install as received.

2. Apply pipe sealant to ¹⁄4-in. NPT threads on replacement

coupling and install in place of original. Do not use pack-

ing nut to tighten coupling. This damages ferrules (see

Fig. 16).

3. Insert new thermistor in coupling body to its full depth.

If thermistor bottoms out before full depth is reached, pull

thermistor back out ¹⁄8 in. before tightening packing nut.

Hand tighten packing nut to position ferrules, then ﬁnish

tightening 1¹⁄4 turns with a suitable tool. Ferrules are now

attached to thermistor which can be withdrawn from cou-

pling for unit servicing.

The EXV test can be repeated as required by enter-

ing any percentage from 0 (

movement.

) to 100 to initiate

To replace thermistors T1, T7, and T8:

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.

Add a small amount of thermal conductive grease to ther-

mistor well. Thermistors are friction-ﬁt thermistors, which

must be slipped into well located in the compressor pump

end.

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Table 17 — Thermistor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ II

TEMPERATURE

(F)

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

TEMPERATURE

(F)

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

TEMPERATURE

(F)

VOLTAGE

DROP (V)

RESISTANCE

(OHMS)

−25.0

−24.0

−23.0

−22.0

−21.0

−20.0

−19.0

−18.0

−17.0

−16.0

−15.0

−14.0

−13.0

−12.0

−11.0

−10.0

−9.0

−8.0

−7.0

−6.0

−5.0

−4.0

−3.0

−2.0

−1.0

0.0

4.821

4.818

4.814

4.806

4.800

4.793

4.786

4.779

4.772

4.764

4.757

4.749

4.740

4.734

4.724

4.715

4.705

4.696

4.688

4.676

4.666

4.657

4.648

4.636

4.624

4.613

4.602

4.592

4.579

4.567

4.554

4.540

4.527

4.514

4.501

4.487

4.472

4.457

4.442

4.427

4.413

4.397

4.381

4.366

4.348

4.330

4.313

4.295

4.278

4.258

4.241

4.223

4.202

4.184

4.165

4.145

4.125

4.103

4.082

4.059

4.037

4.017

3.994

3.968

3.948

3.927

3.902

3.878

3.854

3.828

3.805

3.781

3.757

3.729

3.705

3.679

3.653

3.627

3.600

3.575

3.547

3.520

3.493

3.464

3.437

3.409

3.382

3.353

3.323

3.295

3.267

3.238

3.210

3.181

3.152

3.123

98010

94707

91522

88449

85486

82627

79871

77212

74648

72175

69790

67490

65272

63133

61070

59081

57162

55311

53526

51804

50143

48541

46996

45505

44066

42679

41339

40047

38800

37596

36435

35313

34231

33185

32176

31202

30260

29351

28473

27624

26804

26011

25245

24505

23789

23096

22427

21779

21153

20547

19960

19393

18843

18311

17796

17297

16814

16346

15892

15453

15027

14614

14214

13826

13449

13084

12730

12387

12053

11730

11416

11112

10816

10529

10250

9979

3.093

3.064

3.034

3.005

2.977

2.947

2.917

2.884

2.857

2.827

2.797

2.766

2.738

2.708

2.679

2.650

2.622

2.593

2.563

2.533

2.505

2.476

2.447

2.417

2.388

2.360

2.332

2.305

2.277

2.251

2.217

2.189

2.162

2.136

2.107

2.080

2.053

2.028

2.001

1.973

1.946

1.919

1.897

1.870

1.846

1.822

1.792

1.771

1.748

1.724

1.702

1.676

1.653

1.630

1.607

1.585

1.562

1.538

1.517

1.496

1.474

1.453

1.431

1.408

1.389

1.369

1.348

1.327

1.308

1.291

1.289

1.269

1.250

1.230

1.211

1.192

1.173

1.155

1.136

1.118

1.100

1.082

1.064

1.047

1.029

1.012

0.995

0.978

0.962

0.945

0.929

0.914

0.898

0.883

0.868

0.853

5781

5637

5497

5361

5229

5101

4976

4855

4737

4622

4511

4403

4298

4196

4096

4000

3906

3814

3726

3640

3556

3474

3395

3318

3243

3170

3099

3031

2964

2898

2835

2773

2713

2655

2597

2542

2488

2436

2385

2335

2286

2239

2192

2147

2103

2060

2018

1977

1937

1898

1860

1822

1786

1750

1715

1680

1647

1614

1582

1550

1519

1489

1459

1430

1401

1373

1345

1318

1291

1265

1240

1214

1190

1165

1141

1118

1095

1072

1050

1029

1007

986

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

0.838

0.824

0.810

0.797

0.783

0.770

0.758

0.745

0.734

0.722

0.710

0.700

0.689

0.678

0.668

0.659

0.649

0.640

0.632

0.623

0.615

0.607

0.600

0.592

0.585

0.579

0.572

0.566

0.560

0.554

0.548

0.542

0.537

0.531

0.526

0.520

0.515

0.510

0.505

0.499

0.494

0.488

0.483

0.477

0.471

0.465

0.459

0.453

0.446

0.439

0.432

0.425

0.417

0.409

0.401

0.393

0.384

0.375

0.366

719

705

690

677

663

650

638

626

614

602

591

581

570

561

551

542

533

524

516

508

501

494

487

480

473

467

461

456

450

445

439

434

429

424

419

415

410

405

401

396

391

386

382

377

372

367

361

356

350

344

338

332

325

318

311

304

297

289

282

1.0

2.0

3.0

4.0

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

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

26.0

27.0

28.0

29.0

30.0

31.0

32.0

33.0

34.0

35.0

36.0

37.0

38.0

39.0

40.0

41.0

42.0

43.0

44.0

45.0

46.0

47.0

48.0

49.0

50.0

51.0

52.0

53.0

54.0

55.0

56.0

57.0

58.0

59.0

60.0

61.0

62.0

63.0

64.0

65.0

66.0

67.0

68.0

69.0

70.0

9717

9461

9213

8973

8739

8511

8291

965

8076

945

7868

925

7665

906

7468

887

7277

868

7091

850

6911

832

6735

815

6564

798

6399

782

6238

765

6081

750

5929

734

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Table 18 — Thermistor Temperature (°C) vs Resistance/Voltage Drop; Flotronic™ II

TEMPERATURE

(C)

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

TEMPERATURE

(C)

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

−40

−39

−38

−37

−36

−35

−34

−33

−32

−31

−30

−29

−28

−27

−26

−25

−24

−23

−22

−21

−20

−19

−18

−17

−16

−15

−14

−13

−12

−11

−10

−9

4.896

4.889

4.882

4.874

4.866

4.857

4.848

4.838

4.828

4.817

4.806

4.794

4.782

4.769

4.755

4.740

4.725

4.710

4.693

4.676

4.657

4.639

4.619

4.598

4.577

4.554

4.531

4.507

4.482

4.456

4.428

4.400

4.371

4.341

4.310

4.278

4.245

4.211

4.176

4.140

4.103

4.065

4.026

3.986

3.945

3.903

3.860

3.816

3.771

3.726

3.680

3.633

3.585

3.537

3.487

3.438

3.387

3.337

3.285

3.234

3.181

3.129

3.076

3.023

2.970

2.917

2.864

2.810

2.757

2.704

2.651

2.598

2.545

2.493

2.441

2.389

2.337

2.286

2.236

2.186

2.137

2.087

2.039

1.991

168 230

157 440

147 410

138 090

129 410

121 330

113 810

106 880

100 260

94 165

88 480

83 170

78 125

73 580

69 250

65 205

61 420

57 875

54 555

51 450

48 536

45 807

43 247

40 845

38 592

38 476

34 489

32 621

30 866

29 216

27 633

26 202

24 827

23 532

22 313

21 163

20 079

19 058

18 094

17 184

16 325

15 515

14 749

14 026

13 342

12 696

12 085

11 506

10 959

10 441

9 949

100

101

102

103

104

105

106

107

1.944

1.898

1.852

1.807

1.763

1.719

1.677

1.635

1.594

1.553

1.513

1.474

1.436

1.399

1.363

1.327

1.291

1.258

1.225

1.192

1.160

1.129

1.099

1.069

1.040

1.012

0.984

0.949

0.920

0.892

0.865

0.838

0.813

0.789

0.765

0.743

0.722

0.702

0.683

0.665

0.648

0.632

0.617

0.603

0.590

0.577

0.566

0.555

0.545

0.535

0.525

0.515

0.506

0.496

0.486

0.476

0.466

0.454

0.442

0.429

0.416

0.401

0.386

0.370

2 272

2 184

2 101

2 021

1 944

1 871

1 801

1 734

1 670

1 609

1 550

1 493

1 439

1 387

1 337

1 290

1 244

1 200

1 158

1 118

1 079

1 041

1 006

971

938

906

876

836

805

775

747

719

−8

693

−7

669

−6

645

−5

623

−4

602

−3

583

−2

564

−1

547

531

516

502

489

477

466

456

446

436

427

419

9 485

410

9 044

402

8 627

393

8 231

385

7 855

376

7 499

367

7 161

357

6 840

346

6 536

335

6 246

324

5 971

312

5 710

299

5 461

285

5 225

5 000

4 786

4 583

4 389

4 204

4 028

3 861

3 701

3 549

3 404

3 266

3 134

3 008

2 888

2 773

2 663

2 559

2 459

2 363

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LEGEND

DPT

EXV

OPT

SPT

—

Discharge Pressure Transducer

Electronic Expansion Valve

Oil Pressure Transducer

Suction Pressure Transducer

Thermistor Number

Fig. 14 — Thermistor and Pressure Transducer Locations

Pressure Transducers — A single style of pressure

transducer is used for both high- and low-pressure sensing

on Flotronic™ II chillers. However, this transducer must be

calibrated before the unit will operate. On new units, this

will have been done at the factory in order to test run the

unit. If a transducer or PSIO is replaced in the ﬁeld, how-

ever, the transducer will have to be ﬁeld calibrated as

follows:

4. Press

on the HSIO keypad. This automatically ap-

plies the proper correction factor to all future inputs from

the transducer.

Three pressure transducers are mounted on each lead com-

pressor: 2 low-pressure transducers to monitor compressor

suction pressure and oil pressure, and a high-pressure trans-

ducer to monitor compressor discharge pressure (see

Fig. 17 for exact locations on compressor). Each transducer

is supplied with 5 vdc power from a rectiﬁer which changes

24 vac to 5 vdc.

1. Disconnect transducer from the system.

2. Hang the transducer in the atmosphere.

3. Press

on the HSIO keypad, and Read the pres-

TROUBLESHOOTING — If transducer is suspected of be-

ing faulty, ﬁrst check supply voltage to transducer. Supply

voltage should be 5 vdc ± .2 v. If supply voltage is correct,

compare pressure reading displayed on keypad and display

module against pressure shown on a calibrated pressure gage.

If the 2 pressure readings are not reasonably close, replace

pressure transducer.

sure. Pressures before calibration must be within the

range of Ϯ 5 psig. If the pressure is outside the range of

Ϯ 5 psig, the HSIO display will read ---. If this is the

case, replace the transducer or PSIO or check for a wir-

ing error. If the value of the atmospheric pressure is greater

than 5 psig or less than –5 psig, the transducer will be

considered out of range and will not calibrate.

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Fig. 15 — Thermistor Locations

(Circuits A and B, Lead Compressor Only)

COMPRESSOR SUCTION GAS TEMPERATURE

FLUID-SIDE TEMPERATURE THERMISTOR T2

(ALL UNITS)

THERMISTORS T7 AND T8

(ALL UNITS) AND FLUID-SIDE TEMPERATURE

THERMISTOR T1 (ALL UNITS)

Fig. 16 — Thermistors

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Fig. 17 — Lead Compressor Transducer and Thermistor Locations

TRANSDUCER REPLACEMENT

3. Unscrew transducer from ⁄4-in. male ﬂare ﬁtting. When

installing new pressure transducer, do not use thread

sealer. Thread sealer can plug transducer and render it

inoperative.

Transducers are installed directly in the refrigerant cir-

cuit. Relieve all refrigerant pressure using standard re-

frigeration practices before removing.

4. Insert weathertight wiring plug into end of transducer un-

til locking tab snaps in place.

5. Check for refrigerant leaks.

1. Relieve refrigerant pressure using standard refrigeration

practices.

2. Disconnect transducer wiring at transducer by pulling up

on locking tab while pulling weathertight connection plug

from end of transducer. Do not pull on transducer wires.

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Control Modules

Turn controller power off before servicing controls. This

ensures safety and prevents damage to controller.

PROCESSOR MODULE (PSIO), 4 IN/4 OUT MODULE

(SIO), LOW-VOLTAGE RELAY MODULE (DSIO-LV),

AND EXV DRIVER MODULE (DSIO-EXV) — The PSIO,

DSIO and SIO modules all perform continuous diagnostic

evaluations of the condition of the hardware. Proper opera-

tion of these modules is indicated by LEDs (light-emitting

diodes) on the front surface of the DSIOs, and on the top

horizontal surface of the PSIO and SIO.

RED LED — Blinking continuously at a 3- to 5-second rate

indicates proper operation. Lighted continuously indicates a

problem requiring replacement of module. Off continuously

indicates power should be checked. If there is no input power,

check fuses. If fuse is bad, check for shorted secondary of

transformer or for bad module. On the PSIO module, if the

light is blinking at a rate of twice per second, the module

should be replaced.

GREEN LED — On a PSIO and an SIO, this is the green

LED closest to COMM connectors. The other green LED on

module indicates external communications, when used. Green

LED should always be blinking when power is on. It indi-

cates modules are communicating properly. If green LED is

not blinking, check red LED. If red LED is normal, check

module address switches. See Fig. 18. Proper addresses are:

PSIO (Processor Module) — 01 (different when CCN

connected)

DSIO (Relay Module) — 19

DSIO (EXV Driver Module) — 31

SIO

(4 In/4 Out Module) — 59

If all modules indicate communication failure, check COMM

plug on PSIO module for proper seating. If a good connec-

tion is assured and condition persists, replace PSIO module.

If only DSIO or SIO module indicates communication fail-

ure, check COMM plug on that mode for proper seating. If

a good connection is assured and condition persists, replace

DSIO or SIO module.

All system operating intelligence rests in PSIO module,

the module that controls unit. This module monitors condi-

tions through input and output ports and through DSIO mod-

ules (low-voltage relay module and EXV driver module).

The machine operator communicates with microproces-

sor through keypad and display module. Communication be-

tween PSIO and other modules is accomplished by a 3-wire

sensor bus. These 3 wires run in parallel from module to

module.

On sensor bus terminal strips, terminal 1 of PSIO module

is connected to terminal 1 of each of the other modules.

Terminals 2 and 3 are connected in the same manner. See

Fig. 19. If a terminal 2 wire is connected to terminal 1, sys-

tem does not work.

In Flotronic™ II chillers, processor module, low-voltage

relay module, and keypad and display module are all pow-

ered from a common 21-vac power source which connects

to terminals 1 and 2 of power input strip on each module. A

separate source of 21-vac power is used to power options

module through terminals 1 and 2 on power input strip. A

separate source of 12.5 vac power is used to power EXV

driver module through terminals 1 and 2 on power input strip.

Fig. 18 — Module Address

Selector Switch Locations

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Fig. 19 — Sensor Bus Wiring

(Communications)

PROCESSOR MODULE (PSIO) (Fig. 20)

Inputs — Each input channel has 3 terminals; only 2 of the

terminals are used. Application of machine determines which

terminals are used. Always refer to individual unit wiring

for terminal numbers.

Outputs — Output is 24 vdc. There are 3 terminals, only 2

of which are used, depending on application. Refer to unit

wiring diagram.

NOTE: Address switches (see Fig. 20) must be set at 01 (dif-

ferent when CCN connected).

LOW VOLTAGE RELAY MODULE (DSIO-LV) (Fig. 21)

Inputs — Inputs on strip J3 are discrete inputs (ON/OFF).

When 24-vac power is applied across the 2 terminals in a

channel it reads as on signal. Zero v reads as an off signal.

PWR

—

Power

Outputs — Terminal strips J4 and J5 are internal relays whose

coils are powered-up and powered-off by a signal from

microprocessor. The relays switch the circuit to which they

are connected. No power is supplied to these connections by

DSIO module.

Fig. 20 — Processor Module (PSIO)

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 temperature.

A remote thermistor (Part No. 30GB660002) is also re-

quired.

NOTE: This accessory is not required for return water

temperature reset.

2. Temperature Reset by remote 4 to 20 mA signal.

3. Demand Limit by remote 2-stage switch.

4. Demand Limit by remote 4 to 20 mA signal

5. Dual Set Point by remote switch.

The options module is standard. Remember to reconﬁg-

ure the chiller for each feature selected (see Table 14). For

temperature reset, demand limit, and dual set point, desired

set points must be entered through keypad and display mod-

ule (see Set Point Function section on page 38).

See Table 19 for overall troubleshooting information.

ACCESSORY UNLOADER INSTALLATION

Some of the 30G Flotronic™ II units come standard with

unloader(s), and many permit additional unloader(s) to be

added if desired. See Table 20.

IMPORTANT: The following combinations ARE NOT

permitted (combinations are per circuit):

LEGEND

1. Two unloaders and hot gas bypass

2. Four compressors and 2 unloaders.

3. Four compressors, 1 unloader, and hot gas

bypass.

COMM

—

Communications Bus

Normally Closed

PWR

—

Normally Open

Power

Fig. 21 — Low-Voltage Relay Module (DSIO)

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3. Install the additional unloader cylinder head on the lead

compressor, A1 or B1, according to instructions provided

by the compressor manufacturer in the accessory

package.

4. Continue installation per either 040-110, 130 (60 Hz) units

or 130 (50 Hz), 150-210 units section as appropriate.

040-110, 130 (60 Hz) UNITS (AndAssociated Modular Units)

1. Wire the solenoid before any ﬁeld wiring begins. Wiring

between components and control box must be enclosed

in conduit. All local electrical codes and National Elec-

trical Code (NEC) must be followed. Factory wires are

provided in the compressor harness to connect the sole-

noid. These wires are in the compressor control box.

2. Wire the control side. Open the left side control box door

and remove inner panel. Using the holes provided and

ﬁeld-supplied screws, install ﬁeld-supplied transformer above

the DSIO-LV on the control panel.

Wire the primary side of the transformer in parallel with

TRAN4. See Fig. 23. This supplies transformer with proper

line voltage. Be sure to connect proper tap of the trans-

former to ensure supply of proper secondary voltage.

Wire the secondary side of transformer to DSIO-LV - J5-9,

and a jumper from DSIO-LV - J5-9 to DSIO-LV - J4-9.

Wire the secondary common to TB7-2. Connect the trans-

former ground to ground hole supplied near the trans-

former. These connections provide DSIO with necessary

power to energize the solenoid coils.

3. When all connections are made, check for proper wiring

and tight connections. Replace and secure inner panel.

Restore power to unit.

4. Conﬁgure the processor. With the addition of extra un-

loaders, the unit conﬁguration has changed. To change

the conﬁguration of the processor, enter the service func-

tion using the keypad and display module. Before any

changes can be made, the LOCAL/ENABLE-STOP-

CCN switch must be in the STOP position, and the ser-

vicer must log on to the processor.

LEGEND

COMM

PWR

—

Communications Bus

Power

a. Press

PASSWORD.

b. Enter

LOGGEDON.

. Keypad LCD displays the word

Keypad LCD displays

. Keypad LCD

Fig. 22 — 4 In/4 Out Module (SIO)

If accessory unloaders are desired, an accessory unloader

package is used. Package includes a suction cutoff unloader

head package. The 24-v coil in the package can be used

for 040-110, 130 (60 Hz), and associated modular units

(Table 1). A 115 v or 230 v coil must be used for 130

(50 Hz), 150-210, and associated modular units (Table 1).

Coil voltage depends on control circuit voltage. Consult cur-

rent Carrier price pages for appropriate part numbers.

c. To change conﬁguration, press

displays FLD CFG.

d. If an additional unloader was added to compressor

A1, press

until NULA 1 appears in keypad dis-

play. Press

for the number of unloaders on

circuit A. Keypad display now reads NULA 2.

e. If an additional unloader was added to compressor

NOTE: The accessory package will include all necessary com-

ponents and wiring with the following exceptions: The ﬁeld

must provide screws, and on the 130-210, and associated modu-

lar units, the ﬁeld must also supply a 20 vdc (part number

B1, press

until NULB 1 appears in keypad dis-

HK35AB001) unloader relay and wire (90°

equivalent).

play. Press

for the number of unloaders on

circuit B. Keypad display now reads NULB 2.

Installation

f. When conﬁguration is complete, press

pad display reads LOGGEDON. Press

. Key-

1. Be sure all electrical disconnects are open and tagged be-

fore any work begins. Inspect the package contents for

any damage during shipping. File a claim with the ship-

per if damage has occurred.

until key-

pad display reads LOG OFF. Press

play reads EXIT LOG.

. Keypad dis-

2. For ease of installation, factory-supplied wiring for the

additional unloader is provided in the compressor

harness.

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Table 19 — Troubleshooting

SYMPTOMS

CAUSE

REMEDY

COMPRESSOR DOES

NOT RUN

Power line open

Control fuse open

Reset circuit breaker.

Check control circuit for ground or short.

Replace fuse.

High-Pressure Switch (HPS)

tripped

Move LOCAL/ENABLE-STOP-CCN switch to STOP

position then back to RUN or CCN position.

Tripped power breaker

Check the controls. Find cause of trip

and reset breaker.

Loose terminal connection

Improperly wired controls

Low line voltage

Check connections.

Check wiring and rewire.

Check line voltage. Determine location

of voltage drop and remedy deﬁciency.

Compressor motor defective

Check motor winding for open or short.

Replace compressor if necessary.

Seized compressor

Replace compressor.

Repair leak and recharge.

Replace transducer.

COMPRESSOR CYCLES OFF

ON LOW PRESSURE

Loss of charge

Bad transducer

Low refrigerant charge

Add refrigerant.

COMPRESSOR SHUTS DOWN

ON HIGH PRESSURE

CONTROL

High-pressure control erratic in action

Compressor discharge valve partially closed

Condenser fan(s) not operating

Replace control.

Open valve or replace if defective.

Check wiring. Repair or replace motor(s)

if defective.

Condenser coil plugged or dirty

Low refrigerant charge

Clean coil.

UNIT OPERATES LONG OR

CONTINUOUSLY

Add refrigerant.

Replace control.

Clean or replace.

Control contacts fused

Partially plugged or plugged expansion

valve or ﬁlter driver

Defective insulation

Service load

Replace or repair.

Keep doors and windows closed.

Check valves. Replace if necessary.

Support piping as required.

Inefficient compressor

Piping vibration

SYSTEM NOISES

Expansion valve hissing

Add refrigerant.

Check for plugged liquid line ﬁlter drier.

Check valve plates for valve noise.

Replace compressor (worn bearings).

Check for loose compressor holddown bolts.

Repair leak.

Compressor noisy

COMPRESSOR LOSES OIL

FROSTED SUCTION LINE

Leak in system

Mechanical damage (blown piston or

broken discharge valve)

Repair damage or replace compressor.

Crankcase heaters not energized

during shutdown

Replace heaters, check wiring and

crankcase heater relay contacts.

Expansion valve admitting either too

much or too little refrigerant

Check cooler and compressor thermistors.

Test EXV.

HOT LIQUID LINE

Shortage of refrigerant due to leak

Shutoff valve partially closed or restricted

Burned out coil

Repair leak and recharge.

Open valve or remove restriction.

Replace coil.

FROSTED LIQUID LINE

COMPRESSOR DOES NOT

UNLOAD

Defective capacity control valve

Miswired solenoid

Replace valve.

Rewire correctly.

Weak, broken, or wrong valve body spring

Miswired solenoid

Replace spring

COMPRESSOR DOES NOT

LOAD

Rewire correctly.

Defective capacity control valve

Plugged strainer (high side)

Replace valve.

Clean or replace strainer.

Clean or replace the necessary parts.

Stuck or damaged unloader piston or

piston ring(s)

EXV

—

Electronic Expansion Valve

Table 20 — Standard and Accessory Unloaders

NO. OF ACCESSORY

UNLOADERS

PERMITTED

NO. OF STANDARD

UNLOADER(s)

UNIT

Circuit A

Circuit B

30GN040-070

30GN080-170*

30GN190-210*

1 or 2

*And associated modular units.

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b. Log into the processor and enter the service func-

tion using the keypad and display module.

5. Using test function, check unloaders. Press

pad display reads OUTPUTS. Press

. Key-

until display

Press

The keypad LCD will display

reads UNA2 OFF. Press

and relay deenergizes. Press

UNB2 OFF. Press . Relay energizes. Press

and relay deenergizes.

. Relay energizes. Press

‘‘PASSWORD.’’ Enter

keypad LCD will display ‘‘LOGGEDON.’’

, and the

until display reads

c. To change the conﬁguration, press

, and the

keypad LCD will display ‘‘FLD CFG.’’ Press

6. When unloader check has been performed, return LOCAL/

ENABLE-STOP-CCN to proper position. Close and se-

cure control box door.

until either ‘‘NULA 0’’ or ‘‘NULA 1’’ is displayed

(depending on the number of unloaders provided as

standard). Then press

or (for 2 unloaders on compressor A1). The

display will now read either ‘‘NULA 1’’ or

‘‘NULA 2,’’ as appropriate. Press to get to the

(for 1 unloader on A1)

130 (50 Hz), 150-210 UNITS (AndAssociated Modular Units)

1. Install control wiring. The minimum wire size for instal-

lation is 16 AWG (American Wire Gage). Refer to

Fig. 23 and 24 for proper wiring. Open the control box

door. Locate unloader relays A and B (UA, UB) in place

of the hot gas bypass relays as shown on the component

arrangement diagram on the unit. Mount the relays with

the ﬁeld-supplied screws. Be careful not to damage the

components and wiring in the area when mounting the

relays.

2. Wire the control side. Wire the UA coil in series between

J6-18 and J6-19 of the 4 IN/4 OUT module with the wires

provided. Wire the UB coil in series between J6-21 and

J6-22 of the same module with the wires provided.

NULB display, and change this setting in the same man-

ner as with circuit A.

d. Once the conﬁguration is complete, press

and the keypad LCD will display ‘‘LOGGEDON,’’

Press until the keypad LCD display reads ‘‘LOG

OFF.’’ Press

and the keypad LCD will display

‘‘EXIT LOG.’’

5. Once the unloader heads are installed, the unit is checked

for leaks, and the system is prepared for operation per the

instructions for the compressor unloader head installa-

tion, check the output of the relays using the test function

as follows:

Locate the black wire in the control harness originating

from TRAN5 labeled HGBPR-A-COM. Connect this wire

to the UAterminal COM. Connect the wire labeled HGBPR-

A-NO to UA-NO. Connect the wire from UA-NO to

TB3-5. For an extra unloader on circuit B, connect the

wire labeled HGBPR-B-COM to UR-B-COM, and the wire

labeled HGBPR-B-NO to UB-NO. Connect the wire from

UB-NO to TB3-6.

a. Press

, and the display will read ‘‘COMP.’’

b. Press the

to scroll down until the display reads

‘‘CPA1 OFF.’’

3. Wire in the solenoid valves.

c. Press

d. Press

, and the compressor should start.

, and the compressor should stop.

NOTE: Wires external to the control box must be run in

conduit.

Terminal blocks are provided for easy ﬁeld wiring. Use

one of the isolated ⁷⁄8-in. (22-mm) holes in the side of the

compressor electrical box with a strain relief to run the

wires to the solenoid coil. Connect UA between TB3-5

and TB3-8. Connect UB between TB3-6 and TB3-8. Check

all of the electrical connections for proper location and

tightness, and replace and secure the electrical box of the

compressor.

e. Press

f. Press

until the display reads ‘‘UNA1 OFF.’’

, and the solenoid should energize.

g. Press

and the solenoid should deenergize.

h. Use the

and

keys to check the remainder of

the unloader coils.

6. Once the check has been performed, return the LOCAL/

ENABLE-STOP-CCN switch to the proper position.

7. Close and secure the control box door.

8. Start the unit and conﬁrm that the chiller operates

properly.

4. Conﬁgure the microprocessor. Once the relays are mounted

in the control box, the microprocessor must be conﬁg-

ured for the unloader option. To do so:

a. Be sure the LOCAL/ENABLE-STOP-CCN switch is

in the STOP position.

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LEGEND

*Or HGBPR-A.

†Or HGBPR-B.

—

Contactor

PWR

TRAN

—

Power

Circuit Breaker

Switch

COMM

HGBPR

Communications Bus

Hot Gas Bypass Relay

Transformer

Unloader

Fig. 23 — Accessory Unloader Control Wiring, All Units

LEGEND

COM

HGBPR

—

Communications Bus

Hot Gas Bypass Relay

Normally Open

TRAN

—

Terminal Block

Transformer

Unloader

SNB

Snubber

Fig. 24 — Flotronic™ II 115/230-V (Unloader Wiring, 130 (50 Hz), 150-210 and Associated Modular Units

(See Table 1)

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FIELD WIRING

Refer to Fig. 25-35 for ﬁeld wiring.

NOTE: Contacts must be rated for dry circuit application, capable of

reliably switching a 5 vdc, 1 mA to 20 mA load.

Fig. 25 — Demand Limit — Two External

Switch Inputs

Fig. 26 − Demand Limit — 4-20 mA Signal

Fig. 30 — Remote Reset from 4-20 mA Signal

(Internally Powered)

(Externally Powered)

—

Terminal Block

NOTE: Contacts must be rated for dry circuit application, capable of

reliably switching a 5 vdc, 1 mA to 20 mA load.

Fig. 27 — Demand Limit — 4-20 mA Signal

(Internally Powered)

Fig. 31 — Remote On/Off

Fig. 28 — Remote Reset from Space or

Outdoor-Air Temperature

Fig. 32 — Remote Dual Set Point Control

Fig. 29 — Remote Reset from 4-20 mA Signal

(Externally Powered)

CWP

—

Chilled Water (Fluid) Pump

Terminal Block

Fig. 33 — Chilled Fluid Pump

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4. Remove defective PSIO by removing its mounting screws

with a Phillips screwdriver, and removing the module

from the control box. Save the screws for later use.

5. Use a small screwdriver to set address switches S1 and

S2 on the new PSIO module to exactly match the set-

tings on the defective module.

6. Package the defective module in the carton of the new

module for return to Carrier.

—

Terminal Block

7. Mount the new module in the unit control box using a

Phillips screwdriver and the screws saved in Step 4 above.

Fig. 34 — Remote Alarm

8. Reinstall all 6 wire connectors and the green ground wire.

9. Carefully check all wiring connections before restoring

power.

10. Verify the LOCAL/ENABLE-STOP-CCN switch is in

STOP position.

11. Restore control power. Verify the red and green lights

on top of PSIO and front of each DSIO module respond

as described in Control Modules section on page 63. The

keypad and display module should also begin its rotat-

ing display.

CWP1

CWFS

—

Chilled Water (Fluid) Pump Interlock

Chilled Water (Fluid) Flow Switch (not required — low ﬂow

protection is provided by Flotronic™ II controls)

Terminal Block

—

12. Using the keypad and display module, press

to verify that the software version number matches the

ER (engineering requirement) number shown on the PSIO

label.

Fig. 35 — Interlocks

REPLACING DEFECTIVE

PROCESSOR MODULE

13. Press

to verify that the 7 factory conﬁguration

codes (CODE 1 through CODE 7) exactly match the codes

listed for this unit model on the component arrangement

label diagram on the control box door. If they are dif-

ferent or are all zeros, reenter the 7 codes. If any changes

are required, the PSIO display becomes blank and

The replacement part number is printed on a small label

on the front of the PSIO module. The model and serial num-

bers are printed on the unit nameplate located on an exterior

corner post. The proper software and unit conﬁguration data

is factory installed by Carrier in the replacement module.

Therefore, when ordering a replacement processor module

(PSIO), specify complete replacement part number, full unit

model number, and serial number. If these numbers are not

provided, the replacement module order is conﬁgured in-

stead as a generic Flotronic II replacement module. This re-

quires reconﬁguration of the module by the installer.

reconﬁgures itself after pressing the

key while dis-

playing CODE 7. The display returns in approximately

15 seconds.

NOTE: Codes with leading zeros in the conﬁguration

will be displayed starting with the ﬁrst number greater

than zero.

14. Press

to verify each item is conﬁgured as needed

Electrical shock can cause personal injury. Disconnect

all electrical power before servicing.

for this particular installation. Table 14 shows the fac-

tory conﬁguration code default settings. Table 14 also

shows the service replacement code default settings which

are used if no model number was speciﬁed when order-

ing the replacement PSIO module. It is strongly sug-

gested that the Start-Up Checklist for Flotronic II Chiller

Systems (completed at time of original start-up) be used

at this time to verify and/or reprogram the various op-

tions and conﬁgurations required for this job.

Installation

1. Verify the existing PSIO module is defective by using

the procedure described in the Control Modules section

on page 63.

2. Refer to Start-Up Checklist for Flotronic II Chiller Sys-

tems (completed at time of original start-up) found in

job folder. This information is needed later in this

15. Press

to verify that the 2 ﬁeld conﬁguration

codes (codes 8 and 9) match exactly the codes listed on

the label diagram on the control box door. If they are

different, or are all zeros, reenter the 2 codes.

procedure. If checklist does not exist, ﬁll out the

and

conﬁguration code sections on a new check-

list. Tailor the various options and conﬁgurations as needed

for this particular installation.

16. After completing the conﬁguration steps outlined above,

restore main power and perform a unit test as de-

3. Check that all power to unit is off. Carefully disconnect

all wires from defective module by unplugging the 6 con-

nectors. It is not necessary to remove any of the indi-

vidual wires from the connectors. Remove the green ground

wire.

scribed in

and

sections on page 38.

17. Complete this procedure and restore chiller to normal

operation by returning the LOCAL/ENABLE-STOP-

CCN switch to desired position.

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Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2

PC 903

Catalog No. 563-079

Printed in U.S.A.

Form 30GN-3T

Pg 72

7-95

Replaces: 30G-1T

Tab 5c

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